Seamless Tubular Brassiere via Inversion and Segmentation

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Solution Overview

Problem

Conventional brassieres often have seams that cause physical discomfort and are aesthetically unpleasing due to chafing and visibility through clothing, and the equipment used to manufacture seamless brassieres is expensive and limited in producing smaller sizes.

Innovation Solution

A circular knit tubular garment blank with a series of courses and wales is used to create a two-layer brassiere, where the blank is cut along a defined line to form a seamless design, and brassiere components are applied to the exterior before turning the blank inside out, allowing for a seamless construction that minimizes pressure points and visibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional brassiere manufacturing methods are used, then seams are created to join fabric pieces, but seams cause physical discomfort through chafing and pressure points

Engineering Contradiction:

Improveseamless constructionVSAvoidchafing and pressure points

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The brassiere is constructed from a single tubular knitted blank that is segmented only where necessary (shoulder strap area), eliminating unnecessary seams. The blank is cut into sections that are then joined minimally, creating a substantially seamless garment that prevents chafing and pressure points while maintaining structural integrity.

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If conventional brassiere manufacturing methods are used, then multiple fabric pieces are sewn together, but seams are visible through outer clothing creating aesthetic issues

Engineering Contradiction:

Improveseamless constructionVSAvoidvisibility through clothing

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The tubular blank is segmented minimally to create the brassiere structure, with cuts made only where functionally necessary. This segmentation approach eliminates visible seams that would show through outer clothing, achieving a smooth, aesthetic appearance while maintaining manufacturing feasibility.

Inventive Principle:

Principle #1Segmentation

3Object-affected harmful factors

If expensive specialized equipment is used to manufacture seamless brassieres, then seamless construction is achieved, but manufacturing cost increases significantly

Engineering Contradiction:

Improveseamless qualityVSAvoidmanufacturing cost

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The invention uses a tubular knitted blank that can be produced on standard hosiery knitting machines, which are widely available and cost-effective. This universal approach allows seamless brassiere construction without requiring expensive specialized equipment, making the process accessible to conventional manufacturers.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The tubular blank itself provides the seamless structure through its inherent circular knitting construction. The blank is designed to be self-contained and requires minimal additional processing or specialized equipment to achieve the seamless final product, eliminating the need for expensive dedicated seamless manufacturing machinery.

Inventive Principle:

Principle #25Self-service

4Object-affected harmful factors

If a tubular blank is used to create seamless brassiere, then seam-related discomfort is reduced, but the blank must be cut and assembled requiring precise positioning of components

Engineering Contradiction:

Improvechafing and pressure pointsVSAvoidassembly process

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

Brassiere components such as underwires, cups, and fasteners are attached to the tubular blank before the blank is cut and inverted. This preliminary attachment ensures proper positioning and orientation of components, simplifying the subsequent assembly process while maintaining the seamless benefits of the tubular construction.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The tubular blank is inverted inside out during assembly, allowing components to be positioned on the interior surface and then enclosed within the final garment structure. This inversion technique simplifies component positioning and assembly while maintaining the seamless exterior appearance and comfort characteristics.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS7662019B2Garment blanks, brassieres formed therefrom and method of forming the same

Publication Date: 2010.02.16 HBI BRANDED APPAREL ENTERPRISES LLC

AI summary

A circular knit garment blank is provided. The blank has an internal dimension defined by a series of courses, a length defined by a series of wales, and a first cut line. The length is sufficient to encircle a torso of a wearer. The first cut line is defined in the blank for severing the series of courses along the length.