Variable Depth Die Cut for Elastic Kinesiology Tape
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Solution Overview
Problem
The manufacture and application of kinesiology tape face challenges such as difficulty in cutting due to its elastic nature, issues with adhesive application leading to moisture retention and poor printing quality, making it inconvenient for consumers to use effectively.
Innovation Solution
A continuous feed variable depth die cut system for precise cutting of kinesiology tape, an adhesive applying device with a comb for controlled adhesive application, and a printing device using a woven mesh stencil to prevent ink bleeding, enabling efficient production and application of kinesiology tape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional die cutting methods are used to cut kinesiology tape into individual strips, then the tape can be divided into usable portions, but the production process must stop during cutting and precision is difficult to achieve due to elastic thread thickness variations
Solution Approach 1:
The cutting system transitions from static traditional die cutting to dynamic rotary blade cutting. The rotary blade rotates at high speed to match the tape feed rate, enabling continuous cutting without stopping production. The blade depth is dynamically adjustable to compensate for elastic thread thickness variations, maintaining cutting precision while ensuring production continuity.
Solution Approach 2:
The cutting method changes from intermittent traditional die cutting to continuous rotary blade cutting with variable blade depth. The blade depth parameter can be adjusted to accommodate thickness variations in elastic threads, while the cutting speed and feed rate parameters are synchronized to maintain precision during continuous operation.
2Reliability
If a solid coating of adhesive is applied to kinesiology tape, then the tape adheres well to skin, but the material cannot breathe and moisture is retained causing the tape to fall off
Solution Approach 1:
The adhesive coating transitions from a uniform solid layer to a patterned structure with varying local densities. The comb-shaped applicator creates regions of different adhesive thickness and porosity, allowing moisture vapor to escape through less dense areas while maintaining strong adhesion in denser regions. This local quality variation resolves the contradiction between adhesion strength and breathability.
Solution Approach 2:
The adhesive coating is designed with porous characteristics through the comb-shaped application pattern. The pattern creates micro-channels and varying density regions that allow moisture vapor transmission while maintaining adhesive bonding. This porous structure enables the tape to adhere reliably while allowing the skin to breathe.
3Ease of manufacture
If adhesive is applied in straight tracks, then the application process is simple, but the tape becomes susceptible to forces pushing across the tracks
Solution Approach 1:
The adhesive pattern transitions from symmetric straight tracks to an asymmetric comb-shaped pattern with teeth of varying lengths and angles. This asymmetric design creates interlocking features that resist forces pushing across the tracks in multiple directions, while the comb structure remains simple to manufacture using a comb-shaped applicator.
Solution Approach 2:
The comb-shaped adhesive pattern introduces curved and angled elements compared to straight tracks. The teeth of the comb create a more complex geometry that better distributes and resists applied forces, while the overall comb structure maintains manufacturing simplicity through its regular repeating pattern.
4Illumination intensity
If too much ink is applied to kinesiology tape during printing, then the printing is visible, but the ink smudges and bleeds through the porous material
Solution Approach 1:
The printing process uses a controlled amount of ink that is partially absorbed by the porous tape and partially remains on the surface. The comb-shaped adhesive pattern provides a structured framework that contains the ink, allowing sufficient visibility without excessive ink application that would cause smudging and bleeding.
5Productivity
If kinesiology tape is sold in large rolls, then storage and transport are efficient, but consumers must carry sharp cutting tools and struggle to cut the elastic tape accurately
Solution Approach 1:
The continuous tape is segmented into pre-cut strips with adhesive patterns during manufacturing. This segmentation provides consumers with ready-to-use portions that eliminate the need for cutting tools and accurate cutting skills, while the adhesive patterns ensure proper application. Storage efficiency is maintained by manufacturing in large rolls and segmenting during production.
Data Source
AI summary
An embodiment of the invention includes a continuous feed variable depth die cut for use in cutting kinesiology tape. The die cut includes a housing, including a first opening configured to allow the kinesiology tape to enter the housing and a second opening configured to allow the kinesiology tape to exit the housing. The die cut also includes a roller inside the housing, wherein the roller is configured to rotate as the kinesiology tape passes over the roller and a die formed on the outer surface of the roller, wherein the die includes a cutting edge for cutting the kinesiology tape and wherein the cutting edge is formed in the shape of the strip of kinesiology tape to be cut. The die cut further includes a surface inside the housing, wherein the kinesiology tape passes over the surface when the kinesiology tape is being cut.