Variable Adhesive Zones for Garment Breathability and Support

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Solution Overview

Problem

Existing garments with adhesive layers between plies are uncomfortable due to restricted heat and perspiration escape, lack flexibility, and require uniform adhesive application, leading to unnecessary material and labor costs.

Innovation Solution

A method for applying adhesive to garments in variable zones with different thicknesses and weights to provide structural support, breathability, and flexibility, using a spray device to apply a polyurethane or polyamide adhesive layer with specific zones for controlled porosity and thickness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a uniform adhesive layer is applied to the entire garment, then structural support is provided, but breathability and flexibility are reduced

Engineering Contradiction:

Improvestructural supportVSAvoidrestricted heat and perspiration escape

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent applies adhesive only in specific zones where structural support is needed (waistband, leg openings, armholes) rather than uniformly across the entire garment. This localized application maintains garment flexibility and breathability in non-adhesive areas while providing necessary support in critical zones.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The adhesive application is divided into multiple discrete zones (first zone, second zone, third zone) with different adhesive amounts. The waistband receives adhesive in a first zone, leg openings in a second zone, and armholes in a third zone, allowing differentiated structural support across garment regions.

Inventive Principle:

Principle #1Segmentation

2Strength

If a thick adhesive layer is applied, then structural support is improved, but garment flexibility and comfort are reduced

Engineering Contradiction:

Improvestructural supportVSAvoidgarment flexibility

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

Different adhesive thicknesses are applied to different zones: a first thickness at the waistband for maximum support, a second thickness at leg openings, and a third thickness at armholes. This gradient approach provides necessary structural support while maintaining flexibility in areas requiring movement.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The adhesive thickness parameter is varied across different garment zones to optimize both structural support and flexibility. By changing the thickness parameter locally rather than uniformly, the garment achieves balanced performance in both support and comfort.

Inventive Principle:

Principle #35Parameter changes

3Strength

If adhesive is applied to all areas of the garment, then uniform structural support is achieved, but manufacturing costs and material usage increase

Engineering Contradiction:

Improveuniform structural supportVSAvoidadhesive material and labor

Core Design Contradiction:

StrengthVSLoss of substance

Solution Approach 1:

Adhesive application is extracted from being a universal process applied to the entire garment and is instead selectively applied only to specific zones requiring structural support. This eliminates unnecessary adhesive material usage and reduces application labor in areas where support is not needed.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent implements differentiated adhesive application where the amount and presence of adhesive varies by zone. High-support areas (waistband) receive more adhesive, while lower-support areas receive less or none, optimizing material usage based on local structural requirements.

Inventive Principle:

Principle #3Local quality

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 enhances comfort by allowing heat and perspiration escape, maintains flexibility, and reduces material and labor costs by applying adhesive only where needed, providing structural support and breathability in specific areas.

Implementation Method 1

using a spray device to apply a polyurethane or polyamide adhesive layer with specific zones for controlled porosity and thickness

Methodology Applied

Scientific EffectSpray: Spray

Implementation Method 2

The adhesive may be any heat setting adhesive known in the art. The adhesive is applied and the ply is heated or allowed to dry to connect the ply to another second ply

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 3

the adhesive is applied to some areas for structure and not applied to other areas for increased porosity

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 4

The adhesive layer has a plurality of different zones each having a different amount of adhesive therein

Methodology Applied

Scientific EffectPorosity: Porosity

Data Source

PatentUS12035760B2Methods for controlled application of adhesive and garments formed thereby

Publication Date: 2024.07.16 HBI BRANDED APPAREL ENTERPRISES LLC

AI summary

A method of manufacturing a garment is provided that includes applying an adhesive layer to a first ply and/or a second ply in a first amount in a first zone where structural support is desired and in a second amount in a second zone where breathability is desired; arranging the first and second plies with respect to one another so that the adhesive layer is therebetween; and activating the adhesive layer to secure the first and second plies to one another.