Seamless Elastic Strap With Forked Structures and Ultrasonic Welding
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Solution Overview
Problem
Existing methods for connecting elastic straps to fabric, such as sewing, result in visible seam marks reducing comfort, while adhesive pressing or ultrasonic welding are prone to cracking and lack reliability.
Innovation Solution
An elastic strap with forked structures formed by interweaving upper and lower layer fabric straps, using a combination of single-layer and double-layer weft structures, and a manufacturing method involving alternating weaving patterns and ultrasonic welding, with a reinforcing sheet for hot pressing to create a seamless and reliable connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sewing is used to connect elastic straps to fabric, then the connection is firm and reliable, but visible seam marks are created that reduce wearing comfort
Solution Approach 1:
The patent extracts the harmful sewing seams from the final product by using adhesive pressing or ultrasonic welding to create seamless connections. The connection method is changed to eliminate the visible and tactile seam marks that cause discomfort, while maintaining connection reliability through the forked structure design that distributes stress away from the connection points.
Solution Approach 2:
The patent applies different connection methods to different parts of the elastic strap. The forked structures are positioned at specific locations where connections are needed, while the remaining portions maintain seamless construction. This localized approach ensures reliability at connection points without compromising overall comfort.
2Object-affected harmful factors
If adhesive pressing or ultrasonic welding is used to connect elastic straps, then seamless seams are achieved improving comfort, but the connection is prone to cracking and has low reliability
Solution Approach 1:
The patent divides the elastic strap into multiple layers (upper layer, lower layer, intermediate layer) with forked structures at specific positions. This segmentation allows the seamless adhesive or ultrasonic welding method to be applied to each layer independently, distributing the connection points and reducing stress concentration that would cause cracking in a single-layer construction.
Solution Approach 2:
The patent uses composite construction with multiple fabric layers bonded together through adhesive pressing or ultrasonic welding. The combination of layers with forked structures creates a composite material system that maintains seamless comfort while improving overall connection reliability through distributed bonding.
3Object-affected harmful factors
If alignment of connection parts between inner and outer layers is performed, then seamless connection is achieved, but the connection is prone to cracking
Solution Approach 1:
The patent employs a nested multi-layer structure where the intermediate layer with forked structures is positioned between the upper and lower layers. This nesting arrangement allows the connection parts to be aligned seamlessly while the intermediate forked structures provide reinforcement that prevents cracking at the connection points.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a seamless, comfortable, and reliable connection that maintains elasticity, preventing breakage at the welding and pressing areas, suitable for applications like bras and orthopedic clothing.
Implementation Method 1
The lower layer weft and the upper layer weft are composite weft lines composed of nylon wire and hot melt wire
Implementation Method 2
a reinforcing sheet is added for hot pressing to make it into one layer
Implementation Method 3
Another method is to use adhesive pressing or ultrasonic welding
Data Source
AI summary
A seamless elastic strap with forked structures and a manufacturing method thereof are provided, the elastic strap includes an upper layer fabric strap formed by interweaving an upper layer warp, an upper layer wrapped warp, and an upper layer weft and a lower layer fabric strap formed by interweaving a lower layer warp, a lower layer wrapped warp, and a lower layer weft. By changing the interweaving position of the upper and lower wrapped warps with the upper and lower wefts, a structure consisting of several forking parts and merging parts arranged at intervals on one elastic strap is achieved. It uses the staggered hot-cutting method to make the ends of both ends of the upper and lower fabric straps misaligned. It uses the ultrasonic welding method to form a loop fabric strap. It has the advantage of using adhesive pressing or ultrasonic welding to make seamless marks.