Textile Packaging Using Flat Core Recesses to Prevent Sock Damage
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Solution Overview
Problem
The existing packaging methods for sports socks in large-scale retail, which use T-end fasteners and cores, often result in sock damage and needle breakage due to the large diameter of the applicator needle and the need for perforating the core, leading to significant flaws in the packaging process.
Innovation Solution
A packaging system that eliminates the use of the applicator needle by employing a flat core with recesses and a small polymeric band to secure the piles of socks, allowing for tension adjustment without damaging the socks and avoiding core perforation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hollow needle with large diameter is used to apply T-end fasteners, then the fastener can be securely held and applied, but the needle breaks threads and causes sock damage
Solution Approach 1:
The patent extracts and eliminates the hollow needle from the fastener application system. Instead of using a needle to apply T-end fasteners, the invention uses a band with integrated fastening elements that can be applied without piercing the textile, thereby removing the source of thread breakage while maintaining fastener security
Solution Approach 2:
The patent introduces a band as an intermediary element between the piles of textile articles. This band serves as the medium for securing the articles together without requiring direct penetration through the fabric, thus avoiding damage while achieving the desired fastening function
2Strength
If the core is made strong enough to support the pack weight, then the hook can hold the multi-pack, but the needle has considerable unsupported length causing buckling and breakage
Solution Approach 1:
The patent eliminates the needle from the system entirely, removing the buckling and breakage problems associated with long unsupported needle lengths. The fastening function is achieved through the band mechanism without requiring needle penetration through the strong core
Solution Approach 2:
The band is pre-formed with integrated fastening elements before application. This preliminary preparation allows the band to be secured around the piles without requiring real-time needle application, avoiding the stability issues of long needles while maintaining strong fastening capability
3Strength
If T-end fasteners are used to join multiple pairs of socks, then the multi-pack is securely held together, but the socks are often irreparably damaged during application
Solution Approach 1:
The band acts as an intermediary that secures the multi-pack without directly damaging the socks. Instead of using needles that pierce and break threads, the band wraps around and holds the piles together, maintaining binding strength while protecting the textile integrity
Solution Approach 2:
The patent replaces the mechanical needle-based fastening system with a band-based wrapping system. This substitution eliminates the piercing action that causes damage while maintaining the securing function through friction and tension in the band
Data Source
AI summary
The present invention relates to packaging 10 for textile articles 12. The packaging comprises: a plurality of textile articles overlapping in an X stacking direction, forming at least one pile 14; a flat core 16 arranged substantially perpendicular to the X stacking direction, wherein the flat core comprises recesses 18 along a pair of sides 160; and a small band 20, which surrounds the at least one pile of textile articles and the flat core. In the packaging according to the invention, the band is tied around the pile so as to keep it together and it is received in the recesses of the flat core. The invention also relates to a method for packaging textile articles.