Plush-Coated Textile Support Structure for Flexible Garments
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Solution Overview
Problem
Conventional textile elements with thermoplastic coatings applied to non-plush surfaces are brittle and prone to breakage due to the lack of penetration of the thermoplastic material, resulting in inflexible structures that do not provide adequate support and comfort in garments.
Innovation Solution
A method involving a fabric strip with a plush surface, where a thermoplastic coating is applied and allowed to penetrate and rigidify, embedding surface yarns to form a composite structure, enhancing strength and flexibility, and further reinforced by folding the strip to sandwich the coating between surfaces, preventing leakage and creating textile-only regions for easier sewing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermoplastic coating is applied to a non-plush surface, then the application process is simple, but the resulting textile element is brittle and prone to breakage
Solution Approach 1:
The plush surface provides a porous, absorbent structure that allows molten thermoplastic material to penetrate and embed into the fabric yarns. This penetration creates a strong composite bond that prevents brittleness and breakage, while the plush surface's porous nature facilitates this penetration without requiring complex application processes
Solution Approach 2:
The invention creates a composite structure where thermoplastic material is embedded within and bonded to fabric yarns through penetration. This composite formation occurs naturally as the molten thermoplastic penetrates the plush surface and encapsulates the yarns, creating a unified structure that combines the flexibility of fabric with the strength of thermoplastic
2Strength
If thermoplastic coating is applied to provide structural support, then strength is improved, but flexibility is reduced
Solution Approach 1:
The plush surface's porous structure allows controlled penetration of thermoplastic material, ensuring that the coating bonds to the fabric yarns rather than forming a separate rigid layer. This penetration creates a flexible composite that maintains the fabric's inherent flexibility while providing structural support strength
Solution Approach 2:
The invention changes the physical state and distribution of thermoplastic material by controlling its penetration depth and embedding within the plush surface. The thermoplastic is applied in a molten state, penetrates the plush surface, and then solidifies within the fabric structure, transforming from a potential rigid coating into a flexible integrated component
3Strength
If thermoplastic coating penetrates deeply into plush surface, then bonding strength is improved, but thermoplastic material may leak through the fabric
Solution Approach 1:
The fabric structure is designed with different local properties: the plush surface layer allows penetration and embedding of thermoplastic material to create strong bonding, while the backing layer provides a denser, non-porous structure that prevents through-leakage. This spatial differentiation of fabric properties solves both penetration and containment requirements
Solution Approach 2:
The plush surface acts as a controlled porous medium that allows thermoplastic penetration to a specific depth where embedding occurs, while the inherent structure of the plush fibers and the backing layer work together to contain the material and prevent uncontrolled leakage through the entire fabric thickness
4Strength
If thermoplastic coating is applied to create a rigid structure, then structural support is improved, but wearer comfort is reduced
Solution Approach 1:
The composite structure integrates thermoplastic material within the fabric matrix through penetration and embedding, creating a unified flexible support element. This composite approach eliminates the need for separate rigid components, providing structural support that moves and flexes with the wearer's body, thereby maintaining comfort
Solution Approach 2:
The thermoplastic coating, when penetrated into and embedded within the plush surface, forms a flexible structural layer rather than a rigid shell. This flexible structure provides the necessary support while conforming to body movements, eliminating the discomfort associated with rigid structural components
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 resulting textile element is more flexible and less prone to breakage, offering strength comparable to under-wires while providing greater wearer comfort and ease of integration into garments, with improved aesthetic and functional properties.
Implementation Method 1
a molten thermoplastic material to absorb and penetrate into the plush surface and encase at least surface yarns of the plush surface
Implementation Method 2
the thermoplastic coating penetrates the plush surface so that the thermoplastic coating embeds the surface yarns of the plush surface
Implementation Method 3
allowing the thermoplastic coating to cool and rigidify so as to embed at least surface yarns of the plush surface in the thermoplastic coating
Implementation Method 4
the thermoplastic coating is allowed to cool and rigidify
Implementation Method 5
the fluidity of the thermoplastic material is increased prior to the step of applying the thermoplastic coating to the plush surface
Data Source
AI summary
A method of forming a textile element (10) for use as a structural support component in a garment. The method comprises the steps of: (i) providing a fabric strip (12) having a plush surface (16); (ii) applying a thermoplastic coating (14) to the plush surface (16) of the fabric strip (12) so that the thermoplastic coating (14) penetrates the plush surface (16); and (iii) allowing the thermoplastic coating (14) to cool and rigidify so as to embed at least surface yarns of the plush surface (16) in the thermoplastic coating (14) and thereby form a composite structure at the juncture (J) between the thermoplastic coating (14) and the plush surface (16).