Vacuum-Formed Fabric Items with Polymer Layers

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Solution Overview

Problem

Existing methods for forming three-dimensional fabric-based items, such as bags and electronic device cases, often result in seams that are visually unappealing and create weak points, while compression molding can damage the fabric's texture and appearance.

Innovation Solution

Vacuum-forming technology is used to shape fabric-based items by heating a polymer layer until it becomes soft, then using a vacuum tool to conform the item to a mold, allowing the polymer to harden and hold the fabric's shape, while selectively applying heat or blocking air openings to vary texture and rigidity across regions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If fabric is cut and joined at the edges to form three-dimensional shapes, then the desired shape can be achieved, but seams are created that are visually unappealing and create weak points

Engineering Contradiction:

Improvethree-dimensional shapeVSAvoidstructural strength

Core Design Contradiction:

ShapeVSStrength

Solution Approach 1:

The patent combines multiple fabric pieces into a single continuous piece of fabric that is then vacuum-formed into the desired three-dimensional shape. This merging approach eliminates the need for cutting and joining separate pieces, thereby removing seams and the associated weak points while maintaining structural integrity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces the mechanical system of cutting and stitching fabric pieces with a vacuum-forming process. By using vacuum pressure and heat to mold a single piece of fabric into the desired shape, the need for mechanical joining methods that create seams is eliminated, resulting in a stronger, seam-free structure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Shape

If compression molding is used to reduce seams, then the number of seams is reduced, but the texture and appearance of the fabric are compromised

Engineering Contradiction:

Improvethree-dimensional shapeVSAvoidfabric texture damage

Core Design Contradiction:

ShapeVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a polymer coating as an intermediary layer between the fabric and the mold during vacuum-forming. This polymer layer allows the fabric to conform to the mold's three-dimensional shape without direct compression contact, thereby preserving the fabric's original texture and appearance while still achieving the desired shape.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent uses vacuum pressure (pneumatics) to form the fabric shape instead of compression molding. By applying negative pressure to pull the fabric conformally onto the mold, the process avoids the compressive forces that damage fabric texture, while still achieving seamless three-dimensional shaping.

Inventive Principle:

Principle #29Pneumatics and hydraulics

3Ease of manufacture

If compression molding is used to form three-dimensional shapes, then seams are reduced, but surface deformations occur that compromise the original look and feel of the fabric

Engineering Contradiction:

Improveseam reductionVSAvoidsurface deformation

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the compression molding mechanical system with a vacuum-forming system. Instead of applying compressive force that deforms the fabric surface, the vacuum-forming process uses negative pressure to gently pull the fabric into the desired shape, eliminating surface deformations while maintaining ease of manufacture and seam reduction.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

This method reduces seams, preserves the fabric's original texture and appearance, and allows for varying flexibility and structure, creating seamless three-dimensional shapes without compromising the fabric's integrity.

Implementation Method 1

the fabric based item may be heated until the polymer layer reaches a forming temperature and becomes soft and pliable

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

When heated, a vacuum tool is used to pull the fabric-based item onto a mold

Methodology Applied

Scientific EffectVacuum: Vacuum

Implementation Method 3

As the fabric-based item cools on the mold, the polymer material hardens into the shape imparted by the mold

Methodology Applied

Scientific EffectCooling: Cooling

Data Source

PatentUS10286636B1Fabric-based items with three-dimensional shapes

Publication Date: 2019.05.14 APPLE INC

AI summary

A fabric-based item may be vacuum-formed into a three-dimensional shape. The fabric-based item may include one or more layers of fabric and one more polymer layers that can be molded when heated. To vacuum-form the fabric-based item into a three-dimensional shape, the fabric based item may be heated until the polymer layer reaches a forming temperature and becomes soft and pliable. When heated, a vacuum tool is used to pull the fabric-based item onto a mold so that the fabric-based item conforms to the shape of the mold. As the fabric-based item cools on the mold, the polymer material hardens into the shape imparted by the mold. The polymer material is able to hold the fabric layers in this shape after the layers are removed from the mold.