Rotary Elastomer Printing for Seamless Elastic Garments
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Solution Overview
Problem
Current methods for producing clothing with elastic properties, such as underwear and sports clothing, are inefficient and lack precision in applying elastomers, often resulting in uneven distribution and additional thickness in applied areas.
Innovation Solution
A rotary printing process where a fabric layer is applied to a cylindrical carrier body, allowing for precise and continuous or discontinuous application of elastomer webs, which penetrate into the fabric to create elastic regions without increasing thickness, and can be cut to form seamless edges, with optional patterning and flocking for improved comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If elastomer is applied using screen printing or adhesive coating process, then elastomer can be applied to fabric layer, but the application is time-consuming and lacks precision
Solution Approach 1:
The patent replaces traditional mechanical screen printing or adhesive coating processes with a rotary printing system. The elastomer is applied through a print form that rotates synchronously with the fabric layer on the carrier body, enabling precise and rapid elastomer application. This mechanical substitution resolves the contradiction by achieving both high precision through the print form geometry and high productivity through continuous rotation and synchronous feeding.
Solution Approach 2:
The patent introduces dynamic elements by making both the fabric layer and the print form rotate synchronously on the carrier body. The elastomer container is also rotated to feed elastomer continuously. This dynamic synchronous rotation system enables precise elastomer application at controlled positions while maintaining high processing speed, resolving the contradiction between precision and productivity.
2Strength
If elastomer is applied in traditional methods, then elastic properties are added to clothing, but additional thickness is created in applied areas
Solution Approach 1:
The patent utilizes the porous structure of the fabric layer to resolve the thickness contradiction. The elastomer is applied in a molten or viscous state that allows it to penetrate into the fabric pores. After application and setting, the elastomer becomes integrated within the fabric structure rather than forming a surface layer, thereby providing elastic properties without significant additional thickness.
Solution Approach 2:
The patent changes the physical state parameter of the elastomer during application. The elastomer is supplied in a molten or highly fluid state, allowing it to penetrate the fabric pores easily. After application, the elastomer sets or solidifies within the fabric structure. This parameter change from fluid to solid state enables the elastomer to integrate into the fabric without creating surface buildup, resolving the thickness issue while maintaining elasticity.
3Ease of manufacture
If elastomer is applied continuously to form seamless edges, then cutting is eliminated, but precise control of elastomer distribution is required
Solution Approach 1:
The patent implements a feedback control system where the rotation of the carrier body, fabric layer, and print form are synchronously coordinated. The position of the elastomer application is precisely controlled through this synchronous rotation feedback mechanism, ensuring that elastomer is deposited only at the intended locations and in the correct amounts. This feedback control enables seamless edge formation without cutting while maintaining precise elastomer distribution.
Solution Approach 2:
The patent applies elastomer in a preliminary action before the fabric is cut to final shape. The elastomer is applied to the fabric layer while it is still on the rotating carrier body, forming the desired edge patterns or seamless structures. After the elastomer sets, the fabric can be cut along the elastomer-defined boundaries. This preliminary elastomer application eliminates the need for post-cutting sealing or finishing operations.
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
This method enables rapid, high-precision application of elastomers, enhancing elasticity while maintaining fabric thickness, allowing for seamless construction and improved comfort through uniform elastomer distribution and patterning, suitable for various clothing items like panties, T-shirts, and stockings.
Implementation Method 1
an adhesive or elastomer is applied to the layer of fabric, which penetrates into the fabric of the layer of fabric
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a method for producing an article of clothing (1) by applying an elastomer (10), wherein a fabric layer (5) is applied onto a cylindrical carrier body (7), the application of the elastomer being carried out using the round printing method while the carrier body is rotating.