Stretchable laminates

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Solution Overview

Problem

Conventional stretchable laminates incorporating non-elastic textiles often exhibit a rough or uneven appearance in the non-stretched state, leading to poor aesthetics and customer acceptance, due to issues like bunching, rippling, and buckling, which complicates their integration into garments and footwear.

Innovation Solution

The development of stretchable laminates featuring a textile layer with a non-elastic material and a functional layer, where elastic fibers are strategically arranged in a substantially parallel manner between or adjacent to the textile and functional layers, ensuring an average normalized surface roughness of less than 25 micrometers to maintain a flat appearance without buckling or non-uniformities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If non-elastic textiles are used in stretchable laminates, then stretchability is achieved, but surface appearance deteriorates with bunching, rippling, and buckling

Engineering Contradiction:

ImprovestretchabilityVSAvoidsurface appearance

Core Design Contradiction:

Adaptability or versatilityVSShape

Solution Approach 1:

The patent applies local quality by using elastic fibers only in specific strategic locations rather than throughout the entire textile. The elastic fibers are positioned at high-stress areas such as panel seams and curvature zones where stretch is most needed, while other areas maintain the non-elastic textile's flat appearance. This localized approach allows the garment to achieve stretchability where required without compromising the overall surface appearance.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent employs composite materials by combining non-elastic textile layers with strategically placed elastic fibers. This creates a hybrid structure where the non-elastic textile provides the base fabric with good drape and appearance, while the elastic fibers provide localized stretch capability. The composite construction allows both properties to coexist without the drawbacks of fully elastic textiles.

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If elastic fibers are added to provide stretch, then form-fitting capability is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveform-fitting capabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent applies segmentation by dividing the elastic fiber placement into discrete, separate locations rather than distributing them uniformly. Elastic fibers are placed in specific segments or zones where stretch is most needed, such as at panel seams and high-curvature areas. This segmented approach simplifies manufacturing compared to uniform distribution, as fibers can be inserted at specific points during assembly rather than requiring complex pre-distribution mechanisms.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent uses an intermediary approach by incorporating elastic fibers as separate insertable elements rather than integrating them into the textile structure itself. The elastic fibers act as intermediary components that can be added during the garment assembly process, allowing manufacturers to insert them into pre-formed textile panels. This mediator approach simplifies manufacturing by decoupling the textile production from the elastic fiber insertion.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If uniform elastic fiber distribution is used, then stretchability is improved, but surface flatness deteriorates

Engineering Contradiction:

ImprovestretchabilityVSAvoidsurface flatness

Core Design Contradiction:

Adaptability or versatilityVSShape

Solution Approach 1:

Inventive Principle:

Principle #3Local quality

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 configuration provides a flat and aesthetically appealing surface on the textile layer opposite the functional layer, enhancing the appearance of form-fitting garments and allowing for improved integration into garments and footwear without compromising stretchability or breathability.

Implementation Method 1

a plurality of elastic fibers, having an adjacent fiber spacing distance, disposed in a substantially parallel arrangement on at least one of the textile and/or the functional layer

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

a functional layer disposed on at least one surface of the textile layer

Methodology Applied

Scientific EffectHydrophobicity: Hydrophobe

Implementation Method 3

vapor-permeable laminates

Methodology Applied

Scientific EffectPermeation: Permeation

Data Source

PatentUS11518139B2Stretchable laminates

Publication Date: 2022.12.06 WL GORE & ASSOC INC

AI summary

The present invention provides stretchable laminates with a flat appearance on the visible surface. The laminates comprise a textile layer, a functional layer, and a plurality of elastic fibers. The plurality of elastic fibers are in a substantially parallel arrangement and the internal distance between adjacent fibers does not exceed the maximum fiber spacing, which depends on laminate thickness in a stretched state. Also provided are garments and footwear comprising the stretchable laminates and methods of producing the stretchable laminates.