Textile Functional Element Bonding via Shaped Part Recesses

Solution Overview

Problem

Existing methods for producing clothing with functional elements, such as silicone knops on children's socks, are limited by geometry constraints and inadequate adhesion to the textile main body, particularly when using silk-screen printing.

Innovation Solution

A method involving a shaped part with recesses for functional elements, where the functional-element starting material penetrates into the textile main body under pressure and temperature, forming a substance-to-substance bond, allowing for varied geometry and improved adhesion, and incorporating different Shore A-hardness and heights to create a proprioceptive stimulating effect.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If silk-screen printing process is used to produce functional elements on textile main body, then the production process is simple, but the geometry of functional elements is very much limited and adherence is barely sufficient

Engineering Contradiction:

Improveproduction process simplicityVSAvoidgeometry freedom of functional elements

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by pre-forming recesses in a shaped part that define the desired geometry of functional elements before the actual production process. The starting material is introduced into these pre-defined recesses, allowing complex geometries to be achieved without limiting the manufacturing process itself. This resolves the contradiction by preparing the mold structure in advance to enable geometric freedom during production.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent introduces a shaped part with recesses as an intermediary element between the starting material and the final functional element. This intermediary structure enables the transfer of complex geometries from the mold to the functional element, overcoming the limitations of direct silk-screen printing while maintaining production efficiency. The shaped part acts as a mediator that facilitates both geometric freedom and adequate adherence.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If silk-screen printing process is used to produce functional elements on textile main body, then the production process is simple, but adherence of functional elements to textile main body is barely sufficient

Engineering Contradiction:

Improveproduction process simplicityVSAvoidadherence of functional elements

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies preliminary action by pre-forming recesses in a shaped part that define the desired geometry of functional elements before the actual production process. The starting material is introduced into these pre-defined recesses, allowing complex geometries to be achieved without limiting the manufacturing process itself. This resolves the contradiction by preparing the mold structure in advance to enable geometric freedom during production.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent introduces a shaped part with recesses as an intermediary element between the starting material and the final functional element. This intermediary structure enables the transfer of complex geometries from the mold to the functional element, overcoming the limitations of direct silk-screen printing while maintaining production efficiency. The shaped part acts as a mediator that facilitates both geometric freedom and adequate adherence.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If functional elements are produced with varied geometry and material properties, then sensory stimulating effect is enhanced, but the production process complexity increases

Engineering Contradiction:

Improvesensory stimulating effectVSAvoidproduction process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent applies segmentation by dividing the production process into distinct stages: preparing the shaped part with recesses, introducing starting material into specific recesses, and forming functional elements with varied properties. This segmentation allows different functional elements with varied geometries and material properties to be produced systematically, enhancing sensory stimulation while keeping the overall process manageable through clear process steps.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies local quality by enabling different functional elements to have different geometries, material compositions, and physical properties (such as hardness, elasticity, or temperature) depending on their specific recess in the shaped part. This allows tailored sensory stimulation for different body regions while maintaining a unified production process framework, thus achieving versatility without excessive complexity.

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

The method enables the production of clothing with functional elements that provide a sensory stimulating effect by varying pressure on the wearer's body, preventing habituation and ensuring effective adhesion, thus overcoming geometry and adhesion limitations of previous techniques.

Implementation Method 1

the functional-element starting material penetrates into the textile main body due to the process of bringing the shaped part and the textile main body into contact and subsequently, preferably under the effect of a raised pressure and/or a raised temperature, it sets

Methodology Applied

Scientific EffectPenetration under pressure: Pressure Increase

Implementation Method 2

the functional-element starting material penetrates into the textile main body due to the process of bringing the shaped part and the textile main body into contact and subsequently, preferably under the effect of a raised pressure and/or a raised temperature, it sets

Methodology Applied

Scientific EffectSetting: Phase Change

Data Source

PatentUS11357267B2Method for producing an article of clothing and an article of clothing

Publication Date: 2022.06.14 FALKE KGAA

AI summary

In order to provide a method for producing an article of clothing, which comprises a textile main body and functional elements arranged on the textile main body, which offers a large degree of design freedom with regard to the geometry of the functional elements and ensures good adhesion of the functional elements to the textile main body, it is proposed that the method comprises the following:producing the textile main body;providing a shaped part having at least one functional-element recess for accommodating a functional-element starting material;introducing the functional-element starting material into the at least one functional-element recess;bringing the shaped part, which is provided with the functional-element starting material, and the textile main body into contact;producing at least one functional element connected to the textile main body in a substance-to-substance bonded manner from the functional-element starting material.