Torso Garment Band Integration via Elastomeric Film
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Solution Overview
Problem
Conventional methods for forming chest and waist bands in upper and lower torso garments, such as brassieres and briefs, result in bulky and thick bands that are less comfortable and more visible when worn, often requiring additional labor and increasing costs.
Innovation Solution
A circularly knitted garment with a thin elastomeric band affixed between overlapping plies of fabric, utilizing a thin polyamide film or thermoplastic elastomer with a high modulus to create a stiffer and more resistant band, which is integrated during the knitting process and secured using temperature and pressure, resulting in a thinner and more comfortable band.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional elastomeric band is stitched to the garment edge, then the band provides support and stability, but the band becomes bulky and thick, increasing visibility and reducing comfort
Solution Approach 1:
The elastomeric band is merged with the knitted fabric by integrating it directly into the knitting structure during the knitting process, eliminating separate stitching operations. This integration allows the band to be formed as part of the fabric itself, reducing overall band thickness while maintaining support functionality.
Solution Approach 2:
The patent uses a thin elastomeric band that functions as a flexible film integrated within the knitted structure. This thin film approach provides the necessary support and stability without the bulk associated with conventional stitched bands, directly addressing the contradiction between strength and volume.
2Strength
If an elastomeric band is stitched around the entire periphery, then the band provides encircling support, but additional labor and increased costs are required
Solution Approach 1:
The elastomeric band formation is merged with the knitting process itself. The band is created as an integral part of the knitted fabric structure during normal production, eliminating the need for separate stitching operations around the periphery. This integration significantly reduces labor requirements and manufacturing costs while maintaining encircling support.
Solution Approach 2:
The knitting machine performs multiple functions simultaneously - it knits the fabric and forms the elastomeric band in the same process. The band formation is essentially a self-service function of the knitting process, requiring no additional manufacturing steps or labor beyond the base knitting operation.
3Stability of the object's composition
If a turned welt is knitted during fabric production, then the band is integrated into the fabric, but the band becomes relatively bulky and thick
Solution Approach 1:
Instead of using a traditional turned welt structure that creates bulk, the patent employs a thin elastomeric band integrated within the knitted fabric layers. This thin film approach maintains the stability and integration benefits of a knitted-in band while dramatically reducing the band thickness and associated bulk.
Solution Approach 2:
The patent changes the structural parameters of the band from a bulky turned welt to a thin elastomeric configuration. By altering the band's physical form and material properties while maintaining its integration into the fabric, the solution achieves both fabric stability and reduced thickness.
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 solution provides a thinner, less visible, and more comfortable torso band with improved support and control, maintaining elasticity and durability across a range of sizes and wear conditions, while reducing production costs and labor.
Implementation Method 1
The elastomeric band is affixed to one or both of the inner and outer layers of knitted fabric by the application of temperature and pressure for a selected amount of time
Data Source
AI summary
A torso garment, such as a brassiere or brief, includes a body formed of inner and outer layers, the body including at least one torso band extending from a portion of the body, where the inner and outer layers overlap along a fold line of the torso garment. The torso garment includes an elastomeric band positioned between the inner and outer layers proximate the fold line.