Wearing Article Waist Opening Division for Trunks Shape
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Solution Overview
Problem
Conventional methods for manufacturing boxer shorts result in material loss and increased facility costs due to the need for cutting leg openings, which also compromise wearing comfort and appearance.
Innovation Solution
A wearing article design featuring a ring-shaped waist portion with leg openings created by dividing the waist opening using a crotch portion with shirring, eliminating the need for cutting the waist portion and incorporating a crotch elastic member to form a gusset, thereby reducing material loss and facility costs while enhancing comfort and appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If leg openings are made in the web by cutting, then the wearing article can be formed with proper leg openings, but material loss occurs and facility cost increases
Solution Approach 1:
The web is divided into multiple strips in the width direction, and leg openings are formed by separating these strips rather than cutting through the material. This segmentation approach allows leg openings to be created by dividing the web into functional sections (front outer web, back outer web, crotch outer web) without material loss.
Solution Approach 2:
Instead of creating leg openings by cutting in the plane of the web, the invention forms leg openings by separating the web into multiple strips along the width direction and joining them at the crotch portion. This dimensional approach transforms the problem from a 2D cutting operation to a 3D assembly process, eliminating material waste.
2Ease of manufacture
If leg openings are made in the web by cutting, then the wearing article can be formed with proper leg openings, but facility cost increases due to special cutting apparatus
Solution Approach 1:
The invention extracts the leg opening formation process from the cutting operation. Instead of using cutting apparatus to create leg openings, the method separates the web into strips and joins them at the crotch, thereby eliminating the need for special cutting facilities and reducing device complexity.
Solution Approach 2:
The mechanical cutting system is replaced with a joining system. Rather than using cutting apparatus to remove material, the invention uses joining means (adhesive, ultrasonic welding, or thermal bonding) to connect web strips, substituting a complex cutting mechanism with simpler joining operations.
3Ease of operation
If the crotch portion is formed with shirring, then wearing comfort and appearance are improved, but the manufacturing process becomes more complex
Solution Approach 1:
The shirring is formed in the crotch outer web before the final assembly process. By preparing the elastic member and forming shirring in advance, the manufacturing process integrates the comfort feature into the base material preparation stage, making the overall process more efficient despite the added step.
Solution Approach 2:
The invention changes the physical parameters of the crotch outer web by incorporating an elastic member and forming shirring, which alters the material's elasticity and dimensional stability. This parameter change enables the crotch portion to stretch and adapt to the wearer's body, improving comfort while the joining process integrates this modified material into the final product.
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 reduces material loss and facility costs by eliminating the need for cutting leg openings and improves wearing comfort and appearance by forming a gusset through shirring, resulting in a trunks-type shape that fits well and looks good.
Implementation Method 1
a crotch elastic member extending in the width direction of the both outer webs and joined to the both outer webs placed one on top of the other by folding the crotch outer sheet on the both sides of the crotch outer sheet
Implementation Method 2
the crotch portion is formed with shirring in which the crotch portion is let to shrink in a direction in which mutually opposing inner surfaces of the waist portion come closer to each other
Data Source
AI summary
A wearing article capable of suppressing the occurrence of a loss of materials and an increase of the cost of facilities and a method of manufacturing the same are provided. A wearing article includes a waist portion (3) formed in a ring shape capable of continuously surrounding the waist of the wearer and using one of openings as a waist opening (9), and a crotch portion (4) joined to the waist portion (3) across an opening on the opposite side to the waist opening (9) so that the crotch portion (4) and the waist portion (3) define a pair of leg openings (10) for the wearer to put through his legs individually. Shirring is formed in the crotch portion (4) so as to shorten the distance between the mutually opposing inner surfaces of the waist portion (3) connected to each other by the crotch portion (4).