Garment Band Float Plating for Friction and Bulk Reduction
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Solution Overview
Problem
Existing elastic bands in undergarments and hosiery often cause discomfort due to exposed bare elastomer, leading to increased friction and bulk, which compromises both comfort and fit.
Innovation Solution
A band construction using a combination of covered elastomeric yarn and low friction yarn, where the low friction yarn is float platted with the elastomeric yarn to reduce bulk and friction, while maintaining a tight fit through a specific knitting pattern and yarn distribution, resulting in a dual-layer construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bare elastomer yarns are used in the band to provide elasticity and hold the garment in place, then the garment maintains a tight fit and control, but the exposed bare elastomer causes increased friction and discomfort to the wearer
Solution Approach 1:
A non-slip coating is applied to the elastomer yarns, serving as an intermediary layer between the elastomer and the wearer's skin. This coating reduces friction and discomfort while maintaining the elastic properties and fit control provided by the bare elastomer yarns.
Solution Approach 2:
The surface properties of the elastomer yarns are modified by applying a non-slip coating, changing the friction parameter from high (discomfort-causing) to optimized (comfortable yet secure). This allows the elastomer to maintain its elastic function while eliminating the harmful friction effect.
2Reliability
If traditional elastic bands are used to provide support and control, then the garment maintains proper positioning, but the bands create increased bulk that compromises comfort
Solution Approach 1:
The band is constructed using thin-walled tubular structures formed from knitted fabric with elastomeric yarns integrated throughout. This thin-film approach provides the necessary elastic support and positioning control while minimizing bulk, unlike traditional thick elastic bands.
Solution Approach 2:
The band combines knitted fabric with integrated elastomeric yarns to create a composite structure that provides both support/control functionality and minimal bulk. The elastomeric yarns are distributed within the knitted structure rather than forming a separate thick layer.
3Object-affected harmful factors
If covered elastomeric yarn is float platted with low friction yarn to reduce bulk and friction, then comfort is improved, but the complexity of the knitting process increases
Solution Approach 1:
Multiple yarn types (covered elastomeric yarn and low friction yarn) are combined in a single knitting process using float plating. This merging of yarns into one integrated construction achieves reduced bulk and friction while maintaining comfort, avoiding the need for separate layers or post-processing steps.
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 improved comfort and reduced bulk, maintaining a tight fit and control without the discomfort caused by exposed elastomer, while minimizing slippage through optimized yarn distribution and knitting patterns.
Implementation Method 1
A band construction using a combination of covered elastomeric yarn and low friction yarn, where the low friction yarn is float platted with the elastomeric yarn to reduce bulk and friction
Data Source
Figure 1
Figure 2I~2VIII
Figure 3
AI summary
A garment such as an upper torso garment or a lower torso garment includes a torso encircling band. The band includes an inner layer and an outer layer with each layer having a first series of courses. The first series of courses may include a first, elastomeric yarn and a second, low friction yarn. The first and second yarns are knit such that the second yarn is float platted with the first yarn.