Patterned Filament Overlay for Durable Flexible Shoulder Panels
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Solution Overview
Problem
Existing textiles used in garments and gear often lack the necessary durability, cushioning, and tailored mechanical behavior for extreme environments, particularly in applications involving motion and movement.
Innovation Solution
A method and system for enhancing textile substrates through computer-controlled deposition of thermoplastic polymers using Fused Filament Fabrication (FFF) techniques, allowing for precise, three-dimensional application of polymers to improve mechanical, thermal, and aesthetic performance by varying attributes such as layout, thickness, density, and layering of polymer filaments on textiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional textiles are used in garments and gear, then the items can be manufactured with standard textile properties, but the textiles lack the necessary durability, cushioning, and tailored mechanical behavior for extreme environments
Solution Approach 1:
The patent applies local quality by depositing polymer material in specific patterns and locations on the textile substrate. The system can vary the layout, thickness, density, and layering of polymer filaments in different zones to provide tailored mechanical behavior where needed, such as enhanced durability in high-wear areas while maintaining flexibility in other regions.
Solution Approach 2:
The patent creates composite materials by combining textile substrates with deposited polymer layers. This composite structure integrates the inherent properties of the textile with the mechanical strength and durability of the polymer, resulting in a material that exhibits both flexibility and enhanced durability for extreme environments.
2Strength
If polymer material is deposited on textile substrates to enhance performance, then abrasion resistance and tensile strength are improved, but the manufacturing process complexity increases
Solution Approach 1:
The patent replaces traditional mechanical textile reinforcement methods with a deposition-based system that uses computer-controlled polymer application. This substitution allows for precise control of material placement and properties while simplifying the manufacturing process through automation and digital control.
Solution Approach 2:
The patent employs parameter changes by controlling various deposition parameters such as polymer material viscosity, deposition temperature, nozzle movement speed, and layer thickness. By adjusting these parameters, the system can optimize both the tensile strength of the composite material and the efficiency of the manufacturing process.
3Manufacturing precision
If Fused Filament Fabrication techniques are used for polymer deposition, then precise three-dimensional application is achieved, but the manufacturing time increases
Solution Approach 1:
The patent applies preliminary action by preparing the polymer material in advance (melting and extruding through the nozzle) and using pre-programmed deposition paths based on digital models. This allows the system to maintain high precision while reducing manufacturing time through efficient material flow and optimized toolpaths.
Solution Approach 2:
The patent ensures continuity of useful action by maintaining continuous polymer material flow through the nozzle and implementing uninterrupted deposition processes. The system keeps the polymer material in a ready-to-deposit state and uses continuous nozzle movement along programmed paths, minimizing idle time while maintaining manufacturing precision.
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 textiles with enhanced abrasion resistance, flexibility, moisture management, tensile strength, and thermal regulation, enabling customizable performance for footwear, apparel, and outdoor gear by ensuring precise polymer application and mechanical interlocking with the textile structure.
Implementation Method 1
A heated nozzle melts and deposits a thermoplastic polymer material onto a textile substrate
Implementation Method 2
A heated nozzle melts and deposits a thermoplastic polymer material onto a textile substrate
Data Source
Figure 1
Figure 2A~2C
Figure 3A~3B
AI summary
A wearable item may include at least one panel forming a back portion to extend along a back of a person and shoulder portions extending forwardly from the back portion. A patterned filament overlay (PFO) in the form of an individually formed line of material crossing itself or extending alongside itself over an area is located on the shoulder portions.