Sonic Welding Fabric for 3D Costume Components

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Solution Overview

Problem

Current methods for manufacturing three-dimensional costume garments with anatomical shapes face challenges such as rigidity, discomfort, misalignment of stitching, and increased foam thickness, leading to a clumsy and expensive production process that fails to provide a realistic and comfortable three-dimensional look.

Innovation Solution

The process involves sonic welding of fabric to underlying foam, creating crisp and smooth boundary lines that define three-dimensional areas without the need for thermal or vacuum forming, using a central foam filler sandwiched between fabric layers, with graphic lines guiding the welding process for precise and comfortable integration into costumes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If thermal or vacuum molding is used to create three-dimensional costume components, then the fabric can be formed into anatomical shapes, but the front portion becomes too rigid and heavy for comfortable wear

Engineering Contradiction:

Improvethree-dimensional anatomical shapeVSAvoidweight of costume component

Core Design Contradiction:

ShapeVSWeight of moving object

Solution Approach 1:

The patent changes the physical state and bonding parameters by using sonic welding instead of thermal molding. This creates a lighter foam structure that is bonded to fabric through controlled sonic welding along guide lines, reducing the overall weight while maintaining the three-dimensional anatomical shape needed for costume realism

Inventive Principle:

Principle #35Parameter changes

2Shape

If stitching is used to define muscle boundaries, then three-dimensional areas can be created, but the stitching lines become misaligned and the appearance becomes clumsy

Engineering Contradiction:

Improvedefined muscle boundariesVSAvoidalignment of boundary lines

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

The patent replaces the mechanical stitching system with a sonic welding system guided by printed guide lines. The sonic welder follows the graphic lines on the fabric to create precise, consistent boundary lines that define muscle areas without misalignment, eliminating the clumsiness associated with traditional stitching

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces graphic lines as an intermediary element that guides the sonic welding process. These printed lines serve as a template or mediator between the desired muscle boundary design and the actual welding execution, ensuring precise alignment and consistent appearance

Inventive Principle:

Principle #24Intermediary (Mediator)

3Volume of moving object

If foam thickness is increased to provide three-dimensional relief, then more volume and realism are achieved, but the costume component becomes heavier and more cumbersome

Engineering Contradiction:

Improvevolume of foam materialVSAvoidcomfort of wear

Core Design Contradiction:

Volume of moving objectVSEase of operation

Solution Approach 1:

The patent optimizes the foam density and thickness parameters to achieve the desired three-dimensional volume while controlling weight. By using sonic welding to create defined boundary areas, the foam can be thinner overall while still providing sufficient relief and realism where needed, improving comfort for the wearer

Inventive Principle:

Principle #35Parameter changes

4Shape

If traditional thermal forming is used to create three-dimensional costume components, then anatomical shapes can be formed, but the production process becomes expensive and time-consuming

Engineering Contradiction:

Improveanatomical formVSAvoidproduction speed

Core Design Contradiction:

ShapeVSProductivity

Solution Approach 1:

The patent replaces the complex thermal forming process with a simpler sonic welding process. The foam is cut to shape and bonded to fabric using sonic welding along guide lines, eliminating the need for expensive thermal forming equipment and reducing production time while still achieving the desired anatomical shapes

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 results in lightweight, comfortable, and cost-effective costume components with well-defined three-dimensional features, providing a realistic and aesthetically pleasing appearance without the discomfort of stitches and reduced production time.

Implementation Method 1

a sonic welding device for welding selected lines of the outside fabric layer 14 to the foam layer 12

Methodology Applied

Scientific EffectSonic welding: Ultrasonic Vibration

Data Source

PatentUS9445632B2Sonic welding of fabric for 3-D costume components

Publication Date: 2016.09.20 RUBIES II LLC

AI summary

A three dimensional component for a costume, intended to simulate a three-dimensional body part or other object, comprises an inner soft or cushiony layer of foam, an outer fabric layer, a graphic printed upon the outer layer, and a sonic or ultra high frequency welding of the outer layer to the cushiony layer along the lines defined by the graphic. The sonic well will compress the foam to the fabric and the non-compressed foam and fabric sections will visually and physically provide relatively three dimensional areas.