System and method for winding wire on a movable anchor

Abstract

A method of manufacturing an article of apparel includes forming a thread layer by winding a continuous thread around a plurality of protrusions movably coupled to a support plate. The protrusions may be arranged around the winding area such that the wire layer includes a plurality of wire rows extending between two respective protrusions and across the winding area. After the wire layer is wound on the winding area, at least some of the protrusions can move relative to the area to allow the wire layer to be removed from the support plate.

Description

Technical Field

[0001] The described embodiments generally relate to clothing and methods of making clothing. In particular, the described embodiments relate to clothing including layers made by winding one or more continuous threads around an anchor point. Background Art

[0002] Clothing can be made from a variety of materials using a variety of techniques including weaving and knitting. People generally care about the durability, comfort, and / or performance characteristics of clothing items. This is true for clothing worn for both athletic and non-athletic activities. Appropriate clothing should be durable, comfortable, and provide other beneficial characteristics for an individual. Accordingly, there is a continuing need for innovation in clothing and methods of clothing manufacture to fit an individual in a range of usage scenarios. In particular, there is a need for methods of making materials for clothing that have customizable characteristics but can be effectively manufactured in large quantities and / or large sizes. Summary of the Invention

[0003] A first embodiment (1) of the present application relates to a method of manufacturing a clothing item. The method can include forming a layer of threads by winding a continuous thread around a plurality of protrusions disposed on a support plate. The support plate can include a winding area, and the protrusions are arranged around the winding area and slope away from the winding area. The layer of threads can include a plurality of rows of threads, where each row of threads extends between two corresponding protrusions and spans the winding area. The method can include moving at least some of the protrusions relative to the area. The method can include: after moving at least some of the protrusions relative to the area, removing the layer of threads from the support plate.

[0004] In a second embodiment (2) according to embodiment (1), the method can include: before removing the layer of threads from the support plate, connecting the rows of threads to each other.

[0005] In a third embodiment (3) according to the first embodiment (1) or the second embodiment (2), the method can include: before moving at least some of the protrusions relative to the area, connecting the rows of threads to each other.

[0006] In a fourth embodiment (4) according to any one of embodiments (1)-(3), the protrusions can be pivotally connected to the support plate, and moving at least some of the protrusions relative to the area includes pivoting the protrusions towards the area.

[0007] In a fifth embodiment (5) according to the fourth embodiment (4), the support plate can include a hinge that pivotally connects the protrusions to a base of the support plate.

[0008] In a sixth embodiment (6) according to the fourth embodiment (4) or the fifth embodiment (5), each protrusion can pivot relative to a base of the support plate.

[0009] In a seventh embodiment (7) according to any one of embodiments (4)-(6), the wire layer can be removed from the support plate along the direction of the disassembly axis. And when the protrusions are tilted away from the winding area, the protrusions can each extend further away from the disassembly axis as the distance from the base of the support plate increases.

[0010] In an eighth embodiment (8) according to the seventh embodiment (7), when the protrusions are tilted away from the area, the respective tilt angles of each protrusion can be defined between the protrusion and the disassembly axis. And pivoting the protrusions towards the area can include reducing the tilt angle.

[0011] In a ninth embodiment (9) according to any one of embodiments (4)-(8), the method can include: after pivoting one of the protrusions towards the area, removing the wire layer from one of the protrusions.

[0012] In a tenth embodiment (10) according to any one of embodiments (1)-(9), the method can include: removing the wire layer from at least the first of the protrusions before moving at least the second of the protrusions.

[0013] In an eleventh embodiment (11) according to any one of embodiments (1)-(10), the article of clothing can include an upper of a footwear item.

[0014] In a twelfth embodiment (12) according to any one of embodiments (1)-(11), the support plate can include one or more sliding mechanisms that movably couple the protrusions to the base of the support plate.

[0015] In a thirteenth embodiment (13) according to the twelfth embodiment (12), the method can include forming a wire layer when the sliding mechanism is in a first position. The method can include joining continuous wires within the wire layer while the sliding mechanism remains in the first position. The method can include changing the tension on the continuous wires by moving the sliding mechanism to a second position after joining the continuous wires. And the method can include winding a second wire layer around the plurality of protrusions while the sliding mechanism remains in the second position.

[0016] A fourteenth embodiment (14) of the present invention relates to a support plate for manufacturing an upper of a footwear item. The support plate can include protrusions movably connected to the support plate. The protrusions can be arranged to define a perimeter of an area that - has a flat upper shape of the footwear item.

[0017] In a fifteenth embodiment (15) according to the fourteenth embodiment (14), each protrusion can include a pin.

[0018] In a sixteenth embodiment (16) according to the fourteenth embodiment (14) or the fifteenth embodiment (15), the support plate may include a hinge that pivotally couples one or more respective protrusions to a base of the support plate.

[0019] In a seventeenth embodiment (17) according to any one of embodiments (14)-(16), the support plate may include a slider that movably couples one or more respective protrusions to a base of the support plate.

[0020] In an eighteenth embodiment (18) according to any one of embodiments (14)-(17), the winding region may include two wings joined by a bridge.

[0021] A nineteenth embodiment (19) of the present invention relates to a system for manufacturing an article of clothing. The system may include a support plate that includes protrusions movably connected to the support plate. The protrusions may be arranged to define a perimeter of a winding region on the support plate. The system may include a winding machine configured to wind a continuous line around a plurality of protrusions to form a layer of lines including a plurality of line rows, wherein each line row extends between two corresponding protrusions and spans the winding region.

[0022] In a twentieth embodiment (20) according to the nineteenth embodiment (19), the system may include an actuator configured to move the protrusions on the support plate relative to the winding region. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 A winding system according to some embodiments is shown.

[0024] Figure 2A And Figure 2B A cross-section of a winding plate according to some embodiments is schematically shown.

[0025] Figure 2C And Figure 2D Schematically shows a Figure 2A And Figure 2B cross-section of a winding plate in a stage of the connection process according to some embodiments.

[0026] Figure 3 A cross-section of a winding plate according to some embodiments is schematically shown.

[0027] Figure 4 A cross-section of a winding plate according to some embodiments is schematically shown.

[0028] Figure 5 A cross-section of a winding plate according to some embodiments is schematically shown.

[0029] Figure 6A AndFigure 6B Schematically shows a part of a winding plate according to some embodiments.

[0030] Figure 6C Shows Figure 6A and Figure 6B the winding plate of.

[0031] Figure 7A Shows a winding plate according to some embodiments.

[0032] Figure 7B Schematically shows Figure 7A a cross-section of a part of the winding plate of.

[0033] Figure 7C and Figure 7D Schematically shows Figure 7A the cross-section of the winding plate of.

[0034] Figure 8 Shows a winding plate according to some embodiments.

[0035] Figure 9A and 9B Shows a wire layer according to some embodiments.

[0036] Figure 10 Shows a schematic block diagram of an exemplary computer system in which various embodiments can be implemented. Detailed Description

[0037] The present invention will now be described in detail with reference to embodiments of the invention as shown in the accompanying drawings. When referring to "some embodiments", "an embodiment", "embodiments", "exemplary embodiments", etc., it is meant that the described embodiments may include a particular feature, structure, or characteristic, but each embodiment does not necessarily include the particular feature, structure, or characteristic. Moreover, these phrases do not necessarily refer to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is considered within the knowledge of those skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments, whether or not explicitly described.

[0038] The indefinite articles "a / an" and "the" include plural referents unless there is an obvious contradiction or the context clearly dictates otherwise.

[0039] The term "comprising" is an open transitional phrase. The list of elements after the transitional phrase "comprising" is non-exclusive, such that elements other than those specifically recited in the list may also be present.

[0040] As used herein, unless otherwise specified, references to "first", "second", "third", "fourth", etc. are not intended to denote order, or that a feature with a higher number requires a feature with a lower number. Additionally, unless otherwise specified, the use of "first", "second", "third", "fourth", etc. does not necessarily mean that the "first", "second", "third", "fourth", etc. features have different characteristics or values.

[0041] As used herein, a "thread" refers to a material having a length significantly greater than its width. A "thread" can be a filament, fiber, yarn, cable, rope, tow, tape, ribbon, monofilament, fabric, string, plied yarn, and other forms of material that can be wound and laid in a thread pattern as described herein.

[0042] As used herein, "apparel" can be any item worn or used to adorn an individual, including clothing and accessories. Clothing can include, but is not limited to, pants, shorts, leggings, socks, shoes, shoe uppers, jackets, coats, hats, sleeves, sweaters, shirts, bras, knits, boots, gloves, arm warmers, knee warmers, elbow warmers, wrist warmers, ankle warmers. Accessories can include, but are not limited to, headbands, belts, straps, wristbands, bracelets, watchbands, shoulder straps, tapes, shin guards, caps, ties, scarves, purses, handbags, wallets, backpacks or rucksacks.

[0043] Apparel items have many uses. Among these, apparel can provide a unique aesthetic appearance, provide warmth or coolness characteristics, provide support for parts of an individual's body, and provide other performance characteristics such as breathability, moisture absorption characteristics, and compression characteristics. Each of these purposes, alone or in combination, provides comfortable apparel suitable for a variety of situations (e.g., exercise and daily activities). The characteristics of an apparel item (e.g., the materials and components used to make the apparel, and the way these materials / components are made) can be altered to produce desired characteristics such as durability, stiffness, weight, stickiness, texture, touch, adhesiveness, and / or breathability.

[0044] An apparel item or a part thereof can be configured to provide various degrees of durability, support, weight, breathability, etc. However, the cost of manufacturing an apparel item is also a consideration. Manufacturers and consumers may desire apparel or a part thereof that is manufactured at a relatively low cost. Apparel that can be manufactured using relatively small amounts of resources (e.g., energy and labor), materials, and time reduces the manufacturing cost and can also reduce the environmental impact of manufacturing.

[0045] Further, it may be desirable to have manufacturing equipment and associated processes that facilitate the efficient manufacture of clothing items. Efficient manufacture can be facilitated by equipment and processes that are capable of applying relatively large amounts of material or portions of material simultaneously or in rapid succession. Thus, equipment and processes that contribute to the following ease can improve manufacturing efficiency: using such equipment and processes, a wound thread layer or other wound article can be removed from a frame on which the thread layer or other wound article is wound. Reducing the material cut or otherwise wasted by enabling the removal of the thread layer from the frame with little or no cutting can also contribute to increased efficiency.

[0046] Methods and systems according to embodiments described herein include a support plate having movable protrusions, where the protrusions serve as anchor points for winding one or more continuous threads in the form of a thread layer or thread pattern. After the thread layer or thread pattern has been wound around the protrusions and is ready to be removed from the support plate, the protrusions can be moved to a position that facilitates the easy removal of the thread layer or thread pattern from the support plate. In some embodiments, the protrusions can be moved to bring the free ends of the protrusions closer together. In some embodiments, the protrusions can pivot relative to the base of the support plate. In some embodiments, the protrusions can additionally or alternatively translate relative to the support plate.

[0047] As discussed herein, winding a continuous thread around an anchor point includes: wrapping the continuous thread around a first anchor point, extending the continuous thread to a second anchor point, wrapping the continuous thread around the second anchor point, and so on. The number and position of the anchor points can be used to control the characteristics of the thread layer or thread pattern and, thus, the characteristics of the clothing item. Also, the number of times the continuous thread is wound from anchor point to anchor point can be used to control the characteristics of the thread layer or thread pattern and, thus, the characteristics of the clothing item.

[0048] In some embodiments, the continuous threads of the thread layer or thread pattern can be joined within the thread layer or thread pattern. Joining the continuous threads can consolidate the thread layer or thread pattern and hold the rows of threads in the winding pattern. In some embodiments, joining the continuous threads of the thread layer or thread pattern can be used to control the characteristics of the thread pattern. In some embodiments, the continuous thread can be joined to itself within the thread layer or thread pattern. In some embodiments, the continuous thread can be joined to itself at one or more of the anchor points of the thread layer or thread pattern. In some embodiments, the continuous thread can be joined to itself at an overlap point between different rows of the continuous thread (i.e., at a row crossing). In some embodiments, different continuous threads of the thread pattern can be joined together. In some embodiments, different continuous threads can be joined to each other at one or more of the anchor points of the thread pattern. In some embodiments, different continuous threads can be joined to each other at an overlap point between the different continuous threads (i.e., at a crossing between the different continuous threads). When the thread is wound around the anchor point under tension, joining the continuous threads can join the continuous threads under tension.

[0049] In some embodiments, multiple different continuous lines can be wound around an anchor point to form a line pattern including multiple line layers. In some embodiments, the different continuous lines can be wound in the same layout (i.e., around the same anchor point and along the same path). In some embodiments, the different continuous lines can be wound in different layouts (i.e., around one or more different anchor points and / or along different paths between one or more anchor points). The different continuous lines can define different wound line layers for an article of clothing. And these different line layers can provide different characteristics for the line pattern and thus for the article of clothing.

[0050] Figure 1 System 100 is shown including a winding machine 102 and a support plate 101 according to some embodiments. The winding machine 102 includes one or more robotic arms 105 for winding one or more line layers 120 onto the support plate 101. The line layers 120 can form at least a portion of an article of clothing. In some embodiments, the article of clothing can include the upper of a footwear item. The support plate 101 can be any of the support plates described herein, including support plates 201, 201, 301, 401, 501, 601, 701, and 801.

[0051] The support plate 101 includes a plurality of protrusions 104. In some embodiments, each protrusion 104 can include a pin, knob, stud, or other similar structural member that can serve as an anchor point around which a continuous line can be wound. The protrusions 104 can extend from a base 103 of the support plate 101. The line layer 120 includes a line row 122 that extends between corresponding protrusions 104 and across a winding region 108 defined by the region around which the protrusions 104 are arranged on the support plate 101. Thus, the protrusions 104 can define some or all of the perimeter of the winding region 108.

[0052] The winding machine 102 is configured to produce the line row 122 by winding a continuous line around the protrusions 104 on the support plate 101 and thus, in turn, produce the line layer 120. Thus, once formed, the line row 122 and the line layer 120 extend across the winding region 108. Additionally, in some embodiments, the shape of the line layer 120 can be affected by the shape of the winding region 108 of a particular support plate 101. Thus, in some embodiments, support plates 101 having different shaped winding regions 108 can be used within the system 100 to produce different shaped line layers 120.

[0053] The arm 105 can be a powered arm, such as a robotic arm. The movement of the arm 105 can be controlled by a controller 115, which is, for example, a computer system 100 included in the system 1000 and configured to control one or more motors that move the arm 105. The motorized movement of the arm 105 controlled by the controller 115 can be automatic, manually controlled, or a combination thereof.

[0054] In some embodiments, the controller 115 can include a CNC (Computer Numerical Control) machine tool for controlling the arm 105 and winding a wire layer or wire pattern around the protrusion 104. In some embodiments, the arm 105 can include a CNC machine tool.

[0055] In some embodiments, the system 100 or the arm 105 can include one or more spools 110 for threading and winding the wire rows 122 of the wire layer 120 around the protrusion 104. In some embodiments, the system 100 can include one or more wire tensioners 112 configured to apply a desired tension to the wire wound around the protrusion 104.

[0056] The controller 115 can be configured to wind a desired wire layer or wire pattern around the protrusion 104 using a wire model and input data. The controller 115 can include components of the computer system 1000 discussed herein. In some embodiments, the system 100 or the arm 105 can include a winding assembly that includes a plurality of spools for threading and winding a plurality of different wires of a wire layer or wire pattern. In some embodiments, the spools and wire tensioners can be the same as or similar to those described in U.S. Patent 11,602,196B2, the entire content of which is incorporated herein by reference. In some embodiments, the controller 115 can control the tensioner 112 to wind the wire with a desired tension.

[0057] At least some of the protrusions 104 are movable relative to other protrusions 104 of the support plate 101. As discussed herein, the movable protrusion 104 can be moved to a first position where a continuous wire can be wound around the protrusion 104 to produce one or more wire layers 120. The movable protrusion 104 can also be moved to a second position where the wire layer 120 formed on the support plate 101 can be removed from the protrusion 104. In some embodiments, the movable protrusion 104 can be moved to a second position where the wire layer 120 formed on the support plate 101 can be removed from the protrusion 104 without cutting or otherwise damaging any of the wire rows 122 of the wire layer 120.

[0058] The movable protrusion 104 can be moved to any numbered position. At each position, the wire layer 120 or wire pattern can (i) wrap around the protrusion 104, (ii) connect to itself or a connecting layer, and / or (iii) be removed from the protrusion 104. For example, in some embodiments, the movable protrusion 104 can be moved to the third and / or fourth positions. In some embodiments, the third and / or fourth positions can be positions where wire rows or wire patterns within the wire layer 120 are connected as described herein.

[0059] It can be advantageous to remove the wire layer 120 from the support plate 101 without cutting or damaging the wire rows 122 of the wire layer 120, and this can reduce wasted material. Additionally, in some embodiments, the wire layer 120 removed from the support plate 101 without cutting or otherwise damaging the wire rows 122 can include a loop at the perimeter of the wire layer 120 through which the movable protrusion 104 extends prior to removing the wire layer 120 from the support plate 101. This loop can be used for purposes within the final assembled garment or article in which the wire layer 120 is intended to form a part, which can further contribute to the efficient manufacture of the garment or article. In some embodiments, the loop can be used to lash a shoe last, where a cord passes through the loop around the perimeter edge and is then pulled to tighten the wire layer around the shoe last, thereby forming the desired three-dimensional shape, such as for an upper during shoe assembly. In further embodiments, the loop can be used as a loop for receiving a strap to tighten the garment or article, such as for receiving a shoelace in the case where the garment or article is a shoe. In further embodiments, the loop can be used to attach other materials to the wire layer 120, such as by sewing other materials to the wire layer 120 by passing the wire through the loop and the other material.

[0060] As discussed herein, the system 100 can perform a method of manufacturing a garment article that includes: forming a wire layer 120 by winding a continuous wire around a plurality of protrusions 104 disposed on a support plate 101, the support plate including a winding region 108 around which the protrusions 104 are disposed. In a first position, at least some of the protrusions 104 can be positioned relative to the winding region 108 to prevent removal of the wire layer 120 from the support plate 101. By preventing removal in the first position, the protrusions 104 can facilitate winding of wire rows 122 that extend between two corresponding protrusions 104 and span the winding region 108. The method can further include: moving at least some of the protrusions 104 relative to the region 108 and into a second position. In the second position, the protrusions 104 can be positioned relative to the winding region 108 to allow removal of the wire layer 120 from the support plate 101. After moving at least some of the protrusions 104 relative to the region 108 and into the second position, the method can further include removing the wire layer 120 from the support plate 101.

[0061] The protrusion 104 can move from the first position to the second position in any manner that facilitates the release of the wire layer 120 from the support plate 101. The protrusion 104 can also move from the second position to the first position in the same manner as it moves from the first position to the second position. In some embodiments, the protrusion 104 can pivot relative to the base 103. In some embodiments, the protrusion 104 can pivot relative to other protrusions 104. In some embodiments, the protrusion can translate relative to the base 103. In some embodiments, the protrusion 104 can translate relative to other protrusions 104. In some embodiments, moving the protrusion 104 relative to the winding region 108 can include pivoting the protrusion 104 toward or away from the winding region 108. In some embodiments, moving the protrusion 104 relative to the winding region 108 can include translating the protrusion 104 toward or away from the winding region 108.

[0062] In some embodiments, the method can include: connecting the wires within the wire layer 120 before removing the wire layer 120 from the support plate 101. Thus, the method can include: connecting the wires within one or more wire layers that form a wire pattern. As described herein, connecting the wires within the wire layer 120 can include: connecting the wire rows of the wire layer 120 to each other before removing the wire layer 120 from the support plate 101. In some embodiments, the wire rows can be connected to each other before moving at least some of the protrusions 104 relative to the winding region 108 as described herein. For example, as described herein, the wire rows can be connected to each other before moving at least some of the protrusions 104 from the first position to the second position. In some embodiments, the wire rows can be connected to each other after moving at least some of the protrusions 104 relative to the winding region 108 as described herein. For example, as described herein, the wire rows can be connected to each other after moving at least some of the protrusions 104 from the first position to the second position. In such embodiments, at least some of the protrusions 104 can move to a third position before removing the wire layer 120 from the support plate 101. Connecting the wires can include any process for joining or interconnecting the wires suitable for the intended application. Thus, connecting the wires according to some embodiments can include, for example, baking the wires, thermally melting the wires, thermally pressing the wires, applying a connecting agent to the wires, or any combination of the foregoing.

[0063] In any embodiment of the present disclosure, the removable protrusion 104 may be replaceable. In such an embodiment, the removable protrusion 104 may be removed from the support plate 101 and reattached to the support plate. This can reduce the overall investment as there is no need to remake the protrusions for each plate design. Instead, a common stock of protrusions can be used for a range of base designs with different shaped winding regions. In some embodiments, the replaceable removable protrusion 104 may be hingedly coupled to the support plate 101, snap-fit to the support plate 101, or slidably coupled to the support plate 101. Once attached, the replaceable removable protrusion 104 may move on the support plate 101 as described herein.

[0064] Figure 2A and Figure 2B A cross-section of a support plate 201 having a wire layer 220 formed thereon is shown in accordance with some embodiments. The support plate 201 and the wire layer 220 may be the same in all respects as the support plate 101 and the wire layer 120 described above.

[0065] As Figure 2A shown, the protrusion 204 may be tilted away from the winding region 208 in a first position to prevent removal of the wire layer 220 from the support plate 201. The protrusion 204 being tilted away from the winding region 208 may also facilitate winding of a continuous wire around the protrusion 204 during formation of the wire layer 220. As Figure 2A further shown, the distance between two protrusions 204 may increase as the distance from the base 203 increases. Thus, the free ends 207 of the protrusions 204 may be further apart from each other than the base 209 of the protrusion 204 adjacent to the base 103. In the case where the protrusion 204 is tilted away from the winding region 208, when the protrusion 204 is positioned as Figure 2A shown, the tension in the wire rows of the wire layer 220 may prevent the wire layer 220 from moving away from the base 203.

[0066] The removable protrusion 204 may be moved to a second position to release the completed wire layer 220 from the support plate 201, as Figure 2B illustrated. In some embodiments, moving the protrusion 204 to release the wire layer 220 may include: moving the protrusion 204 such that the free ends 207 of at least some of the protrusions 204 are closer together to enable the wire layer 220 to travel along the protrusions 204 past the free ends 207 of the protrusions 204. In some embodiments, moving the protrusion 204 such that the free ends 207 of at least some of the protrusions 204 are closer together may include: pivoting the protrusion 204 to reduce the tilt angle 236, as Figure 2A and Figure 2B shown.

[0067] In some embodiments, the tilt angle 236 in the first position may be in the range of 30 degrees to 45 degrees. In some embodiments, the tilt angle 236 in the first position may be in the range of 20 degrees to 55 degrees. In some embodiments, the tilt angle 236 in the first position may be in the range of 40 degrees to 50 degrees. In some embodiments, the tilt angle 236 in the second position may be in the range of 0 degrees to 15 degrees. In some embodiments, the tilt angle 236 in the second position may be in the range of 10 degrees to 20 degrees. In some embodiments, when moving the protrusion 204 from the first position to the second position, the tilt angle 236 may change by at least 30 degrees. In some embodiments, when moving the protrusion 204 from the first position to the second position, the tilt angle 236 may change by at least 15 degrees. In some embodiments, when moving the protrusion 204 from the first position to the second position, the tilt angle 236 may change by 20 degrees to 40 degrees.

[0068] In Figure 2A In the first position of the protrusion 204 shown, the wire layer 220 is prevented from being removed from the support plate 201 in a direction parallel to the disassembly axis 230 because the protrusions 204 on which the wire layer 220 is formed are inclined away from each other and away from the winding area 208. Because the protrusions 204 are inclined away from the winding area 208, the protrusions 204 extend away from the disassembly axis 230 as the distance from the base 203 of the support plate 201 increases.

[0069] Figure 2A and Figure 2B The extension 234 shown in indicates the direction in which the protrusion 204 extends. Therefore, the tilt angle 236 shown between the extension 234 and the disassembly axis 230 indicates that the tilt angle 236 can be defined between the protrusion 204 and the disassembly axis 230. Since the protrusion 204 of the illustrated embodiment is pivotally connected to the base 203, the protrusion 204 can pivot relative to the base 203 to change the tilt angle 236, as shown by the transition in Figures 2A to 2B In particular, the protrusion 204 can pivot to reduce the tilt angle 236, enabling the release of the wire layer 220, as shown in Figure 2B shown. Reducing the tilt angle 236 can reduce the distance between the free ends 207 of the protrusion 204, allowing the wire layer 220 to be removed from the protrusion 204.

[0070] In some embodiments, the method described herein may include: removing the wire layer 220 from the support plate 201 after pivoting at least one protrusion 204 to reduce the tilt angle 236 of the protrusion 204. In such an embodiment, the method may include: removing the wire layer 220 from the support plate 201 after pivoting at least one protrusion 204 toward the winding area 208. In some embodiments, the method may include: removing the wire layer 220 from at least one protrusion 204 before moving at least one other protrusion 204, as shown inFigure 2B as shown. In some embodiments, system 100 may include any one of the mechanisms discussed with reference to Figures 3 to 5 and be configured to be able to tilt the protrusion 204 or a set of protrusions 204 towards and away from the winding area 208.

[0071] In some embodiments, the method may include: winding one or more wires around the protrusion 204 when the protrusion 204 is in a first position; then connecting the wires when the free ends 207 are further apart from each other compared to when the protrusion 204 is in the first position; and then, after the connection is completed, moving the free ends 207 together to release the wire layer 220 from the protrusion 204. For example, the method may include: winding a continuous wire around the protrusion 204 when the protrusion 204 is in the first position to form a wire layer 220. The method may include: after forming the wire layer 220, pivoting the protrusion 204 to a second external position, where the free ends 207 are further apart from each other than when the protrusion 204 is in the first position. The method may include: after pivoting the protrusion 204 to the external position and while the protrusion 204 remains in the external position, connecting the wires within the wire layer 220. In some embodiments, the connection may include applying heat, such as applying a heat press 231 to the wire layer 220, as Figure 2C shown. The method may include: after connecting the wires within the wire layer 220, pivoting the protrusion 204 to a third release position, where the free ends 207 are closer to each other than when the protrusion 204 is in the first position and / or the second position. The method may include: after pivoting the protrusion 204 to the release position, removing the wire layer 220 from the protrusion 204. Thus, in some embodiments, Figure 2C the stages depicted in Figure 2A may occur between Figure 2B the stages depicted in

[0072] In some embodiments, the method may include multiple connection processes. In some such embodiments, the method may include: after completing a first connection process when the protrusion 204 is in the external position and before pivoting the protrusion 204 to the release position, pivoting the protrusion 204 to a further fourth external position, where the free ends 207 are either further apart from each other or closer than when the protrusion 204 is in the external position. The method may include: after pivoting the protrusion 204 to another external position and while the protrusion 204 remains in the another external position, applying a second connection process. In some embodiments, the second connection process may be different from the first connection process. For example, the first connection process may include applying a heat press 231, which is configured to melt and compress the wires within the wire layer 220, as Figure 2C shown, and the second connection process may include applying a cold press 232 to cure and further compress the wires within the wire layer 220, as Figure 2DAs shown. Thus, in some embodiments, the method may include Figure 2A the stages depicted in Figure 2C followed by the stages depicted in Figure 2D followed by the stages depicted in Figure 2B followed by the stages depicted in

[0073] As described above, a method including one or more linking steps between a winding layer or wire pattern and removing the wire layer or wire pattern from a support plate can be implemented with any of the support plate embodiments disclosed herein. Thus, for each embodiment of the support plate described herein, a method may include: winding a wire layer around a movable protrusion when the protrusion is in a first position, moving the protrusion to deploy a free end in a second position, performing one or more linking steps, moving the protrusion again to a third position such that the free ends are closer together than in the first and / or second positions, to release the linked wire layer from the support plate. For example, for each embodiment of the support plate described herein, a method may include: winding a wire layer around a movable protrusion when the protrusion is in a first position, moving the protrusion to deploy the free end, applying a hot press, moving the protrusion to deploy the free end further, applying a cold press, and then moving the protrusion again such that the free ends are closer together than in the first and / or second positions, to release the linked wire layer from the support plate.

[0074] In some embodiments, the protrusion 204 may be spring-biased relative to the support plate 201 to remain stable in two or more different positions. In a further embodiment, the protrusion 204 may be connected to the support plate 201 through a central linkage to remain stable in two different positions.

[0075] Figure 3 Shows a portion of a support plate 301 according to some embodiments. The support plate 301 may be similar in all aspects to any of the above support plates 101, 201. Thus, the support plate 301 includes a base 303 and a protrusion 304 extending from the base 303, the protrusion being adjacent to a winding area 308 defined by the protrusion 304.

[0076] One or more protrusions 304 are pivotally coupled to the base 303 by a hinge 338. In some embodiments, the support plate 301 may include features configured to prevent accidental release of the wire layer from the protrusion 304. For example, in some embodiments, the support plate 301 may include a biasing element 340 configured to bias the protrusion 304 towards a position suitable for creating a wire layer on the protrusion 304. The biasing element 340 may include, for example, a spring.

[0077] In some embodiments, the biasing element 340 may include a tension element configured to increase tension as the tilt angle of the projection 304 to which the biasing element 340 is attached decreases. In such embodiments, the biasing element 340 may prevent the projection 304 from moving to a position where the wire layer can be easily removed from the projection 304. In some embodiments, the support plate 301 may include a stop 342 configured to prevent the biasing element 340 from moving the projection 304 beyond a position suitable for winding wire around the projection 304.

[0078] Figure 4 A portion of a support plate 401 according to some embodiments is shown. The support plate 401 may be similar in all respects to any of the support plates 101, 201, 301 described above. Thus, the support plate 401 includes a base 403 and a projection 404 extending from the base 403 adjacent to the winding region 408. One or more projections 404 are pivotally connected to the base 403. The support plate 401 includes an actuator 444 configured to pivot one or more projections 404 relative to the base 403. In some embodiments, the actuator 444 may include a motorized actuator. For example, in some embodiments, the actuator 444 may include a servo motor. In some embodiments, the actuator 444 may be controlled by the controller 115 of the system 100. In some embodiments, the actuator 444 may be controlled by a controller on the support plate 401. In such embodiments, the controller may include a switch or a servo motor.

[0079] In some embodiments, the support plate 401 may include a single actuator 444 configured to pivot a plurality of projections 404. In some embodiments, the support plate 401 may include a respective actuator 444 for each movable projection 404. Pivoting the projection 404 may thus include: operating the actuator 444 to pivot one or more projections 404 relative to the winding region 408.

[0080] Figure 5 A portion of a support plate 501 according to some embodiments is shown. The support plate 501 may be similar in all respects to any of the support plates 101, 201, 301, 401 described above. Thus, the support plate 501 includes a base 503 and a projection 504 extending from the base 503 adjacent to the winding region 508. One or more projections 504 are pivotally connected to the base 503 by a hinge 538.

[0081] The support plate 501 can be used on the platform 546. In such an embodiment, the system 100 can include the platform 546. The platform 546 can include an actuator 548 operably connected to one or more protrusions 504. The actuator 548 can be used to move a portion of the protrusion 504 relative to the hinge 538. Since the hinge 538 pivotally connects the protrusion 504 to the base 503, using the actuator 548 to move a portion of the protrusion 504 relative to the hinge 538 causes the hinge 538 to pivot relative to the base 503 and the winding region 508. Thus, in some embodiments, the system 100 can include an actuator 548 configured to pivot one or more protrusions 504 of the support plate 501 relative to the base 503 of the support plate 501 when the support plate 501 is positioned within the system 100. In some embodiments, the actuator 548 within the system 100 can be configured to pivot the protrusions 504 of the interchangeable support plate 501 that can be used in the system 100.

[0082] Figure 6A and Figure 6B A portion of a support plate 601 is shown in accordance with some embodiments. The support plate 601 can be similar in all respects to any of the support plates 101, 201, 301, 401, 501 described above. Thus, the support plate 601 includes a base 603 and a protrusion 604 extending from the base 603 adjacent to the winding region 608. One or more protrusions 604 of the support plate 601 are pivotally connected to the base 603 by a hinge 638.

[0083] The support plate 601 can include a locking mechanism configured to operate to selectively lock and unlock the protrusion 604. In some embodiments, when unlocked, the protrusion 604 can pivot relative to the base 603, and when locked, it cannot pivot relative to the base 603.

[0084] In some embodiments, the locking mechanism of the support plate 601 can include tabs 650, 652 and a pin 656. In such an embodiment, the support plate 601 includes a protrusion tab 650 connected to one or more protrusions 604 and a base tab 652 connected to the base 603. The protrusion tab 650 and the base tab 652 can each include a respective eyelet 654. As Figure 6A shown, in a first position, the protrusion 604 can pivot relative to the base 603 to a position where the eyelets 654 are coaxially aligned. And, in a second position, as Figure 6B shown, the protrusion 604 can pivot relative to the base 603 to a position where the eyelets 654 are misaligned. When the protrusion 604 is in the first position, the pin 656 can be placed through the eyelets 654 to lock the protrusion 604.

[0085] In some embodiments, for example, as Figure 6CAs shown, a single pin 656 can be configured to extend through a plurality of protrusions 604. In such an embodiment, by sliding the pin 656 relative to the support plate 601, a user can quickly lock or unlock a number of protrusions 604.

[0086] Any support plate described herein, including support plates 101, 201, 201, 301, 401, 501, 701, and 801, may include one or more locking mechanisms, as described in connection with Figures 6A to 6C described.

[0087] Figure 7A A support plate 701 is shown in accordance with some embodiments. The support plate 701 is similar in all respects to any of the above-described support plates 101, 201, 301, 401, 501, 601. Accordingly, the support plate 701 includes a base 703 and a plurality of protrusions 704 that extend from the base 703 and are arranged around a winding area 708.

[0088] The support plate 701 includes a sliding mechanism that movably couples the protrusions 704 to the base 703 and is configured to move the protrusions 704 from a first position to a second position. In some embodiments, the sliding mechanism may include a panel 756 that is slidable on one or more tracks 758. In such an embodiment, one or more tracks 758 are positioned on the base 703, and the panel 756 may be movable relative to the base 703 along the one or more tracks 758. In some embodiments, the support plate 701 may include a plurality of sliding mechanisms, each of which movably couples a different subset of the protrusions 704 to the base 703.

[0089] In some embodiments, the support plate 701 may include a fixing device for fixing the position of the sliding mechanism. In some embodiments, the fixing device may include a clamp 760. In some embodiments, the clamp 760 may be a manually operated clamp mounted to the base 703. In some embodiments, the clamp 760 may be an automated toggle clamp mounted to the base 703. In such an embodiment, the clamp 760 may be controlled by the controller 115 of the system 100.

[0090] In some embodiments, as Figure 7B shown, the panel 756 may include a flange 762 that is configured to connect the panel 756 to the track 758. In such an embodiment, the clamp 760 may be configured to apply a clamping force 764 against the flange 762 to frictionally prevent the flange 762 from sliding along the track 758, thereby reversibly fixing the position of the panel 756 relative to the base 703.

[0091] Figure 7C and Figure 7DIllustrates the operation of the support plate 701 according to some embodiments. In operation, the panel 756 may slide towards a portion of the base 703 on the side opposite the panel 756 in the winding region 708 to reduce the distance between the protrusions 704 on the panel 756 and the protrusions 704 on the side of the winding region 708 opposite the panel 756. Thus, in some embodiments, moving the protrusions 704 to bring some free ends 707 of at least some of the protrusions 704 closer together may include translating the protrusions 704 and the winding region 708 relative to the base 703 to reduce the distance between some of the protrusions 704, as Figure 7C and Figure 7D shown.

[0092] In some embodiments, the method described herein may include removing the wire layer 720 from the support plate 701 after translating at least one protrusion 704 to reduce the distance between at least one protrusion 704 and another protrusion 704. Further, in such embodiments, the method may include removing the wire layer 720 from the support plate 701 after translating at least one protrusion 704 relative to the winding region 708.

[0093] In some embodiments, a method including the support plate 701 may include: winding a portion of a wire layer or wire pattern around the support plate 701 when the sliding mechanism is in a first position, moving the sliding mechanism to a different second position, and then winding another portion of the wire layer or wire pattern around the support plate 701 when the sliding mechanism is in the second position. For example, in some embodiments, the method may include: winding some wire rows around the support plate 701 with the sliding mechanism in the first position, moving the sliding mechanism to the second position to increase the tension on the wire rows, and then winding more wire rows around the support plate 701 with the sliding mechanism in the second position. As another example, in some embodiments, the method may include: winding some wire rows around the support plate 701 with the sliding mechanism in the first position, moving the sliding mechanism to reduce the tension on the wire rows, and then winding more wire rows around the support plate 701 with the sliding mechanism in the second position.

[0094] In some embodiments, after winding in the first position and before moving the sliding mechanism to the second position, the rows of wires within the wire layer or wire pattern may be consolidated. For example, the method may include: winding some rows of wires around the support plate 701 with the sliding mechanism in the first position, joining the rows of wires while the sliding mechanism remains in the first position, and then moving the sliding mechanism to the second position to increase the tension on the joined rows of wires before winding more rows of wires. In some embodiments, the method may include: winding some rows of wires around the support plate 701 with the sliding mechanism in the first position, joining the rows of wires while the sliding mechanism remains in the first position, and then moving the sliding mechanism to the second position to decrease the tension on the joined rows of wires before winding more rows of wires. In any case, after winding and / or joining the rows of wires with the sliding mechanism in the first and second positions, the sliding mechanism may be moved to a third position to allow removal of the completed wire layer or wire pattern.

[0095] In such embodiments, the support plate 701 may be used to produce a wire layer or wire pattern including different groups of rows of wires wound at different degrees of static tension. In such embodiments, the different degrees of static tension may introduce a non-uniform, curved structure into the wire layer or wire pattern.

[0096] Figure 8 A support plate 801 is shown in accordance with some embodiments. The support plate 801 may be similar to any of the support plates 101, 201, 301, 401, 501, 601, 701 described above. Thus, the support plate 801 includes a base 803 and a plurality of protrusions 804 extending from the base 803 and disposed around a winding area 808. At least some of the protrusions 804 are movable protrusions 804. The protrusions 804 may be movably connected to the support plate 801 by any of the pivoting or sliding mechanisms described herein.

[0097] The winding area 808 is in the shape of a flat upper for a footwear item. Thus, the protrusions 804 are arranged to define a perimeter of the winding area 808 in the shape of a flat upper for a footwear item and may include two wings 866 joined by a bridge 868.

[0098] The winding area 808 of the illustrated embodiment includes a relatively large perimeter relative to its area. Thus, cutting the wire layer 820 from the support plate 801 will require a relatively long cutting path and will leave a relatively large amount of wasted material. Thus, in some embodiments, using the movable protrusions 804 according to any of the embodiments described herein to enable removal of the wire layer 820 from the support plate 801 with little or no cutting can accelerate removal of the wire layer 820 from the support plate 801 and reduce wasted material.

[0099] The line patterns described herein may each include a plurality of line layers, such as line layers 120, 220, 720, 820 described above and line layers 900 and 920 described in more detail below. The winding steps regarding system 100 above may be implemented according to the details described below regarding line layers 900 and 920. The line layers (e.g., line layers 900 and 920) as described herein may each include a line boundary 950 defined by the space in which the line rows of the line layer are located. The line boundary 950 for a line layer is: the space in which the line rows of the line layer are located after removing (e.g., cutting) the line layer from the anchor point for winding the line layer. Each anchor point may be a protrusion in a group of protrusions arranged around the winding area, such as protrusion 104. The plurality of line rows within the line pattern may include a first end located on a first side of the line boundary 950 and a second end located on a second side of the line boundary 950. For example, the line row 904 of line layer 900 may include a first end 910 located on a first side of the line boundary 950 and a second end 912 located on a second side of the line boundary 950.

[0100] Figure 9A and Figure 9B Line boundaries 950a - b for line layers 900 and 920 are shown. For a line pattern including a plurality of line layers, the line pattern may include a line pattern boundary 950 defined by the space occupied by the combination of individual line layers.

[0101] As used herein, the sides of a perimeter edge or boundary refer to the top side, bottom side, right side, and left side of the shape defined by the edge or boundary. The top side, bottom side, right side, and left side of the shape are located at the top, bottom, right, and left of the geometric center of the shape. Thus, the perimeter edge or boundary will have a top side defined by the edge portion located above the geometric center, a bottom side defined by the edge portion located below the geometric center, a right side defined by the edge or boundary portion located to the right of the geometric center, and a left side defined by the edge or boundary portion located to the left of the geometric center. The top side and the bottom side do not overlap. Similarly, the left side and the right side do not overlap. The top side and the left side overlap at the portion of the edge or boundary located in the upper left of the geometric center. The top side and the right side overlap at the portion of the edge or boundary located in the upper right of the geometric center. The bottom side and the left side overlap at the portion of the edge or boundary located in the lower left of the geometric center. The bottom side and the right side overlap at the portion of the edge or boundary located in the lower right of the geometric center. To determine the shape defined by a perimeter edge or boundary, the material having the edge or boundary is laid out in a flat configuration and no part of the material overlaps itself.

[0102] As used herein, the first side of a perimeter edge or boundary can be the top, bottom, right, or left side of the edge or boundary, and the second side of the perimeter edge can be the top, bottom, right, or left side of the edge or boundary, provided that the first side and the second side are not the same side. Similarly, the third side of a perimeter edge or boundary can be the top, bottom, right, or left side of the edge or boundary, and the fourth side of the edge or boundary can be the top, bottom, right, or left side of the edge or boundary, provided that the third side and the fourth side are not the same, and are not the same as the first side or the second side.

[0103] In some embodiments, one or more wire layers (e.g., wire layers 900 and 920) can include wires that define: (i) a plurality of wire rows (e.g., wire rows 904 and 924), each wire row extending from a first side of a wire boundary to a second side of the wire boundary and crossing each other at an overlap point between two or more wire rows; and (ii) a plurality of wire rows, each wire row extending from a third side of the wire boundary to a fourth side of the wire boundary and crossing each other at an overlap point between two or more wire rows. The wire rows extending from the first side to the second side can extend continuously from the first side to the second side, and the wire rows extending from the third side to the fourth side can extend continuously from the third side to the fourth side.

[0104] Wire layer 900 includes a continuous wire 902 wound around an anchor point 990. Wire layer 920 includes a continuous wire 922 wound around an anchor point 990. In some embodiments, the anchor point 990 can be different sets of anchor points around which different wire layers are wound. In some embodiments, multiple wire layers can be wound around the same set of anchor points 990. In such embodiments, individual wire layers can be wound on top of each other, with one wire layer disposed on top of one or more other wire layers.

[0105] As used herein, an "anchor point" refers to a location that fixedly attaches a wire or a set of wire rows. Each anchor point can be provided by the protrusion 104 described above. A wire or wire row can be looped, wound, joined, or otherwise attached at the anchor point. In some embodiments, the anchor point can be a location on a garment item. For example, the anchor point can be a hole or opening left by a structure (e.g., a pin, protrusion, or bump) for winding a continuous wire of a wire layer and / or a wire pattern. In some embodiments, a wire layer or wire pattern for a garment item may not include any anchor point locations because all anchor point locations present during the winding of the wire layer or wire pattern have been removed (e.g., cut off). An anchor point can be a structure (e.g., a pin, protrusion, or bump) for winding a continuous wire of a wire layer and / or a wire pattern. And the anchor point structure can or can not form part of the wire layer or wire pattern of a garment item.

[0106] A continuous line that wraps or coils around an anchor point need not wrap or coil completely (i.e., 360 degrees) around the anchor point. The continuous line that wraps or coils around the anchor point may wrap or coil around only a portion of the anchor point. For example, the continuous line that wraps or coils around the anchor point may wrap or coil around 25% (90 degrees), 50% (180 degrees), 75% (270 degrees), or 100% (360 degrees) of the perimeter of the anchor point. In some embodiments, the continuous line may wrap or coil around the perimeter of the anchor point more than once before being threaded to the next anchor point. For example, the continuous line may wrap or coil around the perimeter of the anchor point one and a half times (540 degrees) or twice (720 degrees) before being threaded to the next anchor point.

[0107] The continuous line 902 may wrap around a plurality of anchor points 990 and includes a plurality of thread lines 904. Each thread line 904 extends between two corresponding anchor points 990.

[0108] The continuous line 902 may be wrapped around the plurality of anchor points 990 under tension such that when wrapped around the anchor points 990, an individual thread line 904 is under tension. In some embodiments, the tension at which the thread line 904 is wound may be in the range of 0 centinewtons (cN) to 25 cN, including sub-ranges. For example, in some embodiments, the tension at which the thread line 904 is wound may be in the range of 0.01 cN to 25 cN, 0.1 cN to 25 cN, 1 cN to 25 cN, 5 cN to 25 cN, 10 cN to 25 cN, or 15 cN to 25 cN. In some embodiments, the tension at which the thread line 904 is wound may be in the range of 2 cN to 10 cN. In some embodiments, the tension at which the thread line 904 is wound may be in the range of 2 cN to 6 cN.

[0109] The number of thread lines 904 of the thread layer 900 fixed at the anchor point 990 is defined by the "thread line communication number" of the anchor point 990. As used herein, "thread line communication number" refers to the number of thread lines that extend from one anchor point to a different anchor point. Two thread lines that extend between the same two anchor points (i.e., overlapping thread lines) are counted as only "1" for purposes of calculating the thread line communication number of the anchor point. For example, a thread line communication number of five means that the anchor point has five thread lines extending from it, each of the five thread lines leading to a different anchor point. As another example, a thread line communication number of six means that the anchor point has six thread lines extending from it, each of the six thread lines leading to a different anchor point.

[0110] Similarly, for a line pattern including multiple line layers, the number of line rows fixed at the anchor point 990 is defined by the "number of line row communications" of the anchor point 990 of the line pattern. For a line pattern, the "number of line row communications" of the anchor point 990 is the total number of line rows of multiple layers extending from the anchor point to different anchor points.

[0111] The anchor point 990 may have an "X" or more number of line row communications for a line layer or a line pattern. In some embodiments, two or more corresponding anchor points 990 may have an "X" or more number of line row communications. In some embodiments, all anchor points 990 of a line layer or a line pattern may have an "X" or more number of line row communications. "X" may be, for example, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, or 50, within a range having any two of these values as endpoints. For example, in some embodiments, "X" may be in the range of 2 to 50, 3 to 50, 4 to 50, 5 to 50, 6 to 50, 7 to 50, 8 to 50, 9 to 50, 10 to 50, 15 to 50, 20 to 50, 25 to 50, 30 to 50, 35 to 50, 40 to 50, or 45 to 50. In some embodiments, "X" may be greater than 50. In some embodiments, "X" may be in the range of 2 to 100, 10 to 100, or 20 to 100. In some embodiments, the range of "X" may be 2 to 100, 10 to 100, 20 to 100, 10 to 200, 20 to 200, 50 to 200, 10 to 300, 20 to 300, or 50 to 300.

[0112] A line layer, such as line layer 900, may include any suitable number of line rows. In some embodiments, the line layer may include 10 or more line rows. In some embodiments, the line layer may include 20 or more line rows. In some embodiments, the line layer may include 50 or more line rows. In some embodiments, the line layer may include 100 or more line rows. In some embodiments, the line layer may include 200 or more line rows. In some embodiments, the line layer may include 300 or more line rows. In some embodiments, the line layer may include 500 or more line rows. In some embodiments, the line layer may include a number of line rows in the range of 10 to 300. For example, the line layer may include 10 to 300, 50 to 300, 100 to 300, or 150 to 300 line rows. In some embodiments, the line layer may include 10 to 500 line rows. In some embodiments, the line layer may include 100 to 500 line rows. In some embodiments, the line layer may include 100 to 1000 line rows.

[0113] In some embodiments, the wire array 904 can be joined at the anchor point 990. In such embodiments, the wire array 904 can be joined at the anchor point 990 via an adhesive, a joining layer, thermal (conduction or convection) heating (e.g., in a heat press or oven), IR (infrared) heating, laser heating, microwave heating, steam, mechanical fasteners (e.g., clips), hook-and-loop fasteners, needling, hydroentanglement, ultrasonic / vibrational entanglement, felting, knotting, chemical bonding with a catalyst of a biomaterial, spray gluing (e.g., CNC spray glue deposition), or by pushing the wire array through other wire arrays.

[0114] In some embodiments, the wire arrays 904 can be directly joined together at the anchor point 990. In some embodiments, the wire arrays 904 can be directly joined together at the anchor point 990 via the polymeric material of the continuous wire 902. For example, heat and / or pressure can be applied to directly join the wire arrays 904 at the anchor point 990. In embodiments where heat and / or pressure are utilized to directly join the polymeric material of the wire arrays 904, the wire arrays 904 can be heat melted together at one or more anchor points 990. In embodiments that include directly joining the wire arrays 904 at the anchor point 990, the wire arrays 904 can be directly joined at the anchor point 990 without using an adhesive or a joining layer.

[0115] In some embodiments, the wire arrays 904 can be joined together via a joining layer. In some embodiments, the wire arrays 904 can be joined together at the anchor point 990 via a joining layer. In such embodiments, the joining layer can be, for example, a laminate layer, an adhesive layer, a suture layer, a curing layer, a screen printing layer, or a blown fiber layer. In some embodiments, the blown fiber layer can include polymeric fibers capable of joining the wire arrays 904.

[0116] In some embodiments, the wire arrays 904 can be joined together without using a joining layer. For example, in some embodiments, the wire arrays 904 can be directly joined together via, for example but not limited to, direct local joining of the material of the wire arrays 904, needling, hydroentanglement, and ultrasonic / vibrational entanglement.

[0117] In some embodiments, the wire arrays 904 can be joined at the overlap points (i.e., the crossover points 906) where two or more wire arrays 904 overlap in the wire layer 900. The wire arrays 904 can be joined at the crossover points 906 via an adhesive, a joining layer, thermal (conduction or convection) heating (e.g., in a heat press or oven), IR (infrared) heating, laser heating, microwave heating, steam, mechanical fasteners (e.g., clips), hook-and-loop fasteners, needling, hydroentanglement, ultrasonic / vibrational entanglement, felting, knotting, chemical bonding with a catalyst of a biomaterial, spray gluing (e.g., CNC spray glue deposition), or by pushing the wire arrays through other wire arrays. The crossover points 906 for the wire arrays can be referred to as "overlap points" or "points of overlap".

[0118] In some embodiments, the line rows 904 may be directly joined together at the intersections 906. In some embodiments, the line rows 904 may be directly joined together at the intersections 906 via the polymeric material of the continuous line 902. In embodiments including directly joining the line rows 904 at the intersections 906, the line rows 904 may be joined at the intersections 906 without using an adhesive or joining layer. For example, heat and / or pressure may be applied to the line layer 900 to directly join the line rows 904 at the intersections 906. In embodiments utilizing heat and / or pressure to directly join the polymeric material of the line rows 904, the line rows 904 may be heat melted together at one or more intersections 906.

[0119] In some embodiments, a joining layer may join the line rows 904 together at multiple intersections 906 within the line layer 900. In such embodiments, the joining layer may be, for example, a laminate layer, an adhesive layer, a stitching layer, a curing layer, a screen printing layer, or a blown fiber layer, which includes polymeric fibers that can join the line rows 904.

[0120] In some embodiments, the continuous line 902 may include overlapping line rows 904. As used herein, "overlapping line rows" refers to two or more line rows along the same path between two corresponding anchor points. The overlapping line rows do not need to directly overlap each other. Two or more line rows are considered to be overlapping as long as they extend between the same two anchor points.

[0121] The line rows 904 of the line layer 900 may not be woven or knitted together. In such embodiments, the line rows 904 may be referred to as "non-woven" and "non-knitted" line rows. The line rows 904 of the line layer 900 may not be embroidery threads stitched to a base. In such embodiments, the line rows 904 may be referred to as "non-embroidery" line rows.

[0122] In some embodiments, the continuous line 902 may be a polymeric line. As used herein, "polymeric line" refers to a line that is at least partially composed of a polymeric material. In some embodiments, the polymeric line may be entirely composed of one or more polymeric materials. In some embodiments, the polymeric line may include a polymeric material coated around a core (which may or may not include polymeric material).

[0123] Suitable polymeric materials for the polymeric line discussed herein include, but are not limited to, thermoplastic polyurethane (TPU), rubber, and silicone. In some embodiments, the TPU may be recycled TPU.

[0124] In some embodiments, the polymeric material for the polymeric thread can include a melting temperature in the range of greater than or equal to 110 °C to less than or equal to 150 °C. In such embodiments, the polymeric material can be referred to as a "low melting temperature polymeric material".

[0125] In some embodiments, the continuous threads 902 of the thread layer 900 can have a denier in the range of 1 denier to 3000 denier, including sub - ranges. For example, the continuous thread 902 can have a denier of 1, 10, 50, 100, 200, 300, 400, 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2500, or 3000 denier, or in any range having any two of these values as endpoints. For example, in some embodiments, the continuous thread 902 can have a denier in the range from 10 denier to 2500 denier, from 50 denier to 2000 denier, from 100 denier to 1900 denier, from 200 denier to 1800 denier, from 300 denier to 1700 denier, from 400 denier to 1600 denier, from 500 denier to 1500 denier, from 600 denier to 1400 denier, from 700 denier to 1300 denier, from 800 denier to 1200 denier, from 900 denier to 1100 denier, or from 900 denier to 1000 denier.

[0126] The thread pattern as described herein can include any number of thread layers. For example, the thread pattern can include two or more, three or more, four or more, five or more, six or more, seven or more, eight or more, nine or more, ten or more, fifteen or more, or twenty or more thread layers. For example, the thread pattern can include the thread layer 900 and the thread layer 920.

[0127] The continuous threads of any thread layer can be wound around the anchor points 990 and extend therebetween in the same manner as the continuous thread 902 described above. Further, the rows of continuous threads of any thread layer can be joined in the same manner as the thread layer 900 described above.

[0128] Like the continuous thread 902, the continuous threads for other thread layers can include multiple rows wound around two corresponding anchor points and extending between the two corresponding anchor points. In some embodiments, the continuous threads of different thread layers can be the same thread material. In some embodiments, the continuous threads of different thread layers can include different thread materials. In such embodiments, the materials for the different continuous threads in the thread pattern can be selected to provide target characteristics to regions of the thread pattern and thus to the clothing article. In some embodiments, the deniers of the continuous threads in different thread layers within the thread pattern can be selected to provide different degrees of characteristics (e.g., strength or stretchability) to different regions of the thread pattern.

[0129] In embodiments including a line pattern having multiple line layers, the multiple line layers may be stacked on top of each other. For example, line layer 900 may define the line pattern of the first layer, and second line layer 920 may define the line pattern of the second layer. Different line layers of a line pattern may be disposed overlapping each other in an overlapping region between the two line layers. For example, in the overlapping region between the two line layers, the first line layer 900 may be disposed on the second line layer 920, or vice versa.

[0130] In embodiments including a line pattern having multiple line layers, the multiple line layers may be joined to each other in the line pattern. In some embodiments, one or more of the layers may be directly joined to each other via a polymeric material of a continuous line, where the continuous line defines a row of lines for at least one of the layers. In some embodiments, one or more of these layers may be joined via a joining layer. In such embodiments, the joining layer may be, for example, a laminated layer, an adhesive layer, a stitched layer, a cured layer, a screen printed layer, or a blown fiber layer.

[0131] In some embodiments, one or more line layers of a line pattern may be used to join other line layers of the line pattern together. In such embodiments, these one or more line layers may be wound with polymeric threads which, when heated, join the other layers of the line pattern together at the anchor points and / or intersections between the continuous lines. For example, in a line pattern including three line layers, one of the three line layers (e.g., the middle line layer) may be the winding with polymeric threads for joining all three line layers together. In some embodiments, one or more line layers of a line pattern may be defined by a continuous line wound and coated with or impregnated with an adhesive. In some embodiments, the adhesive may be activated by applying heat. In some embodiments, the adhesive may be a soluble adhesive which, when contacted with a solvent such as water, dissolves completely or partially to join the line layers together.

[0132] Figure 10 An exemplary computer system 1000 is shown, in which an embodiment or portions thereof may be implemented as computer-readable code. The system 100 may include the computer system 1000 such that the computer system 1000 acts as a controller of the system 100. For example, aspects of the methods discussed herein may be implemented in the computer system 1000 using hardware, software, firmware, a tangible computer-readable medium storing instructions, or a combination thereof, and may be implemented in one or more computer systems or other processing systems.

[0133] If programmable logic is used, such logic can be executed on commercially available processing platforms or dedicated devices. Those of ordinary skill in the art will appreciate that various embodiments of the disclosed subject matter can be implemented with a variety of computer system configurations, including multi-core, multiprocessor systems, minicomputers, mainframe computers, computers linked or grouped by distributed functionality, and pervasive or miniature computers that can be embedded in almost any device.

[0134] For example, at least one processor device and a memory can be used to implement the above embodiments. The processor device can be a single processor, multiple processors, or a combination thereof. The processor device can have one or more processor "cores".

[0135] The various embodiments described herein can be implemented in accordance with this exemplary computer system 1000. After reading this specification, those skilled in the relevant art will understand how to implement one or more of the described embodiments using other computer systems and / or computer architectures. Although operations may be described as sequential processes, some operations can in fact be performed in parallel, concurrently, and / or in a distributed environment, and program code having local or remote storage can be accessed by a single or multi-processor machine. Additionally, in some embodiments, the order of operations can be rearranged without departing from the spirit of the disclosed subject matter.

[0136] The processor device 1004 can be a dedicated or general-purpose processor device. As will be understood by those skilled in the relevant art, the processor device 1004 can also be a single processor in a multi-core / multi-processor system, such a system operating alone, or in a group of computing devices operating in a group or server farm. The processor device 1004 is connected to a communication infrastructure 1006, such as a bus, message queue, network, or multi-core messaging scheme.

[0137] The computer system 1000 also includes a main memory 1008, such as random access memory (RAM), and can also include an auxiliary memory 1010. The auxiliary memory 1010 can include, for example, a hard disk drive 1012 or a removable storage drive 1014. The removable storage drive 1014 can include a floppy disk drive, tape drive, optical disk drive, flash memory, universal serial bus (USB) drive, etc. The removable storage drive 1014 reads from and / or writes to a removable storage unit 1018 in a well-known manner. The removable storage unit 1018 can include floppy disks, tapes, optical disks, etc., which are read from and written to by the removable storage drive 1014. As will be understood by those skilled in the relevant art, the removable storage unit 1018 includes a computer-usable storage medium having computer software and / or data stored therein.

[0138] The computer system 1000 optionally includes a display interface 1002 (which may include input and output devices such as a keyboard, mouse, etc.), which forwards graphics, text, and other data from the communication infrastructure 1006 (or from a frame buffer not shown) for display on the display unit 1030.

[0139] In additional and / or alternative implementations, the secondary storage 1010 may include other similar means for allowing computer programs or other instructions to be loaded into the computer system 1000. Such means may include, for example, a removable storage unit 1022 and an interface 1020. Examples of such means may include a program cartridge memory and cartridge interface (such as found in video game devices), a removable memory chip (such as an EPROM or PROM) and associated socket, and other removable storage units 1022 and interfaces 1020 that allow software and data to be transferred from the removable storage unit 1022 to the computer system 1000.

[0140] The computer system 1000 may also include a communication interface 1024. The communication interface 1024 allows software and data to be transferred between the computer system 1000 and external devices. The communication interface 1024 may include a modem, a network interface (such as an Ethernet card), a communication port, a PCMCIA slot and card, etc. The software and data transmitted via the communication interface 1024 may be in the form of signals, which may be electrical, electromagnetic, optical, or other signals capable of being received by the communication interface 1024. These signals may be provided to the communication interface 1024 via the communication path 1026. The communication path 1026 carries the signals and may be implemented using wires or cables, optical fibers, telephone lines, cellular phone links, RF links, or other communication channels.

[0141] In this document, the terms "computer program medium" and "computer usable medium" are used generally to refer to media such as the removable storage unit 1018, the removable storage unit 1022, and the hard disk installed in the hard disk drive 1012. The computer program medium and the computer usable medium may also refer to memories, such as the main memory 1008 and the secondary storage 1010, which may be memory semiconductors (e.g., DRAM, etc.).

[0142] A computer program (also known as computer control logic) is stored in the main memory 1008 and / or the secondary memory 1010. The computer program can also be received via the communication interface 1024. When such a computer program is executed, it enables the computer system 1000 to implement the embodiments discussed herein. In particular, the computer program, when executed, enables the processor device 1004 to implement the processes of the embodiments discussed herein. Thus, such a computer program represents the controller of the computer system 1000. In cases where the embodiments are implemented using software, the software can be stored in a computer program product and loaded into the computer system 1000 using the removable storage drive 1014, the interface 1020, and the hard disk drive 1012 or the communication interface 1024.

[0143] It should be understood that the detailed description section, rather than the summary and abstract sections, is intended to be used to interpret the claims. The summary and abstract sections may set forth one or more, but not all, exemplary embodiments contemplated by the inventors, and thus are not intended to limit the invention and the appended claims in any way.

[0144] The description of the above specific embodiments will fully disclose the general nature of the present invention, so that others can, by applying the knowledge of those skilled in the art, easily modify and / or adapt these specific embodiments for various applications without undue experimentation without departing from the general concept of the present invention. Therefore, such adaptations and modifications are intended to be within the meaning and scope of the equivalents of the disclosed embodiments based on the teachings and guidance presented herein. It should be understood that the language or terminology herein is for the purpose of description and not limitation, so that the terms or phrases of this specification can be interpreted by those skilled in the art according to the teachings and guidance.

[0145] The breadth and scope of the present application should not be limited by any of the above exemplary embodiments, but should be defined only in accordance with the appended claims and their equivalents.

Claims

1. A method of manufacturing an article of clothing, the method comprising: forming a wire layer by winding a continuous wire around a plurality of protrusions provided on a support plate; wherein the support plate comprises a winding region, the protrusions are arranged around the winding region and are inclined away from the winding region; and wherein the wire layer comprises a plurality of wire rows, each wire row extending between two corresponding protrusions and across the winding region; moving at least some of said projections relative to said wrapping region; as well as After moving at least some of the protrusions relative to the winding area, the wire layer is removed from the support plate. 2 . The method of claim 1 , comprising bonding the rows of wires to each other before removing the wire layer from the support plate.

3. The method of claim 1, comprising joining the rows of wires to each other before moving at least some of the protrusions relative to the winding area.

4. The method of claim 1, wherein the protrusions are pivotally connected to the support plate, and wherein moving at least some of the protrusions relative to the wrapping area comprises pivoting the protrusions toward the wrapping area.

5. The method of claim 4, wherein the support plate includes a hinge pivotably connecting the protrusion to a base of the support plate.

6. The method of claim 4, wherein each protrusion pivots relative to a base of the support plate.

7. The method of claim 4, wherein the wire layer is removed from the support plate in the direction of a removal axis, and when the protrusions tilt away from the winding area, the protrusions each extend further away from the removal axis as the distance from the base of the support plate increases.

8. The method of claim 7, wherein a respective tilt angle of each protrusion is defined between the protrusion and the removal axis when the protrusion tilts away from the winding region, and pivoting the protrusion toward the winding region comprises reducing the tilt angle.

9. The method of claim 4, comprising removing the wire layer from one of the protrusions after pivoting the one of the protrusions toward the wrapping region.

10. The method of claim 1, comprising removing the wire layer from at least a first one of the protrusions before moving at least a second one of the protrusions.

11. The method of claim 1 , wherein the article of apparel comprises an upper of an article of footwear.

12. The method of claim 1, wherein the support plate includes one or more sliding mechanisms that movably couple the protrusions to a base of the support plate.

13. The method according to claim 12, comprising: forming a line layer when the sliding mechanism is in a first position; attaching the continuous thread within the thread layer while the sliding mechanism remains in the first position; After joining the continuous line, changing the tension on the continuous line by moving the slide mechanism to a second position; as well as A second wire layer is wound around the plurality of protrusions while the sliding mechanism remains in the second position.

14. A support plate for manufacturing an upper of an article of footwear, the support plate comprising: A protrusion is movably connected to the support plate, wherein the protrusion is arranged to define a perimeter of an area in the shape of a flat upper of the article of footwear.

15. A support plate according to claim 14, wherein each protrusion comprises a pin.

16. The support plate of claim 14, comprising a hinge pivotably coupling one or more respective protrusions to a base of the support plate.

17. The support plate of claim 14, comprising a slider that movably couples one or more corresponding protrusions to a base of the support plate.

18. The support plate of claim 14, wherein the wrap region comprises two wings joined by a bridge.

19. A system for manufacturing an article of apparel, the system comprising: a support plate comprising a protrusion movably connected to the support plate, wherein the protrusion is arranged to define a perimeter of a winding area on the support plate; as well as A winding machine is configured to wind a continuous wire around a plurality of said protrusions to form a wire layer comprising a plurality of wire rows, each wire row extending between two respective protrusions and across said winding area.

20. The system of claim 19, comprising an actuator configured to move the protrusion on the support plate relative to the wrapping area.

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