Seamless Molded Brief Structure for Breathable Body Conformity
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Solution Overview
Problem
Conventional undergarments, such as briefs, are uncomfortable due to low breathability and the presence of seams, which exacerbate wearer discomfort and fail to conform to the body, particularly the buttocks and genitals.
Innovation Solution
A seamless brief design using stretchable fabrics with integrated molded sacs and pouches formed by stretching and infusing synthetic compounds to accommodate and conform to the wearer's body, eliminating seams and enhancing breathability through larger holes for improved air circulation and humidity management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional undergarments are designed with seams and standard fabric construction, then manufacturing is simpler and cost is lower, but wearer comfort deteriorates due to chafing and lack of breathability
Solution Approach 1:
The patent merges multiple fabric layers into a single integrated garment construction where the front and back panels are formed as one piece through stretching and infusing synthetic compounds. This eliminates seams between panels while maintaining manufacturing feasibility through a unified process approach.
Solution Approach 2:
The patent applies parameter changes by controlling the stretching degree and synthetic compound infusion during manufacturing to create different fabric densities and breathability levels in specific zones. This allows optimization of comfort properties while maintaining overall manufacturing simplicity.
2Object-affected harmful factors
If fabric holes are made larger to improve breathability, then air circulation improves, but structural integrity and fabric strength deteriorate
Solution Approach 1:
The patent applies local quality by creating different hole size distributions in different zones of the garment. The pouch area has larger holes for enhanced breathability, while other areas maintain smaller holes for structural integrity. This is achieved through selective stretching and synthetic compound infusion during manufacturing.
Solution Approach 2:
The patent uses composite materials by combining stretched fabric with infused synthetic compounds to create a multi-layered structure that provides both breathability and strength. The synthetic compounds fill and reinforce the fabric matrix while allowing controlled porosity for air circulation.
3Ease of operation
If the brief is designed to conform to body contours, then wearer comfort and support improve, but manufacturing complexity increases due to need for precise shaping
Solution Approach 1:
The patent applies preliminary action by pre-shaping the fabric panels and pre-positioning synthetic compound infusion zones before final assembly. The stretching and infusing processes are performed in advance to create pre-formed contours that naturally conform to body shapes, reducing the need for complex post-processing.
Solution Approach 2:
The patent uses parameter changes by controlling stretching ratios and synthetic compound infusion levels to create three-dimensional body contours directly during manufacturing. By adjusting these parameters, the fabric naturally conforms to body shapes without requiring complex molding or assembly processes.
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 seamless design provides enhanced comfort and support by conforming to the body, promoting sperm health and maintaining optimal genital temperature while reducing chafing and discomfort.
Implementation Method 1
The core pushes a section of the gluteal portion into the cavity such that the section is stretched from a non-stretched state to a stretched state with respect to a remaining section of the gluteal portion
Implementation Method 2
applying heat and pressure at the section to cause a volume of the synthetic compound to melt while retaining the section in the stretched state
Implementation Method 3
applying heat and pressure at the section to cause a volume of the synthetic compound to melt while retaining the section in the stretched state
Implementation Method 4
cooling the section such that a melted volume of the synthetic compound is infused or incorporated into a remainder of the section and solidified therewithin
Data Source
AI summary
A method for manufacturing a brief includes use of a first stretchable fabric and a second stretchable fabric adherable to the first stretchable fabric. The second stretchable fabric defines a gluteal portion. The second stretchable fabric is placed between a core, having a buttocks profile, and a cavity of a die assembly. The core pushes a section of the gluteal portion into the cavity. Heat and pressure are applied at the section to cause a volume of a synthetic compound of the section to melt while retaining the section in the stretched state. The section is cooled such that a melted volume of the synthetic compound is infused into a remainder of the section and solidified therewithin to cause the section to acquire a shape as that acquired in the stretched state and form a molded sac configured to accommodate and conform to buttocks of a wearer.