Apparel Protective Element Thinned Plate Attachment

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The existing methods for attaching multiple layers of dissimilar materials in athletic apparel protective elements are time-consuming and require expensive manual labor, necessitating a more efficient design for securing plate and cushioning components.

Innovation Solution

A protective element design that secures a plate component to a cushioning component using stitching or staples through a thinned portion of the plate, with a guide pattern on the cushioning component to facilitate accurate positioning and attachment, and an attachment area on the plate component to simplify the assembly process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional methods are used to attach multiple layers of dissimilar materials, then secure attachment is achieved, but assembly time increases and labor costs increase

Engineering Contradiction:

Improveattachment reliabilityVSAvoidassembly speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The plate component is pre-formed with an integrated attachment area that has a thinned portion, preparing the attachment zone in advance before the assembly process begins. This preliminary preparation eliminates the need for post-manufacturing modifications and enables faster assembly while maintaining secure attachment through the pre-configured thinned region that facilitates easier penetration by attachment elements.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The plate component features a localized thinned portion specifically at the attachment area, while the rest of the plate maintains its full thickness and structural integrity. This local modification allows attachment elements to pass through more easily at the attachment zone without compromising the overall strength and rigidity of the plate, thus enabling faster assembly while preserving attachment reliability.

Inventive Principle:

Principle #3Local quality

2Reliability

If traditional methods are used to attach multiple layers of dissimilar materials, then secure attachment is achieved, but labor cost increases

Engineering Contradiction:

Improveattachment reliabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The attachment area is integrated directly into the plate component as a single molded feature, combining the plate structure and attachment interface into one unified element. This merging eliminates the need for separate attachment hardware or complex multi-step assembly processes, thereby reducing manufacturing complexity and labor costs while maintaining secure attachment through the integrated thinned portion.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The local thickness parameter of the plate is modified at the attachment area to create a thinned portion, changing the physical parameter from uniform thickness to variable thickness. This parameter change facilitates easier penetration by attachment elements, simplifying the manufacturing and assembly process while ensuring reliable attachment without requiring complex manual labor.

Inventive Principle:

Principle #35Parameter changes

3Strength

If the plate component has uniform thickness, then structural integrity is maintained, but attachment process becomes more difficult

Engineering Contradiction:

Improveplate strengthVSAvoidattachment ease

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS9149084B2Apparel incorporating a protective element and method for making

Publication Date: 2015.10.06 NIKE INC

AI summary

Protective elements for an article of apparel may include a plate component and a cushioning component that are secured together by stitching which passes through the plate component. The cushioning component may include a pair of material layers and at least one pad located between the material layers. The plate component may include a polymer material and the pad may include a polymer foam material, with the polymer material of the plate element having greater rigidity and density than the polymer foam material of the pads. An attachment area may be formed on an outer perimeter of the plate component that is provided with a reduced thickness relative to adjacent areas of the plate component. An attachment element may be passed through the attachment area and at least one layer of the cushioning component thereby attaching the plate component to at least the one layer.