Rotary winding device and method

Abstract

A winding apparatus and method for manufacturing an article of apparel. A winding device may include a winding unit including a rotatable shaft, a thread guide movable along an axis perpendicular to the shaft, and a plate including a base coupled to the shaft and a plurality of protrusions extending from the base. The winding device may also include a first actuator configured to rotate the shaft and a second actuator configured to move the thread guide along the axis and between respective ones of the plurality of protrusions to wind the continuous wire around the plurality of protrusions.

Description

Technical Field

[0001] The described embodiments generally relate to apparatuses and methods for manufacturing clothing. Specifically, the described embodiments relate to an apparatus for winding one or more continuous threads around an anchor point to produce material for clothing. 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 applies to clothing worn for both athletic and non-athletic activities. Suitable 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 manufacturing clothing to suit an individual in a range of usage scenarios. In particular, there is a need for methods of manufacturing material for clothing that has customizable characteristics but can be manufactured efficiently in large quantities and / or sizes. Summary of the Invention

[0003] A first embodiment (1) of the present application relates to a winding apparatus for manufacturing a clothing item, the winding apparatus comprising: a winding unit including: a rotatable shaft, a thread guide, and a plate, the thread guide being movable along an axis perpendicular to the axis of the shaft, the plate including a base coupled to the shaft and a plurality of protrusions extending from the base; a first actuator configured to rotate the shaft; and a second actuator configured to move the thread guide along the axis and between corresponding ones of the plurality of protrusions.

[0004] In a second embodiment (2), the thread guide according to the first embodiment (1) is movable along the axis between points located outside the perimeter of the plate, regardless of the orientation of the plate.

[0005] In a third embodiment (3), the base according to any one of embodiments (1)-(2) is coupled to the shaft adjacent the centroid of the plate.

[0006] In a fourth embodiment (4), the axis according to any one of embodiments (1)-(3) passes above the shaft.

[0007] In a fifth embodiment (5), the minimum diameter of the base according to any one of embodiments (1)-(4) is greater than or equal to half of the maximum diameter of the base.

[0008] In a sixth embodiment (6), each of the plurality of protrusions according to any one of embodiments (1)-(5) extends from the base at an angle of 90 to 175 degrees.

[0009] In the seventh embodiment (7), the winding device according to any one of embodiments (1)-(6) includes a plurality of winding units, wherein the shaft of each of the plurality of winding units is operatively coupled to a first actuator, and the thread guide of each of the plurality of winding units is operatively coupled to a second actuator.

[0010] In the eighth embodiment (8), the winding device according to any one of embodiments (1)-(6) includes a plurality of winding units, a plurality of first actuators, and a plurality of second actuators, wherein each of the plurality of first actuators is operatively coupled to the shaft of a winding unit among the plurality of winding units, and each of the plurality of second actuators is operatively coupled to the thread guide of a winding unit among the plurality of winding units, and wherein the plurality of first actuators are independently controllable, and the plurality of second actuators are independently controllable.

[0011] In the ninth embodiment (9), the thread guide according to any one of embodiments (1)-(8) is slidably coupled to a rod.

[0012] The tenth embodiment (10) of the present application relates to a method of manufacturing a clothing article, the method comprising: rotating a plate about a rotational axis, the plate including a base and a plurality of protrusions extending from the base; dispensing a continuous line via a thread guide capable of moving laterally along a transverse axis; and moving the thread guide along the transverse axis and between respective ones of the plurality of protrusions to wind the continuous line around the plurality of protrusions.

[0013] In the eleventh embodiment (11), in the method according to the tenth embodiment (10), only the translation of the thread guide along the transverse axis and the rotation of the plate about the rotational axis are required to wind the continuous line around the plurality of protrusions.

[0014] In the twelfth embodiment (12), in the method according to any one of embodiments (10)-(11), the length of the continuous line wound around the plurality of protrusions is greater than the distance traveled by the thread guide during the winding of the continuous line.

[0015] In the thirteenth embodiment (13), the method according to any one of embodiments (10)-(12) further comprises changing at least one of the rotational speed or the rotational direction of the plate while moving the thread guide.

[0016] In the fourteenth embodiment (14), winding the continuous line around the plurality of protrusions according to any one of embodiments (10)-(13) forms a line layer including a plurality of line rows, wherein each line row extends between two respective ones of the plurality of protrusions and spans the plate.

[0017] In the fifteenth embodiment (15), the method according to the fourteenth embodiment (14) further comprises joining the line rows among the plurality of line rows to each other while the line layer is on the plate.

[0018] In the sixteenth embodiment (16), the method according to any one of embodiments (14)-(15) further includes cutting the wire layer while the wire layer is on the board.

[0019] In the seventeenth embodiment (17), the method according to any one of embodiments (14)-(16) further includes winding a second continuous wire around a plurality of protrusions to form a second wire layer including a second plurality of wire rows, wherein each wire row in the second plurality of wire rows extends between two corresponding protrusions of the plurality of protrusions and spans the board.

[0020] In the eighteenth embodiment (18), the board according to any one of embodiments (10)-(17) rotates about a rotational axis by an axis coupled to a base, and a transverse axis passes above the axis. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1A-1B Garment articles according to some embodiments are shown.

[0022] Figure 2A-2C Wire layers according to some embodiments are shown.

[0023] Figure 3 Wire patterns according to some embodiments are shown.

[0024] Figure 4 Apparatuses for producing wire layers according to some embodiments are shown.

[0025] Figure 5 Boards for winding wire layers according to some embodiments are shown.

[0026] Figure 6 Boards and wire rows according to some embodiments are shown Figure 5 are shown.

[0027] According to some embodiments, Figure 7A-7B boards and wire guides for starting wire rows are shown Figure 5 are shown.

[0028] According to some embodiments, Figure 8A-8B boards and wire guides for continuing wire rows Figure 5 are shown Figure 7A-7B are shown, which continue Figure 7A-7B wire rows.

[0029] According to some embodiments, Figure 9A-9B boards and wire guides for completing wire rows and starting second wire rows are shown Figure 5 are shown Figure 7A-7B thereby completing Figure 7A-7B wire rows and starting a second wire row.

[0030] According to some embodiments, Figure 10A-10B boards and wire guides are shown Figure 5the board and Figure 7A-7B the wire guide, which continues Figure 9A-9B the second row of wires.

[0031] According to some embodiments, Figure 11A-11B shows Figure 5 the board and Figure 7A-7B the wire guide, completing Figure 9A-9B the second row of wires and starting the third row of wires.

[0032] According to some embodiments, Figure 12A-12B shows Figure 5 the board and Figure 7A-7B the wire guide, which continues Figure 11A-11B the third row of wires.

[0033] Figure 13A-13B Shows according to some embodiments Figure 5 the board and Figure 7A-7B the wire guide, completing Figure 11A-11B the third row of wires and starting the fourth row of wires.

[0034] Figure 14A-14B Shows according to some embodiments Figure 5 the board and Figure 7A-7B the wire guide, completing Figure 13A-13B the fourth row of wires.

[0035] Figure 15 Shows Figure 6-14B the distance table of the rows of wires.

[0036] Figure 16 Shows a device for producing line layers according to some embodiments.

[0037] Figure 17 is an exemplary flowchart of a method according to some embodiments.

[0038] Figure 18 Shows a schematic block diagram of an exemplary computer system, using which the embodiments can be implemented. DETAILED DESCRIPTION

[0039] The present invention will now be described in detail with reference to embodiments of the invention as illustrated in the accompanying drawings. When referring to "some embodiments", "an embodiment", "embodiments", "exemplary embodiments", etc., it means that the described embodiments may include specific features, structures or characteristics, but each embodiment may not necessarily include the specific feature, structure or characteristic. In addition, such phrases do not necessarily refer to the same embodiment. Further, when describing a specific feature, structure or characteristic 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.

[0040] As used herein, unless otherwise indicated, references to "first," "second," "third," "fourth," etc. are not intended to denote order, or that features with higher numbers require features with lower numbers. Additionally, unless otherwise specified, the use of "first," "second," "third," "fourth," etc. does not necessarily imply that the "first," "second," "third," "fourth," etc. features have different properties or values.

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

[0042] Garment articles serve many purposes. Among these, clothing can provide a unique aesthetic appearance, provide warmth or cooling properties, provide support for parts of an individual's body, and provide other performance properties such as breathability, moisture-wicking properties, and compression properties. Each of these purposes, alone or in combination, provides a comfortable garment suitable for use in a variety of situations (e.g., exercise and daily activities). The characteristics of a garment article (e.g., the materials and components used to make the garment, and the manner in which these materials / components are made) can be varied to produce desired properties such as durability, stiffness, weight, tack, texture, feel, stickiness, and / or breathability.

[0043] Automated or partially automated production of garment articles can involve many different techniques. In some techniques, computer numerical control (CNC) can be used to control and move components of equipment used to produce materials for garment articles. CNC may require programming computer software to perform the desired movements of the components of the apparatus, such as the movements required to wind a continuous thread around an anchor point to create a thread layer or thread pattern as described herein. In the embodiments described herein, the simultaneous and / or successive movement of a plate including the anchor point and a thread guide for guiding the continuous thread can be used to reduce the amount of movement required during production, thereby reducing manufacturing time.

[0044] The apparel articles described herein can be made by winding one or more continuous lines around anchor points to create a desired line layer or line pattern, or can include layers made by winding one or more continuous lines around anchor points to create a desired line layer or line pattern. Winding a continuous line around an anchor point includes: wrapping a continuous line around a first anchor point, extending that continuous line to a second anchor point, wrapping the continuous line around the second anchor point, and so on. The number and location of the anchor points can be used to control the characteristics of the line layer or line pattern and thus the characteristics of the apparel. Also, the number of times the continuous line is wound from anchor point to anchor point can be used to control the characteristics of the line layer or line pattern and thus the characteristics of the apparel.

[0045] The continuous lines of the line layer or line pattern can be joined within the line layer or line pattern. Joining the continuous lines of the line layer or line pattern can strengthen the layer or pattern and hold the lines in place within the layer or pattern. In some embodiments, joining the continuous lines of the line layer or line pattern can be used to control the characteristics of the line layer or line pattern. In some embodiments, a continuous line can be joined to itself within the line layer or line pattern. In some embodiments, a continuous line can be joined to itself at an overlap point between different rows of the continuous line (i.e., at a row intersection). In some embodiments, different continuous lines of the line layer or pattern can be joined together. In some embodiments, different continuous lines can be joined to each other at an overlap point between different continuous lines (i.e., at an intersection between different continuous lines). Since the continuous lines can be wound around the anchor points under tension, joining the continuous lines can hold the continuous lines in a state of tension.

[0046] In some embodiments, multiple different continuous lines can be wound around anchor points to form a line layer or line pattern. In some embodiments, the different continuous lines can be wound in the same layout (i.e., around the same anchor points 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). In some embodiments, the different continuous lines can define different winding layers for the apparel article or a portion thereof. In such embodiments, the different layers can provide different characteristics to the line pattern and thus different characteristics on the apparel article.

[0047] Continuous lines can be wound around an anchor point (such as the protrusions discussed herein) in various layouts to provide different degrees of characteristics to a garment article. The number of anchor points, the location of the anchor points, the way the continuous line is wound around the anchor points, and / or the material of the line wound around the anchor points can be used to produce a garment with desired characteristics, such as strength, stiffness, breathability, comfort, abrasion resistance, fit, texture, touch, adhesiveness, and durability. The characteristics of the garment article can be changed by varying the arrangement of the anchor points and / or the way the continuous line is wound around the anchor points. The characteristics can also be changed by varying the material of the continuous line.

[0048] In some embodiments, different line layers of the line pattern can provide a first degree of characteristics in one area of the garment article and a second degree of characteristics in a second area of the garment article. In some embodiments, different line layers of the line pattern can provide target characteristics to different regions of the garment article. In some embodiments, different line layers of the line pattern can include rows of lines oriented in different directions to provide target characteristics to different areas of the garment article.

[0049] In some embodiments, a line layer or a line pattern can be attached to the surface of one or more base layers. In some embodiments, a line layer or a line pattern can be directly attached to the surface of one or more base layers. In such embodiments, the rows of lines of the line layer or line pattern can be directly attached to the surface of the base layer. Direct attachment to one or more base layers can impart unique characteristics to the base layer and thus to the garment article. For example, direct attachment of a line layer or a line pattern can impart desired mechanical or aesthetic properties to all or a part of the garment article. In some embodiments, once the line pattern or line layer is removed from the anchor point, the direct attachment of the line layer or line pattern wound under tension can apply a compressive force to the surface of the base layer. The compressive force can impart the desired mechanical or aesthetic properties. For example, the compressive force can impart a desired shape to the garment article.

[0050] As used herein, two components (e.g., a line and a fabric) described as being "attached" to each other means that the first component and the second component are attached to each other by direct contact and / or attachment between the two components or via an adhesive or an attachment layer. Two components (e.g., a line and a fabric) described as being "directly attached" to each other means that the two components are directly attached to each other via the material of the first component, the material of the second component, or both. For example, in a case where the polymeric material of a line is directly attached to a base layer using heat and / or pressure, the line is directly attached to the base layer via the polymeric material of the line. In such an embodiment, the polymeric material can be heat-melted to the base layer.

[0051] FIG. 1 illustrates a garment article 100 according to some embodiments. The garment article 100 may include one or more base layers 110 and one or more thread layers, e.g., thread layers 120, 130, and 140. The thread layers 120, 130, 140 may be any of the exemplary thread layers described herein, e.g., thread layers 200, 220, and 240. In some embodiments, a thread layer, e.g., thread layer 120, may include multiple thread layers (e.g., thread layer 200 and thread layer 220). In such embodiments, a thread layer may refer to a thread pattern that includes multiple thread layers. In some embodiments, the garment article 100 may not include the base layer 110. In such embodiments, one or more thread layers (e.g., 120, 130, and 140) or one or more thread patterns that include multiple thread layers may define all or a portion of the garment article 100.

[0052] The garment article 100 may include any number of thread layers produced according to Figure 4-17 the embodiments. Each thread layer 120, 130, 140 (or thread pattern) may be defined by one or more threads that include multiple thread rows that cross each other at overlapping points between two or more thread rows. Each thread row of the thread layer extends continuously across the thread layer (or thread pattern). The thread rows that extend continuously across the thread layer (or thread pattern) are not woven or knitted threads. Similarly, the thread rows that extend continuously across the thread layer (or thread pattern) are not embroidery threads sewn to the base layer 110. Instead, as described herein, the thread rows are formed by winding a thread around an anchor point and thus forming the thread layer.

[0053] In some embodiments, the thread rows that extend continuously across the thread layer (or thread pattern) may extend continuously without forming a knitted structure or a woven structure between opposite ends of the thread row. In some embodiments, the thread rows that extend continuously across the thread layer (or thread pattern) may extend continuously without forming a knitted structure or a woven structure along a distance that is greater than or equal to at least 90% of the length of the thread row measured between opposite ends of the thread row. In some embodiments, the thread rows that extend continuously across the thread layer (or thread pattern) may extend continuously without forming an embroidery structure between opposite ends of the thread row. In some embodiments, the thread rows that extend continuously across the thread layer (or thread pattern) may extend continuously without forming an embroidery structure along a distance that is greater than or equal to at least 90% of the length of the thread row measured between opposite ends of the thread row.

[0054] In some embodiments, the rows of threads of thread layers 120, 130, 140 may be coupled to the surface 112 of the base layer 110 along at least a portion of the length of the row of threads. In some embodiments, the rows of threads of thread layers 120, 130, 140 may be directly coupled to the surface 112 of the base layer 110 along at least a portion of the length of the row of threads. In some embodiments, the surface 112 may be the outer surface of the base layer 110 that faces away from the wearer's body during use. In some embodiments, the surface 112 may be the inner surface of the base layer 110 that faces the wearer's body during use. In some embodiments, the apparel article 100 may include one or more thread layers coupled (or directly coupled) to the outer surface of the base layer 110 and one or more thread layers coupled (or directly coupled) to the inner surface of the base layer 110.

[0055] In some embodiments, the thread layers 120, 130, 140 may be coupled to different regions on the surface 112 of the base layer 110. In some embodiments, the thread layers 120, 130, 140 may define all or a portion of different regions of the apparel article 100. The apparel article 100 may include any number of thread layers (or thread patterns) that are coupled to or define different regions of the apparel article 100. For example, FIG. 1 shows an apparel article 100 that includes a first thread layer 120 coupled to a first region on the apparel article 100, a second thread layer 130 coupled to a second region on the apparel article 100, and a third thread layer 140 coupled to a third region on the apparel article 100. In such embodiments, the thread boundaries 250 of each thread layer may define the corresponding regions on the apparel article 100. In some embodiments, the thread layers (or thread patterns) may overlap in an overlapping region. The apparel article 100 may include any thread layers produced according to Figure 4-17 the embodiments of.

[0056] In some embodiments, the thread layers 120, 130, 140 (or the thread pattern including the thread layers 120, 130, 140) may completely wrap around all or a portion of the apparel article 100. For example, the thread layers 120, 130, 140 (or the thread pattern) may completely wrap around all or a portion of the apparel article 100 to provide support for the wearer's joints during use. The thread layer (or thread pattern) may completely wrap around the leg, sleeve, waist, torso portion, abdominal portion, or chest portion of the apparel article 100.

[0057] Thread layers (or thread patterns) applied to different regions of a clothing article can impart desired characteristics to the corresponding regions. Exemplary characteristics include, but are not limited to, strength, support, breathability, comfort (stretchability), aesthetics, abrasion resistance, water resistance, texture, adhesion, and tactility. In some embodiments, the material of the continuous thread used to wind the thread layer can impart the desired characteristics. For example, a thread layer wound with hydrophobic threads can impart water resistance to a specific region on the clothing article. In some embodiments, the tension during winding of the continuous thread can impart the desired characteristics. For example, a thread wound with high tension can apply a high compression to a specific region on the clothing article.

[0058] In some embodiments, each thread layer 120, 130, 140 (or thread pattern) can occupy a surface area defined by thread boundaries 250 (e.g., boundaries 250a, 250b, or 250c). In some embodiments, each thread layer 120, 130, 140 (or thread pattern) can occupy a surface area defined by thread boundaries 250 (e.g., boundaries 250a, 250b, or 250c) on the surface 112 of the base layer 110. Each thread row within the thread layer (or thread pattern) can continuously extend across the layer and includes a first end disposed at a thread boundary and a second end disposed at a thread boundary. In some embodiments, the first end and the second end of each thread row can be connected to the surface 112 of the base layer 110. In some embodiments, the first end and the second end of each thread row can be directly connected to the surface 112 of the base layer 110.

[0059] In some embodiments, the thread layer or thread pattern can be visibly exposed on the surface 112 of the clothing article 100. In some embodiments, no laminate layer or support textile layer is provided on the thread layer or thread pattern on the surface 112 of the clothing article 100. In some embodiments, the region on the clothing article 100 including the thread layer or thread pattern can be without a laminate layer.

[0060] In some embodiments, the surface area of the first thread layer (or thread pattern) and the surface area of the second thread layer (or thread pattern) can partially overlap on the clothing article 100 in an overlapping region. In some embodiments, the surface area of the first thread layer (or thread pattern) and the surface area of the second thread layer (or thread pattern) can partially overlap on the surface 112 of the base layer 110 in an overlapping region. In such embodiments, the first thread layer (or thread pattern) and the second thread layer (or thread pattern) can partially overlap on the clothing article 100. In some embodiments, the first thread layer (or thread pattern) and the second thread layer (or thread pattern) can be connected to each other at the overlapping region between the first thread layer (or thread pattern) and the second thread layer (or thread pattern). In some embodiments, the first thread layer (or thread pattern) and the second thread layer (or thread pattern) can be directly connected to each other at the overlapping region between the first thread layer (or thread pattern) and the second thread layer (or thread pattern).

[0061] In some embodiments, one or more wire layers 120, 130, 140 (or wire patterns) may occupy a surface area defined by a wire boundary that is the same as the peripheral edge 114 of the base layer 110. In such embodiments, one or more wire layers 120, 130, 140 (or wire patterns) may include occupying the entire surface area of the base layer 110. In some embodiments, one or more wire layers 120, 130, 140 (or wire patterns) may occupy a surface area defined by a wire boundary that is at least partially surrounded by the peripheral edge 114 of the base layer 110. In such embodiments, the peripheral edge 114 may define at least partially the surface area that includes the surface area defined by the wire boundary. In some embodiments, one or more wire layers 120, 130, 140 (or wire patterns) may occupy a surface area defined by a wire boundary that is surrounded by the peripheral edge 114 of the base layer 110. In such embodiments, the peripheral edge 114 may define the surface area that completely includes the surface area defined by the wire boundary.

[0062] In some embodiments, a row of wires of the wire layer (or wire pattern) may apply a compressive force on the surface 112 of the base layer 110, and the compressive force is applied along an axis extending from the first end of the wire to the second end. In such embodiments, the compressive force applied via each row of wires may be configured to impart a desired shape on the garment.

[0063] In some embodiments, the base layer 110 may include a single piece of material. In some embodiments, the base layer 110 may include multiple pieces of material. In such embodiments, the base layer 110 may include a first piece of material and a second piece of material adjacent to the first piece of material. The pieces of material adjacent to each other may be adjacent to the peripheral edge of the first piece and adjacent to the peripheral edge of the second piece and are arranged in a side-by-side relationship. In some embodiments, the first piece of material and the second piece of material may be joined at a seam. In some embodiments, the first piece of material and the second piece of material may not be joined at a seam, such that there is a gap between the adjacent pieces of material. In either case, one or more rows of wires for the wire layers 120, 130, 140 (or wire patterns) may extend across and be coupled to the first piece of material and the second piece of material. In some embodiments, one or more rows of wires for the wire layers 120, 130, 140 (or wire patterns) may extend across and be directly coupled to the first piece of material and the second piece of material.

[0064] As used herein, "seam" is any attachment area between two portions of a single material piece or between two different material pieces. Exemplary attachment areas include, but are not limited to: stitched attachment areas, adhesive attachment areas, thermally joined attachment areas, and interlocking attachments. Exemplary seam structures include, but are not limited to: self-attaching seams, hems, butt stitches, Merrow stitches (tight overlock stitches), gathered edges, surge stitches, overlock stitches, and interlocking seam configurations. In some embodiments, a "seam" may include an area where two portions of a single material piece or two different material pieces overlap. For example, a seam can be an area where a first material piece overlaps a second material piece and is joined to the second piece.

[0065] In some embodiments, the base layer 110 may include three or more adjacent material sheets. For example, the base layer 110 may include three, four, five, six, seven, eight, nine, or ten material sheets.

[0066] In some embodiments, the base layer 110 or the material sheets defining the base layer 110 may include a fabric material. In some embodiments, the fabric material may be a nonwoven, woven, or knitted fabric material. In some embodiments, the base layer 110 or the material sheets defining the base layer 110 may include a foam material. Exemplary fabric materials for the base layer 110 include, but are not limited to, thermoplastic polyurethane (TPU), polyester, polyamide, polyethylene (PE), PE foam, polyurethane (PU) foam, nylon, ultra-high molecular weight polyethylene (e.g., (a type of ultra-high molecular weight polyethylene)), carbon fiber, (a type of para-aramid), synthetic spider silk, cotton, wool, natural or artificial silk, polyethersulfone (PES), (a polyether-polyurea copolymer), or a blend of two or more of these materials. In some embodiments, the base layer 110 or the material sheets defining the base layer 110 may include a polymer sheet or film, such as a TPU sheet or film. In some embodiments, the base layer 110 or the material sheets defining the base layer 110 may include a mesh material.

[0067] In some embodiments, the base layer 110 or a sheet of material defining the base layer 110 may include a first base layer disposed below the wire layer or wire pattern and a second base layer disposed above the wire layer or wire pattern. In such embodiments, the wire layer or wire pattern may be sandwiched between the first base layer and the second base layer. Also in such embodiments, the rows of wires of the wire layer or wire pattern may (i) be connected to the surface 112 of the first base layer along at least a portion of the length of the row of wires, (ii) be connected to the surface 112 of the second base layer along at least a portion of the length of the row of wires, or (iii) both. In some embodiments, the row of wires may be directly connected to the surface 112 of the first base layer, directly connected to the surface 112 of the second base layer, or both.

[0068] Although the garment article 100 is depicted as a shirt in FIG. 1, other types of garment articles including wire layers 120, 130, 140 (or wire patterns) as described herein are also contemplated. As used herein, "garment" can be any item worn or decorated on a person, 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, cords, shin guards, hats, ties, scarves, purses, handbags, wallets, backpacks or rucksacks.

[0069] The wire layers (e.g., wire layers 200, 220, and 240) as described herein may each include a wire boundary 250 defined by the space in which the rows of wires of the wire layer are disposed. The wire boundary 250 for a wire layer is: the space in which the rows of wires of the wire layer are located after removing (e.g., cutting) the wire layer from the anchor points for winding the wire layer. The multiple rows of wires within a wire pattern may include a first end located on a first side of the wire boundary 250 and a second end located on a second side of the wire boundary 250. For example, the row of wires 204 of the wire layer 200 may include a first end 210 located on a first side of the wire boundary 250 and a second end 212 located on a second side of the wire boundary 250.

[0070] Figure 2A-2C Wire boundaries 250a-c of wire layers 200, 220, and 240 are shown. For a wire pattern including multiple wire layers, the wire pattern may include a wire pattern boundary 250 defined by the space occupied by the combination of individual wire layers. For example, a wire pattern including wire layers 200, 220, and 240 includes a wire pattern boundary defined by the space occupied by the combination of boundary 250a and boundary 250c. Boundary 250b is completely contained within boundary 250a.

[0071] As used herein, the sides of a perimeter edge or boundary refer to the top, bottom, right, and left sides of a shape defined by the edge or boundary. The top, bottom, right, and left sides of the shape are located at the top, bottom, right, and left of the geometric center of the shape. Thus, a perimeter edge or boundary will have a top side defined by an edge portion located above the geometric center, a bottom side defined by an edge or boundary portion located below the geometric center, a right side defined by an edge portion located to the right of the geometric center, and a left side defined by an edge or boundary portion located to the left of the geometric center. The top and bottom sides do not overlap. Similarly, the left and right sides do not overlap. The top and left sides overlap at an edge or boundary portion located in the upper left of the geometric center. The top and right sides overlap at an edge or boundary portion located in the upper right of the geometric center. The bottom and left sides overlap at an edge or boundary portion located in the lower left of the geometric center. The bottom and right sides overlap at an edge or boundary portion 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 such that no portion of the material overlaps itself.

[0072] As used herein, a first side of a perimeter edge or boundary can be the top, bottom, right, or left side of the perimeter edge or boundary, and a second side of the perimeter edge can be the top, bottom, right, or left side of the perimeter edge or boundary, provided that the first side and the second side are not the same side. Similarly, a third side of the perimeter edge or boundary can be the top, bottom, right, or left side of the perimeter edge or boundary, and a fourth side of the perimeter edge or boundary can be the top, bottom, right, or left side of the perimeter 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.

[0073] In some embodiments, one or more line layers (e.g., line layers 120, 130, 140) can include lines that define (i) multiple line rows each extending from a first side of a line boundary to a second side of the line boundary and crossing each other at overlap points between two or more line rows, and (ii) multiple line rows each extending from a third side of the line boundary to a fourth side of the line boundary and crossing each other at overlap points between two or more line rows. The line rows extending from the first side to the second side can extend continuously from the first side to the second side, and the line rows extending from the third side to the fourth side can extend continuously from the third side to the fourth side.

[0074] The wire layer 200 includes a continuous wire 202 wound around an anchor point 290. The wire layer 220 includes a continuous wire 222 wound around an anchor point 290. The wire layer 240 includes a continuous wire 242 wound around an anchor point 290. In some embodiments, the anchor point 290 may be different groups of anchor points around which different wire layers are wound. In some embodiments, multiple wire layers may be wound around the same set of anchor points 290. In such embodiments, the individual wire layers may be wound on top of each other, with one wire layer disposed on top of one or more other wire layers.

[0075] As used herein, "anchor point" means a location to which a wire or a group of wire rows is fixedly attached. The wire or wire rows may be wrapped, wound, joined, or otherwise attached at the anchor point. In some embodiments, the anchor point may be a location on a garment article. For example, the anchor point may be a hole or opening left by a structure (e.g., a pin, a protrusion, or a bump) for winding a continuous wire of a wire layer or a wire pattern. In some embodiments, a wire layer or a wire pattern for a garment article may not include any anchor point locations because all the anchor point locations that existed during the winding of the wire layer or wire pattern have been removed (e.g., cut off). The anchor point may also be a structure (e.g., a pin, a protrusion, or a bump) for winding a continuous wire of a wire layer or a wire pattern. And the anchor point structure may or may not form part of a wire layer or a wire pattern for a garment article.

[0076] The continuous wire wrapped or wound around an anchor point does not need to completely (i.e., 360 degrees) wrap or wind around the anchor point. The continuous wire wrapped or wound around an anchor point may only wrap or wind around a portion of the anchor point. For example, a continuous wire wrapped (enclosed) or wound around an anchor point may wrap or wind around 25% (90 degrees) of the circumference of a pin, 50% (180 degrees) of the circumference of an anchor point, 75% (270 degrees) of the circumference of an anchor point, or 100% (360 degrees) of the circumference of an anchor point. In some embodiments, the continuous wire may wrap or wind around the circumference of the anchor point more than once before passing to the next anchor point. For example, the continuous wire may wrap or wind around the circumference of the anchor point one and a half times (540 degrees) or twice (720 degrees) before passing to the next anchor point.

[0077] The continuous wire 202 may wrap around multiple anchor points 290 and includes multiple wire rows 204. Each wire row 204 extends between two corresponding anchor points 290.

[0078] The continuous line 202 can enclose a plurality of anchor points 290 in a tension state such that when enclosing around the anchor points 290, the individual line rows 204 are in a tension state. In some embodiments, the tension of the winding of the line rows 204 can be in the range of 0 centinewtons (cN) to 25 cN, including sub-ranges. For example, in some embodiments, the tension of the winding of the line rows 204 can 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 of the winding of the line rows 204 can be in the range of 2 cN to 10 cN. In some embodiments, the tension of the winding of the line rows 204 can be in the range of 2 cN to 6 cN. In such embodiments, the tension can generate a compressive force applied along the line rows as described herein. In some embodiments, the compressive force can be in the range of 0 cN to 25 cN, including sub-ranges. For example, in some embodiments, the compressive force can 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 compressive force can be in the range of 2 cN to 10 cN. In some embodiments, the compressive force can be in the range of 2 cN to 6 cN.

[0079] The line rows 204 directly connected to the surface 112 of the base layer 110 can apply a compressive force on the surface 112 along an axis extending from the first end 210 to the second end 212 of the line rows 204. This compressive force can be the result of the line rows 204 winding around the anchor points under tension and being directly connected to the surface while still under tension.

[0080] In some embodiments, different line rows 204 can enclose the anchor points 290 at different tensions to impart desired characteristics to the line layer 200. In some embodiments, the first set of line rows 204 can be wound at a first tension in any of the above centinewton ranges, and the second set of line rows 204 can be wound at a second tension in any of the above centinewton ranges, where the first tension is greater than or less than the second tension. In some embodiments, the first tension can be at least 0.5 cN greater or less than the second tension. In some embodiments, the first tension can be at least 1 cN greater or less than the second tension.

[0081] In embodiments where different line rows 204 are wound at different tensions, within the line layer 200, the different line rows 204 of the line layer 200 will be at different tension values. The tension of the line rows 204 can be used to control the characteristics of the line layer 200 and thus control the characteristics of the garment product including the line layer 200.

[0082] The number of thread lines 204 for a thread layer 200 fixed to an anchor point 290 is defined by the "thread line communication number" of the anchor point 290. As used herein, "thread line communication number" means the number of thread lines extending from one anchor point to different anchor points. For the purpose of calculating the thread line communication number of an anchor point, two thread lines (i.e., overlapping thread lines) extending between the same two anchor points are only counted as "1". For example, a thread line communication number of 5 means that an anchor point has 5 thread lines extending from that anchor point, and each of the 5 thread lines leads to a different anchor point. As another example, a thread line communication number of 6 means that the anchor point has 6 thread lines extending from that anchor point, and each of the 6 thread lines leads to a different anchor point.

[0083] Similarly, the number of thread lines fixed to an anchor point 290 of a thread pattern including multiple thread layers is defined by the "thread line communication number" of the anchor point 290 of the thread pattern. For a thread pattern, the "thread line communication number" of the anchor point 290 is the total number of thread lines of multiple layers extending from the anchor point to different anchor points.

[0084] For a thread layer or a thread pattern, the thread line communication number of the anchor point 290 can be "X" or more. In some embodiments, the thread line communication numbers of two or more separate anchor points 290 can be "X" or more. In some embodiments, the thread line communication numbers of all anchor points 290 for a thread layer or a thread pattern can be "X" or more. "X" can 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" can 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" can be greater than 50. In some embodiments, "X" can be in the range of 2 to 100, 10 to 100, or 20 to 100, or 10 to 200, or 20 to 200, or 50 to 200, or 10 to 300, or 20 to 300, or 50 to 300.

[0085] A wire layer, such as wire layer 200, may include any suitable number of wire rows. In some embodiments, the wire layer may include 10 or more wire rows. In some embodiments, the wire layer may include 20 or more wire rows. In some embodiments, the wire layer may include 50 or more wire rows. In some embodiments, the wire layer may include 100 or more wire rows. In some embodiments, the wire layer may include 200 or more wire rows. In some embodiments, the wire layer may include 300 or more wire rows. In some embodiments, the wire layer may include 500 or more wire rows. In some embodiments, the wire layer may include a number of wire rows within the range of 10 to 300. For example, the wire layer may include 10 to 300, 50 to 300, 100 to 300, or 150 to 300 wire rows. In some embodiments, the wire layer may include 10 to 500 wire rows. In some embodiments, the wire layer may include 100 to 500 wire rows. In some embodiments, the wire layer may include 100 to 1000 wire rows.

[0086] In some embodiments, wire rows 204 may be joined at the anchor point 290. In such embodiments, wire rows 204 may be joined at the anchor point 290 via an adhesive, a joining layer, thermal (conduction or convection) heating (e.g., in a hot 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 joining using a catalyst of a biological material, adhesive spraying (e.g., CNC adhesive spray deposition), or by pushing one wire row through other wire rows.

[0087] In some embodiments, wire rows 204 may be directly joined together at the anchor point 290. In some embodiments, wire rows 204 may be directly joined together at the anchor point 290 via the polymeric material of the continuous wire 202. For example, heat and / or pressure may be applied to the anchor point 290 to directly join wire rows 204 at the anchor point 290. In embodiments where heat and / or pressure is used to directly join the polymeric material of wire rows 204, wire rows 204 may be heat melted together at one or more anchor points 290. In embodiments including directly joining wire rows 204 at the anchor point 290, wire rows 204 may be directly joined at the anchor point 290 without using an adhesive or a joining layer.

[0088] In some embodiments, wire rows 204 may be joined together via a joining layer. In some embodiments, wire rows 204 may be joined together at the anchor point 290 via a joining layer. In such embodiments, the joining layer may be, for example, a laminate layer, an adhesive layer, a suture layer, a curing layer, a screen printing layer, or a blown fiber. In some embodiments, the blown fiber layer may include polymeric fibers that can join wire rows 204.

[0089] In some embodiments, the thread lines 204 may be joined together without using a joining layer. For example, in some embodiments, the thread lines 204 may be directly joined together in a manner such as, but not limited to: direct local joining of the materials of the thread lines 204, needling, hydroentanglement, and ultrasonic / vibrational entanglement.

[0090] In some embodiments, the thread lines 204 may be joined at the points where two or more thread lines 204 overlap in the thread layer 200 (i.e., the intersection points 206). The thread lines 204 may be joined via an adhesive, a joining layer, thermal (conduction or convection) heating (e.g., in a hot 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 joining using a catalyst of a biological material, adhesive spraying (e.g., CNC adhesive spraying deposition), or by pushing one thread line through other thread lines at the intersection points 206. The intersection points 206 of the thread lines may be referred to as "overlap points" or "points of overlap".

[0091] In some embodiments, the thread lines 204 may be directly joined together at the intersection points 206. In some embodiments, the thread lines 204 may be directly joined together at the intersection points 206 via the polymeric material of the continuous thread 202. In embodiments including directly joining the thread lines 204 at the intersection points 206, the thread lines 204 are joined at the intersection points 206 without using an adhesive or a joining layer. For example, heat and / or pressure may be applied to the thread layer 200 to directly join the thread lines 204 at any intersection point 206. In embodiments using heat and / or pressure to directly join the polymeric materials of the thread lines 204, the thread lines 204 may be heat melted together at one or more intersection points 206.

[0092] In some embodiments, a joining layer may join the thread lines 204 together at a plurality of intersection points 206 within the thread layer 200. 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 containing polymeric fibers that can join the thread lines 204.

[0093] In some embodiments, the continuous thread 202 may include overlaying thread lines 204. As used herein, "overlaying thread line" means two or more thread lines that follow the same path between two separate anchor points. The overlaying thread lines do not need to directly cover each other. As long as they extend between the same two anchor points, two or more thread lines are considered to be overlaying.

[0094] In some embodiments, the yarn rows 204 of the yarn layer 200 may not be woven or knitted together. In such embodiments, the yarn rows 204 may be referred to as "non-woven" and "non-knitted" yarn rows. The yarn rows 204 of the yarn layer 200 may not be embroidery yarns stitched to the base layer. In such embodiments, the yarn rows 204 may be referred to as "non-embroidery" yarn rows.

[0095] In some embodiments, the continuous yarn 202 may be a polymer yarn. As used herein, "polymer yarn" means a yarn that is at least partially composed of polymeric material. In some embodiments, the polymer yarn may be entirely composed of one or more polymeric materials. In some embodiments, the polymer yarn may include a polymeric material around a coated core (which may or may not be composed of polymeric material). In such embodiments, the core may be encapsulated by the coating material. In some embodiments, the polymer yarn may include a non-polymeric core coated, covered, or encapsulated with a polymeric material. In some embodiments, the polymer yarn may include a polymeric core coated, covered, or encapsulated with a non-polymeric material. In some embodiments, the polymer yarn may be a braided yarn having one or more braids composed of polymeric material. In some embodiments, the polymeric material of the polymer yarn may be a thermoplastic material. In some embodiments, the continuous yarn 202 may be a yarn coated with an activator, such as a heat-activated adhesive or a UV-activated adhesive. In some embodiments, the CNC machine for winding the continuous yarn 202 having an activator coating may include a robotic arm for activating the coating as the continuous yarn 202 is wound around the anchor point 290. In some embodiments, the coating may be initiated by the thread guide 480.

[0096] Suitable polymeric materials for the polymer yarns discussed herein include, but are not limited to, thermoplastic polyurethane (TPU), rubber, and silicone. In some embodiments, the TPU may be recycled TPU. In some embodiments, the polymeric material may be a photo-reactive (infrared or ultraviolet light-reactive) polymeric material, such as photo-reactive TPU. In some embodiments, the polymeric material may be soluble (e.g., water-soluble). In embodiments including a polymer yarn having a coated core, suitable materials for the core include, but are not limited to, polyester, nylon, ultra-high molecular weight polyethylene (e.g., (a type of ultra-high molecular weight polyethylene)), carbon fiber, (One type of para-aramid), bioengineered woven, knitted, or laminated materials (e.g., synthetic spider silk), woven, knitted, or laminated plant-based materials, cotton, wool, and natural or artificial silk. In some embodiments, the polymer thread can be a polyester thread coated with thermoplastic polyurethane. In some embodiments, the continuous thread 202 can be a non-polymer thread composed of a non-polymer material, such as carbon fiber, cotton, wool, or silk. In some embodiments, the continuous thread 202 can be a thread composed of a biomaterial, such as mango yarn or biofilament. In some embodiments, the polymer thread can be a thermoplastic melt yarn, a polymer thread with a non-molten core, and other similar types of threads.

[0097] In some embodiments, the polymer material for the polymer 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 polymer material can be referred to as a "low melting temperature polymer material".

[0098] In some embodiments, the continuous thread 202 can be a plied thread. In some embodiments, the plied thread can be plied while the thread 202 is being wound. For example, the winding unit 450 for winding the thread 202 can ply the thread (e.g., see the winding unit 450) using threads from multiple spools. In some embodiments, the plied thread can be a pre-plied thread wound around a spool.

[0099] In some embodiments, the denier of the continuous thread 202 of the thread layer 200 can be in the range of 1 denier to 3000 denier, including sub-ranges. For example, the denier of the continuous thread 202 can be: 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 with any two of these values as endpoints. For example, in some embodiments, the denier of the continuous thread 202 can be in the range of 10 denier to 2500 denier, 50 denier to 2000 denier, 100 denier to 1900 denier, 200 denier to 1800 denier, 300 denier to 1700 denier, 400 denier to 1600 denier, 500 denier to 1500 denier, 600 denier to 1400 denier, 700 denier to 1300 denier, 800 denier to 1200 denier, 900 denier to 1100 denier, or 900 denier to 1000 denier.

[0100] The wire patterns as described herein may include any number of wire layers. For example, the wire pattern may 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 wire layers. For example, the wire pattern may include wire layer 200, wire layer 220, and wire layer 240.

[0101] The continuous wires of any wire layer (e.g., wire layers 220 and 240) can be wound around the anchor point 290 and extend therebetween in the same manner as described above for the continuous wire 202. In addition, the rows of continuous wires of any wire layer (e.g., wire layers 220 and 240) can be joined in the same manner as the wire layer 200 described above.

[0102] Similar to the continuous wire 202, the continuous wires for other wire layers (e.g., wires 222 and 242) may include a plurality of rows of wires (e.g., wire rows 224 and 244) that are wound around two corresponding anchor points and extend between the two corresponding anchor points. In some embodiments, the continuous wires of different wire layers can be the same wire material. In some embodiments, the continuous wires of different wire layers can be composed of different wire materials. In such embodiments, the materials of the different continuous wires in the wire pattern can be selected to provide target properties to the regions of the wire pattern (and thus to the garment). In some embodiments, the deniers of the continuous wires of different wire layers in the wire pattern can be selected to provide different degrees of properties (e.g., strength or stretchability) to different regions of the wire pattern.

[0103] In embodiments including a wire pattern having a plurality of wire layers, the plurality of wire layers can be laminated to each other. For example, wire layer 200 can define the first layer of the wire pattern, and the second wire layer 220 can define the second layer of the wire pattern. And the different wire layers of the wire pattern can be stacked on top of each other in the overlapping region between the two wire layers. For example, the first wire layer 200 can be disposed on the second wire layer 220 in the overlapping region between the two wire layers, or vice versa.

[0104] In embodiments including a wire pattern having a plurality of wire layers, the plurality of wire layers can be joined to each other in the wire pattern. In some embodiments, one or more layers can be directly joined to each other via the polymeric material defining the rows of continuous wires for at least one layer. In some embodiments, one or more layers can be joined via a joining layer. In such embodiments, the joining layer can be, for example, a laminated layer, an adhesive layer, a stitched layer, a cured layer, a screen printed layer, or blown fibers. In some embodiments, the joining layer can be a non-woven joining layer.

[0105] In some embodiments, one or more wire layers of a wire pattern can be used to join other wire layers of the wire pattern together. In such embodiments, these one or more wire layers can use polymeric wire winding that, when heated, joins the other layers of the wire pattern together at the anchor points and / or intersection points between the continuous wires. For example, in a wire pattern including three wire layers, one of the three wire layers (e.g., the middle wire layer) can be wound with a polymeric wire that is used to join all three wire layers together. In some embodiments, one or more wire layers of the wire pattern can be defined by continuous wires that are coated or impregnated with an adhesive. In some embodiments, the adhesive can be activated by applying heat. In some embodiments, the adhesive can be a soluble adhesive that, when contacted with a solvent (such as water), dissolves completely or partially to join the wire layers together.

[0106] Figure 3 A wire pattern 300 is shown in accordance with some embodiments. The wire pattern 300 can include a plurality of wire layers, e.g., a first wire layer 310, a second wire layer 320, and a third wire layer 330. Similar to wire layers 200, 220, and 240, each of wire layers 310, 320, 330 can include continuous wires wound around a plurality of anchor points 290. The wire pattern 300 can be a wire pattern produced using the apparatus and method described with respect to Figure 4-17 In some embodiments, the first wire layer 310, the second wire layer 320, and the third wire layer 330 can each include different continuous wires. In some embodiments, the first wire layer 310, the second wire layer 320, and the third wire layer 330 can be wound sequentially. For example, the first wire layer 310 can be wound around the anchor points 290 first, followed by the second wire layer 320 wound around the anchor points 290, and then the third wire layer 330 wound around the anchor points 290. Although Figure 3 three wire layers 310, 320, 330 are shown, the wire pattern 300 can include any number of wire layers, e.g., two, four, five, six, seven, eight, nine, ten, eleven, or twelve wire layers.

[0107] As Figure 3 shown, each of the first, second, and third wire layers 310, 320, 330 can be wound using a different winding pattern (defined by the angle at which the rows of wires in the wire layer extend relative to the perimeter of the wire layer and relative to each other). The winding pattern can be selected to affect various properties of the resulting wire layers 310, 320, 330 or wire pattern 300, such as durability, stiffness, weight, tack, texture, haptic, and / or breathability.

[0108] Figure 4Illustrated is a winding device 400 for winding a continuous wire according to some embodiments. In some embodiments, the winding device 400 may be operated using computer numerical control (CNC) as described herein. In some embodiments, the winding device 400 may include a frame 410. In some embodiments, the frame 410 may include a top surface 412 and a support 414. In some embodiments, the frame 410, such as the support 414, may support a rod 416. In some embodiments, the rod 416 may include a groove 418. As described below, in some embodiments, a wire guide (e.g., wire guide 480) may be movably coupled to the rod 416 through the groove 418 such that the wire guide may move parallel to the rod 416. For example, the wire guide 480 may be slidably coupled to the rod 416 such that the wire guide 480 may slide along the rod 416.

[0109] The winding device 400 may include one or more winding units 450. In some embodiments, the winding unit 450 may include a shaft 452. In some embodiments, the shaft 452 may rotate relative to the frame 410 (e.g., the top surface 412). In some embodiments, the winding unit 450 may include a plate 460. In some embodiments, the plate 460 may include a base 462 and an anchor point 464. The anchor point 464 may be formed separately from and subsequently coupled to the base 462, or may be integrally formed with the base 462. In some embodiments, the base 462 may be fixedly coupled to the shaft 452 such that the plate 460 is rotatable relative to the frame 410.

[0110] As Figure 4 shown, the plate 460 may rotate about a rotation axis A. In some embodiments, the axis A may pass through the geometric center of the shaft 452. In some embodiments, the axis A may be perpendicular to the plane defined by the base 462. In some embodiments, the plate 460 may rotate counterclockwise. In some embodiments, the plate 460 may rotate clockwise. In some embodiments, the plate 460 may rotate counterclockwise or clockwise about the rotation axis A.

[0111] In some embodiments, during operation of the winding device 400, the rotation axis A may be substantially parallel to the gravity vector (i.e., the vector pointing downward towards the center of the Earth). In some embodiments, during operation of the winding device 400, the rotation axis A may be substantially perpendicular to the gravity vector. In some embodiments, during operation of the winding device 400, the rotation axis A may be inclined relative to the gravity vector.

[0112] The anchor point 464 may be with Figure 3is the same as the anchor point 290 shown. The anchor point 464 can be coupled to and extend from the base 462. In some embodiments, the anchor point 464 can extend from the base 462 in a direction parallel to the axis A. In some embodiments, the anchor point 464 can extend beyond the perimeter of the base 462 in a direction perpendicular to the axis A. In some embodiments, the anchor point 464 can additionally or alternatively extend beyond the perimeter of the base 462 in a direction parallel to the axis A (e.g., they can extend diagonally from the base 462). In some embodiments, the anchor point 464 can be a structure, such as, a pin, a protrusion, or a nodule.

[0113] In some embodiments, the winding unit 450 can include a coupler 470 to couple a wire guide (such as the wire guide 480) to the rod 416. In some embodiments, the coupler 470 can include a protrusion 472 that can engage a groove 418 of the rod 416. In some embodiments, the protrusion 472 can engage the groove 418 movably such that the protrusion can move or slide within the groove 418 and the coupler 470 can move relative to the rod 416 along a translation axis B. In some embodiments, the translation axis B can be defined as an axis passing through the rod 416 along which the coupler 470 can translate. In some embodiments, the protrusion 470 can include a wheel, a ball, a cylinder, or any other structure configured to roll or slide within the groove 418. By firmly connecting the wire guide 480 to the rod 416, the groove 418 and the protrusion 470 can minimize an undesired movement of the wire guide 480 during winding a continuous line around the anchor point 464 while still allowing the wire guide 480 to move relative to the rod 416.

[0114] Although the sliding engagement of the coupler 470 and the rod 416 has been described above as being implemented using the groove 418 and the protrusion 472, any coupler (e.g., a rolling engagement) that allows the wire guide 480 to move relative to the rod 416 can be implemented in the winding device 400. Additionally, the coupler 470 can include a groove or other notch while the rod 416 includes a protrusion.

[0115] As Figure 4As shown, the winding device 450 may include one or more wire guides 480 to guide the continuous line as it is wound around the anchoring points 464. In some embodiments, the one or more wire guides 480 may be moved laterally (i.e., above the top surface 412). In some embodiments, the wire guide 480 may include a tube, an eyelet, or other aperture through which the continuous line may pass while being guided by the wire guide 480. For example, in some embodiments, the wire guide 480 may include one or more tubes 482 or other structures for passing the continuous line between adjacent anchoring points 464. As the wire guide 480 moves along a wire guide translation axis C parallel to the translation axis B, the continuous line may enter and exit the tube 482 from a spool supported on the frame 410. The wire guide translation axis C may be defined as an axis parallel to the translation axis B that passes through the point where the continuous line exits the wire guide 480 when the continuous line is wound around the anchoring point 464. In some embodiments, the wire guide translation axis C may pass above the shaft 452. In some embodiments, the wire guide translation axis C may intersect the axis A. In some embodiments, the wire guide translation axis C may be laterally displaced from the axis A. In some embodiments, the wire guide translation axis C may be a lateral axis (i.e., an axis that extends at a non-zero angle relative to the rotational axis A). In some embodiments, the wire guide translation axis C may be perpendicular to the rotational axis A.

[0116] In some embodiments, a portion of the wire guide 480, such as the tube 482 or the eyelet or any other structure for guiding the continuous line, is configured to pass between adjacent anchoring points of the anchoring points 464 to wind the continuous line around one of the adjacent anchoring points 464. As used herein, a first anchoring point described as "adjacent" to a second anchoring point means that the second anchoring point is the first or second closest anchoring point neighbor of the first anchoring point. An anchoring point typically has two "adjacent" anchoring point neighbors, usually located on opposite sides of the anchoring point. In embodiments including equally spaced anchoring points, the first closest anchoring point neighbor and the second closest anchoring point neighbor of an anchoring point may be located at the same distance from the anchoring point. As an example, in Figure 3 anchoring points 290a and 290c are adjacent to anchoring point 290b. Anchoring points 290a and 290b include a pair of adjacent anchoring points, and anchoring points 290b and 290c include a pair of adjacent anchoring points.

[0117] In some embodiments, multiple continuous lines can pass through the wire guide 480 and be wound around one or more anchor points 464 simultaneously. In such embodiments, the wire guide 480 can include a single tube 482 or an eyelet or other structure for guiding the continuous lines, and multiple continuous lines can pass through the tube or other structure. In some embodiments, the wire guide 480 can include multiple tubes 482 or eyelets or other structures configured to move uniformly to pass between pairs of adjacent anchor points 464, and one or more continuous lines can pass through each of the multiple tubes 482 or eyelets or other structures. In some embodiments, passing multiple continuous lines through the wire guide 480 and winding them around the anchor points 464 simultaneously can improve the efficiency of the winding device 400.

[0118] As Figure 4 shown, the winding device 400 can include a first actuator 420 configured to rotate the shaft 452 and thus rotate the plate 460. In some embodiments, the first actuator 420 can include a motor 422. Additionally, in some embodiments, the first actuator 420 can include one or more of a gear assembly, a belt and pulley, or a cable and pulley. In some embodiments, the first actuator 420 can be coupled to the shaft 452 to generate a torque on the shaft 452 about an axis A. This torque can rotate the first shaft 452 and the plate 460. In some embodiments, the first actuator 420 can include a gear assembly between the motor 422 and the shaft 452, which can change the gear ratio to increase the rotational accuracy or efficiency of the plate 460. For example, in some embodiments, such a gear assembly can cause a full rotation of the shaft within the motor 422 to result in less than a full rotation of the shaft 452, which can increase the accuracy of obtaining a specific predetermined orientation of the plate 460. In some embodiments, such a gear assembly can alternatively or additionally cause a full rotation of the shaft within the motor 422 to result in more than a full rotation of the shaft 452.

[0119] The first actuator 420 can be connected to a control system that can change the torque magnitude and / or direction of the electric motor 422 to thereby change the angular velocity of the plate 460 when the wire guide 480 is stationary or in motion, as described in more detail herein.

[0120] As Figure 4 shown, the winding device 400 can include a second actuator 430 configured to translate along the wire guide axis C and move the wire guide 480 between the corresponding anchor points 464. In some embodiments, the second actuator 430 can be an electromechanical linear actuator (e.g., a motor coupled to a belt, chain, cable, or rack), a hydraulic linear actuator, or a pneumatic linear actuator. As Figure 4As shown, in some embodiments, the second actuator 430 may include a motor 432 and a flexible coupling 434 (e.g., a belt, chain, cable, or rack) coupled to the motor 432 and extending along the rod 416. In some embodiments, the flexible coupling 434 may be coupled to the coupling 470 such that activation of the motor 432 moves a point on the flexible coupling 434, thereby moving the coupling 470 along the translation axis B. Similar to the first actuator 420, the second actuator 430 may be coupled to a control system that can vary the torque magnitude and / or direction of the motor 432 to vary the translation speed of the wire guide 480 when the plate 460 is stationary or rotating, as described in more detail herein. In embodiments where the second actuator 430 is a hydraulic or pneumatic linear actuator, the control system can vary the pressure of the liquid or gas to vary the translation speed of the wire guide 480.

[0121] In some embodiments, during winding of the continuous wire, the wire guide 480 may move only along an axis perpendicular to axis A (e.g., the wire guide translation axis C). For example, during winding, the wire guide 480 may move along an axis perpendicular to axis A but not along any axis parallel to axis A. In some embodiments, the coupling 470 and / or the wire guide 480 may move the wire guide 480 and / or the tube 482 along an axis parallel to axis A. In such embodiments, movement of the wire guide 480 and / or the tube 482 along an axis parallel to axis A may only require setting the wire guide 480 and / or the tube 482 in an initial position prior to winding. In some embodiments, when the wire guide 480 reaches the anchor point 464 and is used to wrap the continuous wire around the anchor point 464, the wire guide 480 and / or the tube 482 move along an axis parallel to axis A.

[0122] In some embodiments, winding the continuous wire around the anchor point 464 may only require movement of the wire guide 480 along a single axis, e.g., the wire guide translation axis C described herein. For example, during the process of winding the continuous wire around the anchor point 464, the wire guide 480 may move only along the wire guide translation axis C, which may remain constant and not be adjusted laterally (away from or toward axis A) or longitudinally (parallel to axis A) during winding. Thus, the winding device 400 can complete a winding operation, e.g., produce a wire layer, without moving the wire guide 480 along multiple axes (after the wire guide 480 has optionally been set to the initial position). In some embodiments, the single axis along which the wire guide 480 moves during the winding operation may be perpendicular to axis A.

[0123] To achieve the winding of a continuous line around the anchoring point 464, the second actuator 430 can move the coupler 470 such that the wire guide 480 (e.g., components of the wire guide 480 such as the tube 482 or the eyelet) passes between adjacent anchoring points of the anchoring point 464. The second actuator 430 can move the coupler 470 such that the wire guide 480 moves along the wire guide translation axis C and between adjacent anchoring points of the anchoring point 464. Thereafter or simultaneously, the first actuator 420 can rotate the plate 460. In some embodiments, without any movement parallel to the axis A, the wire guide 480 can pass back through the first pair of adjacent anchoring points (e.g., Figure 3 the shown anchoring points 290a and 290b) after or while the plate 460 rotates, and pass through between the second pair of adjacent anchoring points (e.g., anchoring points 290b and 290c). Thus, the wire guide 480 can loop a continuous line around an anchoring point (e.g., anchoring point 290b).

[0124] After looping the continuous line around the first anchoring point (e.g., anchoring point 290b), the coupler 470 can move the wire guide 480 towards another pair of adjacent anchoring points 464, which are proximal or distal to the first anchoring point. After the movement, the wire guide 480 can loop the continuous line around the second anchoring point of another pair of adjacent anchoring points 464 in the same manner as the first anchoring point.

[0125] In some embodiments, the anchoring point 464 can extend at an angle relative to the base 462. For example, the longitudinal axis of the anchoring point 464 (e.g., the protrusion) can extend outward from the perimeter of the base 462 at an angle θ in the range of 90 degrees (°) to 180° (including sub - ranges). For example, θ can be in the range of 90° to 175°, 95° to 175°, 100° to 175°, 105° to 175°, 110° to 175°, 115° to 175°, 120° to 175°, 125° to 175°, 130° to 175°, 100° to 170°, 115° to 160°, or 125° to 145°. θ can be measured between the longitudinal axis of the anchoring point 464 and the line connecting from the geometric center of the base 462 (e.g., Figure 6 the point P in C ) to the anchoring point 464.

[0126] When θ is less than 180°, the wire guide 480 does not need to move along multiple axes to wind the continuous wire around the anchor point 464. This is because after the plate 460 has rotated or while the plate 460 is rotating, the continuous wire can catch the anchor point 464 when the wire guide 480 passes near the base 462, between adjacent anchor points 464, reverses, and passes between other adjacent anchor points 464. In some embodiments, for example, when θ is 180° or greater, the coupler 470 and / or the wire guide 480 can provide additional degrees of freedom for the movement of the wire guide 480 and / or the tube 482, such that the wire guide 480 can still pass between adjacent anchor points 464, for example, by moving through the plate 460 along a first axis and along a second axis parallel to axis A to pass between adjacent anchor points 464.

[0127] In some embodiments, θ is in the range greater than 90° to less than 180°. In some embodiments, θ is in the range of 95 °C to 175 °C. In some embodiments, θ can be selected such that the continuous wire is unlikely to slip off the anchor point 464 after winding. Additionally, θ can be selected such that the anchor point 464 projects from the bottom 462 by a sufficient amount in a direction perpendicular to the wire guide translation axis C, such that the wire guide 480 can pass through the region between the bottom 462 and a line parallel to the bottom 462 when moving only along the wire guide translation axis C, the line contacting the outermost end of the anchor point 464. In some embodiments, even greater values of θ, such as from 120° to 175°, can preferably prevent the continuous wire being wound around the anchor point 464 from being forced away from other portions of the continuous wire (or another continuous wire) that have already been wound around the same anchor point 464.

[0128] In some embodiments, as described above, the winding device 400 can include a control system for controlling the first actuator 420 and the second actuator 430. In some embodiments, the control system can include a computer system, such as Figure 18 the computer system 1800 shown, but the control system does not need to include Figure 18All of the components shown. The control system can include programmable memory (e.g., main memory 1808 and / or auxiliary memory 1810). The programmable memory can store a computer program that can direct the rotation of the platen 460 and the movement of the traverser 480. For example, the programmable memory can store a computer program that instructs the first actuator 420 and the second actuator 430 to operate under certain conditions. In the case of the first actuator 420, the conditions can include the rotation rate and the rotation direction. In the case of the second actuator 430, the conditions can include the translation rate and the translation direction. The control system can set and change the following conditions, either individually or in combination with any other conditions, to achieve a desired winding pattern (defined by the angle at which the rows of wire in the wound wire layer extend relative to the perimeter of the wire layer and relative to other rows of wire): i) the rotation rate of the platen 460; ii) the rotation direction of the platen 460; iii) the translation rate of the traverser 480; and iv) the translation direction of the traverser 480.

[0129] In some embodiments, these conditions can be set by a programmer of the control system, who separately specifies the angular and linear positions (and / or angular velocity and translation velocity) of the platen 460 and the traverser 480 at different times or in different time sequences. In some embodiments, the programmer can specify these angles and linear positions (and / or angles and translation velocities) in one or more files. In some embodiments, one or more files can include a file that describes the position of the anchor points 464 in three dimensions (3D). In such embodiments, each anchor point 464 can be associated with a unique identifier (e.g., a number or an alphanumeric code) specified in the file. In some embodiments, one or more files can be JSON files, but one or more files are not limited to a particular format. In some embodiments, one or more processors (e.g., processor 1804) in the control system can interpret the content of one or more files into CNC G-code commands that control the first actuator 420 and the second actuator 430 to move the platen 460 and the traverser 480. In some embodiments, the content of one or more files can also include instructions for changing a continuous wire to another continuous wire, such as instructions for transitioning between winding a first wire layer and winding a second wire layer.

[0130] The programmable memory can be pre-programmed with a series of instructions to achieve a single or multiple winding patterns during wire layer production. The control system can change the winding pattern during the winding of the wire layer or wire pattern. The winding pattern can be selected to affect various properties of the resulting wound material (e.g., wire layer or wire pattern), such as durability, stiffness, weight, tackiness, texture, haptic, and / or breathability.

[0131] In some embodiments, the angular velocity value of the plate 460 (which is a vector defining the rate and direction of rotation) and the translational velocity of the wire guide 480 (which is a vector defining the rate and direction of translation) can be pre-programmed at various times or in various time sequences throughout the winding operation. In some embodiments, the orientation value of the plate 460 (e.g., determined by the angle between the plate axis D as shown by Figure 5 and axes B and / or C) and the translational position of the wire guide 480 (determined by the position of the wire guide along axis B and / or C) can be pre-programmed at various times or in various time sequences throughout the winding operation. In some embodiments, the programming of the angle / translational velocity / orientation can be accomplished by a programmer specifying, for example, using a unique identifier associated with the anchor point 464, the order in which successive lines should be wound around the anchor point 464. The distance between adjacent anchor points 464 and the dimensions of the wire guide 480 (e.g., the dimensions of the dispensing end of the wire guide 480 passing between adjacent anchor points 464 during the winding process) can also be calculated by programming the entry and exit vectors. Limiting the movement of the wire guide 480 as described herein can reduce the complexity of the coupler 470 and / or the wire guide 480. For example, in some embodiments, no additional actuators are required to provide additional degrees of freedom for the movement of the wire guide 480 and / or the tube 482 in order to wind successive lines around the anchor point 464.

[0132] In some embodiments, one or more of these conditions can remain constant while a subset of these conditions changes periodically. For example, the rotational speed and the rotational direction of the plate 460 can remain constant while the translational velocity of the wire guide 480 changes to periodically reverse the translational direction of the wire guide 480. In some embodiments, the translational direction of the wire guide 480 can be reversed at regular time intervals. In some embodiments, the translational direction of the wire guide 480 can be reversed at irregular time intervals. In some embodiments, the wire guide 480 can pause for any time interval between reversals of the translational direction.

[0133] In some embodiments, when changing the rotational direction or pausing the rotation of the plate 460, the angular velocity of the plate 460 can change smoothly. That is, the plate 460 can gradually accelerate as it moves toward the midpoint of its movement (i.e., the segment of movement between the direction reversal point or the stop point) and gradually decelerate after it has moved past the midpoint. Similarly, in some embodiments, when changing the translational direction of the wire guide 480 or pausing the translation, the velocity of the wire guide 480 can change smoothly. That is, the wire guide 480 can gradually accelerate as it moves toward the midpoint of its movement (i.e., the segment of movement between the direction reversal point or the stop point) and gradually decelerate after it has moved past the midpoint. In some embodiments, smoothly changing the angular velocity of the plate 460 and / or the translational velocity of the wire guide 480 can minimize mechanical strain and degradation of the components of the first actuator 420 and the second actuator 430.

[0134] In some embodiments, for example, in the "simultaneous mode", the wire guide 480 can pass between pairs of adjacent anchor points 464 as the plate 460 rotates. For example, the plate 460 can rotate continuously in a particular rotational direction while the wire guide 480 passes between one or more pairs of adjacent anchor points 464. In the simultaneous mode, the plate 460 can change the rotational direction, but may not pause without performing the change in rotational direction.

[0135] In some embodiments, for example, in the "continuous" or "partially continuous" mode, the wire guide 480 can pass between a pair of adjacent anchor points 464 while the plate 460 is stationary. For example, when the plate 460 is stationary, the wire guide 480 can pass between a pair of adjacent anchor points, the plate 460 can rotate a predetermined amount and stop, and when the plate 460 is stationary again, the wire guide 480 can pass between another pair of adjacent anchor points 464.

[0136] In some embodiments, for example, in the "continuous mode", the movement of the plate 460 and the wire guide 480 can be continuous. For example, the wire guide 480 can pass between a pair of adjacent anchor points, reach a point beyond the perimeter of the plate 460 while the plate 460 is stationary and stop; the plate 460 can rotate a predetermined amount and stop; and the wire guide 480 can pass between another pair of adjacent anchor points 464, reach a point within the perimeter of the plate 460 while the plate 460 is stationary and stop. Then, when the plate 460 rotates a predetermined amount and stops, the wire guide 480 can remain at a point within the perimeter of the plate 460, and when the plate 460 is stationary and stops, the wire guide 480 can pass between another pair of adjacent anchor points 464, reach a point beyond the perimeter of the plate 460. Similar continuous movements can be repeated to create wire layers.

[0137] In some embodiments, for example, in the "partially continuous mode", the movement of the plate 460 and the wire guide 480 can be partially simultaneous and partially continuous. For example, when the plate 460 is stationary, the wire guide 480 can pass between a pair of adjacent anchor points to reach a point beyond the perimeter of the plate 460, the plate 460 can rotate a predetermined amount and stop, and when the plate 460 is stationary again, the wire guide 480 can pass between another pair of adjacent anchor points 464 to reach a point within the perimeter of the plate 460. However, when the plate 460 rotates, the wire guide 480 does not remain at a point within the perimeter of the plate 460, but can move past at least a portion of the plate 460 when the plate 460 rotates a predetermined amount and stops, and when the plate 460 is stationary, the wire guide 480 can pass between another pair of adjacent anchor points 464, reach a point beyond the perimeter of the plate 460. Similar partially continuous and partially simultaneous movements can be repeated to produce wire layers.

[0138] In some embodiments, the winding wire layer may include winding the wire layer in a simultaneous mode. In some embodiments, the winding wire layer may include winding the wire layer in a continuous mode. In some embodiments, the winding wire layer may include winding the wire layer in a partially continuous mode. In some embodiments, the winding wire layer may include winding the wire layer in at least one of a simultaneous mode, a continuous mode, a partially continuous mode, or a combination thereof.

[0139] The winding device 400 may include one or more spools for threading and winding a row of wires of one or more wire layers around an anchor point 464. In some embodiments, the spools may be stored on a frame 410. In some embodiments, the winding device 400 may include multiple spools for threading and winding multiple different wires. The spools may be operatively connected to one or more wire guides 480 such that the wire guides 480 guide the continuous wire unwound from the spools during winding around the anchor point 464, as described herein.

[0140] In some embodiments, the winding device 400 may include one or more wire tensioners configured to apply a desired tension to the continuous wire when the continuous wire is wound around the anchor point 464. In some embodiments, a control system controlling the first actuator 420 and the second actuator 430 may control one or more tensioners to wind the continuous wire with a desired tension. In some embodiments, the spools and the wire tensioners may be the same as or similar to those described in U.S. Patent 11,602,196B2, which is incorporated herein by reference in its entirety.

[0141] In some embodiments, the winding device 400 may wind multiple wires simultaneously from multiple spools when winding the wire layer. In some embodiments, the winding device 400 may be used to wind overlapping rows of wires simultaneously from multiple spools.

[0142] In some embodiments, the winding device 400 may include two or more wire guides 480 and / or second actuators 430 for simultaneously winding multiple wires on a single plate 460. In such embodiments, the two or more wire guides 480 and / or second actuators 430 may simultaneously wind different wires in different regions of the wire pattern.

[0143] In some embodiments, the winding device 400 may ply two or more wires from different spools. In such embodiments, the wire layer or wire pattern may include one or more plied wires. As used herein, "plying" two or more wires refers to joining two or more wires together by twisting at least one of the two or more wires. In some embodiments, plying may include twisting one or more wires around one or more untwisted wires. In some embodiments, plying may include twisting two or more wires together.

[0144] In some embodiments, a wire tensioner (e.g., tensioning unit 2020) can be a mechanical tensioning device with digitally controlled impedance that is used to dynamically control how tight the wire supplied through the wire guide 480 is. In some embodiments, by adjusting the voltage in the tensioner, the tension value of the wire can be dynamically changed. In some embodiments, the tensioner can be a manually adjustable tensioner. In some embodiments, the tensioner can include a spring configured to adjust the amount of tension applied to the wire. The spring can be manually controlled or digitally controlled.

[0145] In some embodiments, the tension of the continuous wire winding can be in the range of 0 centinewtons (cN) to 25 cN, including sub-ranges. For example, in some embodiments, the tension can 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 of the continuous wire winding can be in the range of 2 cN to 10 cN. In some embodiments, the tension of the continuous wire winding can be in the range of 2 cN to 6 cN.

[0146] In some embodiments, a first wire layer (e.g., wire layer 200) can include a continuous wire (e.g., Figure 2A continuous wire 202) wound with a first tension, and a second wire layer (e.g., wire layer 220) disposed above the first wire layer can include a continuous wire (e.g., Figure 2B continuous wire 222) wound with a second tension greater than the first tension. In some embodiments, the second tension can be at least 0.5 cN greater than the first tension. In some embodiments, the second tension can be at least 1 cN greater than the first tension.

[0147] Figure 5 A board 460 is shown in accordance with some embodiments. The board 460 can have any suitable peripheral shape, such as circular, oval, elliptical, triangular, rectangular, square, trapezoidal, pentagonal, hexagonal, octagonal, etc. Additionally, the peripheral shape of the board 460 can be any combination of shapes, e.g., in some embodiments, elliptical in one area and having triangular corners and flat sides in another area, as Figure 5 shown.

[0148] In some embodiments, the plate 460 can be substantially flat (i.e., the surface of the base 462 facing the wire guide 480 can be substantially flat). In some embodiments, the surface of the base 462 facing the wire guide 480 can be curved, e.g., convexly curved, such that a continuous wire wound around the anchor point 464 assumes the shape of the surface. In such embodiments, the wire guide 480 can be moved along multiple axes (e.g., the wire guide translation axis C and an axis parallel to the rotation axis A) to conform the continuous wire to the surface as the continuous wire is wound. In some embodiments, the convex shape can help to shape the resulting wire layer or wire pattern to fit the body of a wearer when used in a garment article.

[0149] In some embodiments, the base 462 can comprise a polymer. In some embodiments, the base 462 can comprise a polymer composite, such as a reinforced polymer. In some embodiments, the base 462 can comprise a metal, such as aluminum or steel.

[0150] In some embodiments, the plate 460 can have a longitudinal plate axis D and a transverse plate axis E. As Figure 5 shown, the longitudinal plate axis D can be defined as the line passing through the geometric center point P C of the base 462, where the line is the longest, i.e., the line passing through but not extending beyond the base 462. The transverse plate axis E can be defined as the line passing through the geometric center point P C of the base 462, where the line is the shortest line passing through but not extending beyond the base 462. In some embodiments, the geometric center point P C can be defined as the arithmetic mean position of all points in the surface of the base 462 facing the wire guide 480. In some embodiments, the transverse plate axis E can be perpendicular to the longitudinal plate axis D (e.g., when the base 462 is symmetric about the longitudinal plate axis D). In some embodiments, the transverse plate axis E can be angled relative to the longitudinal plate axis D.

[0151] The plate 460 can have a maximum diameter d MAX . d MAX can be the length of the longitudinal plate axis D. Similarly, the plate 460 can have a minimum diameter d MIN . d MIN can be the length of the transverse plate axis E. In identifying d MAX and d MIN , the thickness of the base 462 along the rotation axis A is not considered (i.e., it cannot be the minimum diameter). Further, in accordance with the above definitions of the longitudinal plate axis D and the transverse plate axis E, d MAX and d MIN can be measured when the plate 460 is any shape and not just circular.

[0152] In some embodiments, d MINThe ratio to d MAX can be in the range of 1:1 to 1:5, including sub-ranges. For example, in some embodiments, d MIN The ratio to d MAX can be in the range of 1:1 to 1:4.5, 1:1 to 1:4, 1:1 to 1:3.5, 1:1 to 1:3, 1:1 to 1:1, 1:1 to 1:2.5, 1:1 to 1:2, or 1:1 to 1:1.5. In some embodiments, d MIN can be greater than or equal to half of d MAX . In such embodiments, d MAX that is greater than or equal to half of d MIN can minimize the average distance that the wire guide 480 must travel to move between the corresponding anchor points 464. In some embodiments, the circular or square plate 460 can preferably minimize the average distance that the wire guide 480 must travel to move between the corresponding anchor points 464.

[0153] In some embodiments, d MIN can be in the range of 10 centimeters (cm) to 2 meters (m), including sub-ranges. For example, d MIN can be in the range of 10 cm to 1.75 m, 10 cm to 1.5 m, 10 cm to 1.25 m, 15 cm to 1.25 cm, 15 cm to 1 m, 15 cm to 75 cm, 20 cm to 75 cm, or 20 cm to 50 cm. In some embodiments, d MAX can be in the range of 10 centimeters (cm) to 3 meters (m), including sub-ranges. For example, d MAX can be in the range of 10 cm to 2.5 m, 10 cm to 2 m, 10 cm to 1.75 m, 15 cm to 1.75 cm, 15 cm to 1.5 m, 15 cm to 1.25 m, 20 cm to 1.25 m, 20 cm to 1 m, 20 cm to 75 cm, 30 cm to 75 cm, 40 cm to 75 cm, or 50 cm to 75 cm.

[0154] The plate 460 can also have a rotational peripheral diameter d RP . d RP can be the distance between two points P1 and P2, which mark the farthest the plate 460 will extend from the axis of rotation A when rotating. Each of P1 and P2 can be the same distance from the axis of rotation A, e.g., the farthest distance the plate 460 extends from the axis of rotation A when the plate 460 rotates. Additionally, P1, P2, and the intersection of the axis of rotation A and the plate 460 can form a single line.

[0155] In some embodiments, d RP can be 10 cm to 6 m, including sub-ranges. For example, in some embodiments, d RPIt can be within the range of 10 cm to 5.5 m, 10 cm to 5 m, 10 cm to 4.5 m, 15 cm to 4.5 m, 15 cm to 4 m, 15 cm to 3.5 m, 20 cm to 3.5 m, 20 cm to 3 m, 20 cm to 2.5 m, 30 cm to 2.5 m, 30 cm to 2 m, 30 cm to 1.5 m, 40 cm to 1.5 m, 40 cm to 1 m, 40 cm to 75 cm, or 50 cm to 75 cm.

[0156] In some embodiments, the wire guide 480 can move between points located outside the circle along the wire guide translation axis C, and the boundary of the circle includes points P1 and P2. Thus, during winding of the continuous wire around the anchor point 464, the wire guide 480 can move between points located outside the perimeter of the plate 460 along the wire guide translation axis C, regardless of the orientation of the plate 460.

[0157] In some embodiments, the shaft 452 can be coupled to the base 462 near the centroid of the plate 460. In such embodiments, the rotation axis A can pass through or be adjacent to the centroid of the plate 460. In such embodiments, the shaft 452 coupled to the base 462 near the centroid of the plate 460 can reduce the mechanical imbalance when the plate 460 rotates, thus resulting in less strain on the components of the shaft 452 and / or the first actuator 420.

[0158] In some embodiments, the shaft 452 can be coupled to the base 462 near the center point P C . In such embodiments, the rotation axis A can pass through or be adjacent to the center point P C . In some such embodiments, for example, when the thickness along the rotation axis A of the base 462 is substantially evenly distributed on the base 462, the centroid of the plate 460 can be substantially aligned with the center point P Figure 5 in the view of. Thus, the shaft 452 can be coupled to the base 462 near the centroid of the plate 460 and near the center point P C . As used in the context of the coupling of the shaft 452 to the base 462, "adjacent" to the centroid or "adjacent" to the center point P C can mean within one-eighth of d C from the centroid or from P C . MAX within.

[0159] Figure 6 Shows a plurality of wire rows 602 of the continuous wire 600 extending between corresponding anchor points according to some embodiments. For ease of illustration of the order in which the wire guide 480 travels around each of these anchor points, as Figure 7A-14B shown, the anchor points are labeled 1, 2, 3, 4, and 5; however, the anchor points 1-5 can be the same as the anchor point 464. Additionally, although Figure 7A-14BThe wire guide 480 is shown to travel sequentially around the anchor points 1-5. The wire guide 480 can travel around the anchor points 1-5 in the reverse order, e.g., starting from anchor point 5.

[0160] Figure 6 The first wire row 602a, the second wire row 602b, the third wire row 602c, and the fourth wire row 602d are shown. As Figure 6 shown, the first wire row 602a extends between the anchor points 1 and 2, the second wire row 602b extends between the anchor points 2 and 3, the third wire row 602c extends between the anchor points 3 and 4, and the fourth wire row 602d extends between the anchor points 4 and 5. The first, second, third, and fourth wire rows 602a-d can be part of the continuous wire 600, which can be the same as the continuous wires 202, 222, or 242. Each of the first, second, third, and fourth wire rows 602a-d can have a length.

[0161] Figure 7A-14B The process of winding the continuous wire 600 around the anchor points 1-5 to produce the first, second, third, and fourth wire rows 602a-d according to some embodiments is shown. Although for ease of illustration, all of the first, second, third, and fourth wire rows 602a-d are shown (but not labeled) in Figure 7A-14B it should be understood that at the stages shown in Figure 7B , 8B , 9B, 10B, 11B, 12B, 13B, and 14B, only the labeled wire rows (e.g., Figure 7B the first wire row 602a in

[0162] Figure 7A-7B The position of the wire guide 480 and the orientation of the plate 460 are shown when the wire guide 480 winds the continuous wire 600 around the anchor point 1. The orientation of the plate 460 when the wire guide 480 winds the continuous wire 600 around the anchor point 1 can be quantified by the angle φ1 between the longitudinal plate axis D and the translation axis B. However, the angle between the longitudinal plate axis D and the translation axis B can be used to quantify the orientation of the plate 460, and any axis of the plate 460 and any axis (e.g., the wire guide translation axis C) arranged parallel to or relative to the translation axis B can be used to quantify the orientation of the plate 460. When the wire guide 480 winds the continuous wire 600 around the anchor point 1, the position of the wire guide 480 can be quantified by the distance d1 between the rotation axis A and the wire guide 480 (e.g., the point where the continuous wire 600 leaves the wire guide 480). d1 can represent the farthest distance that the wire guide 480 must travel from the rotation axis A while being restricted to a single axis to wind the continuous wire 600 around the anchor point 1.

[0163] Figure 8A-8BShows the position of the wire guide 480 and the orientation of the plate 460 when the wire guide 480 is between the anchor point 1 and the anchor point 2. When the wire guide 480 is between the anchor point 1 and the anchor point 2, the orientation of the plate 460 can be quantified by the angle φ between the longitudinal plate axis D and the translation axis B 1.5 to quantify. When the wire guide 480 is between the anchor point 1 and the anchor point 2, the position of the wire guide 480 can be quantified by the distance d between the rotation axis A and the wire guide 480 1.5 to quantify (e.g., the tip of the continuous line 600 leaves the wire guide 480). d 1.5 can represent the closest distance that the wire guide 480 must move from the rotation axis A while being restricted to a single axis to move the continuous line 600 between the anchor point 1 and the anchor point 2.

[0164] Between Figure 7A-7B and Figure 8A-8B the plate 460 can rotate (e.g., counterclockwise) by an angle of φ 1.5 - φ1, and the wire guide 480 can travel a distance of d1 - d 1.5 .

[0165] Figure 9A-9B Shows the position of the wire guide 480 and the orientation of the plate 460 when the wire guide 480 winds the continuous line 600 around the anchor point 2 to complete the first wire row 602a and the second wire row 602b. When the wire guide 480 winds the continuous line 600 around the anchor point 2, the orientation of the plate 460 can be quantified by the angle φ2 between the longitudinal plate axis D and the translation axis B. When the wire guide 480 winds the continuous line 600 around the anchor point 2, the position of the wire guide 480 can be quantified by the distance d2 (e.g., the point where the continuous line 600 leaves the wire guide 480) between the rotation axis A and the wire guide 480. d2 can represent the farthest distance that the wire guide 480 must travel from the rotation axis A while being restricted to a single axis to wind the continuous line 600 around the anchor point 2.

[0166] Between Figure 8A-8B and Figure 9A-9B the plate 460 can rotate (e.g., counterclockwise) by an angle of φ2 - φ 1.5 and the wire guide 480 can travel a distance of d2 - d 1.5 .

[0167] Figure 10A-10B Shows the position of the wire guide 480 and the orientation of the plate 460 when the wire guide 480 is between the anchor point 2 and the anchor point 3. When the wire guide 480 is between the anchor point 2 and the anchor point 3, the orientation of the plate 460 can be quantified by the angle φ between the longitudinal plate axis D and the translation axis B 2.5To quantify. When the wire guide 480 is located between the anchor point 2 and the anchor point 3, the position of the wire guide 480 can be quantified by the distance d between the axis of rotation A and the wire guide 480 2.5 (e.g., the tip of the continuous wire 600 leaves the wire guide 480). d2.5 can represent the closest distance that the wire guide 480 must move from the axis of rotation A while being restricted to a single axis to move the continuous wire 600 between the anchor point 2 and the anchor point 3.

[0168] Between Figure 9A-9B And Figure 10A-10B The plate 460 can rotate (e.g., clockwise) by an angle φ2 - φ 2.5 And the wire guide 480 can travel a distance d2 - d 2.5 . After the continuous wire 600 has been wrapped around the anchor point 2, the plate 460 can be rotated clockwise or counterclockwise to achieve the Figure 10A-10B Orientation shown in. However, in some embodiments, it may be more efficient for the plate 460 to reverse direction and rotate clockwise to achieve the Figure 10A-10B Orientation shown in. Thus, the winding device 400 can be configured to rotate the plate 460 in the most efficient direction (i.e., the direction that requires the least rotation) to wind the continuous wire 600 around a preselected anchor point (e.g., the anchor point 3).

[0169] Figure 11A-11B Shows the position of the wire guide 480 and the orientation of the plate 460 when the wire guide 480 winds the continuous wire 600 around the anchor point 3 to complete the second wire row 602b and start the third wire row 602c. When the wire guide 480 winds the continuous wire 600 around the anchor point 3, the orientation of the plate 460 can be quantified by the angle φ3 between the longitudinal plate axis D and the translation axis B. When the wire guide 480 winds the continuous wire 600 around the anchor point 3, the position of the wire guide 480 can be quantified by the distance d3 between the axis of rotation A and the wire guide 480 (e.g., the point where the continuous wire 600 leaves the wire guide 480). d3 can represent the farthest distance that the wire guide 480 must travel from the axis of rotation A while being restricted to a single axis to wind the continuous wire 600 around the anchor point 3.

[0170] Between Figure 10A-10B And Figure 11A-11B The plate 460 can rotate (e.g., clockwise) by an angle φ 2.5 + φ3, and the wire guide 480 can travel a distance d3 - d 2.5 .

[0171] Figure 12A-12BShows the position of the wire guide 480 and the orientation of the plate 460 when the wire guide 480 is located between the anchor point 3 and the anchor point 4. When the wire guide 480 is at the mid - position between the anchor point 3 and the anchor point 4, the orientation of the plate 460 can be determined by the angle φ between the longitudinal plate axis D and the translation axis B 3.5 When the wire guide 480 is at the mid - position between the anchor point 3 and the anchor point 4, the position of the wire guide 480 can be determined by the distance d between the rotation axis A and the wire guide 480 3.5 (e.g., the point where the continuous line 600 leaves the wire guide 480). d 3.5 can represent the closest distance that the wire guide 480 must move from the rotation axis A while being restricted to a single axis to move the continuous line 600 between the anchor point 3 and the anchor point 4.

[0172] Between Figure 11A-11B and Figure 12A-12B the plate 460 can rotate (e.g., counter - clockwise) by an angle of φ3 + φ 3.5 and the wire guide 480 can travel a distance of d3 - d 3.5 .

[0173] Figure 13A-13B Shows the position of the wire guide 480 and the orientation of the plate 460 when the wire guide 480 winds the continuous line 600 around the anchor point 4 to complete the third wire row 602c and start the fourth wire row 602d. When the wire guide 480 winds the continuous line 600 around the anchor point 4, the orientation of the plate 460 can be quantified by the angle φ4 between the longitudinal plate axis D and the translation axis B. When the wire guide 480 winds the continuous line 600 around the anchor point 4, the position of the wire guide 480 can be quantified by the distance d4 between the rotation axis A and the wire guide 480 (e.g., the point where the continuous line 600 leaves the wire guide 480). d4 can represent the farthest distance that the wire guide 480 must travel from the rotation axis A while being restricted to a single axis to wind the continuous line 600 around the anchor point 4.

[0174] Between Figure 12A-12B and Figure 13A-13B the plate 460 can rotate (e.g., counter - clockwise) by an angle of φ4 - φ 3.5 and the wire guide 480 can travel a distance of d4 - d 3.5 .

[0175] Figure 14A-14BIllustrates the position of the wire guide 480 and the orientation of the plate 460 when the wire guide 480 winds the continuous wire 600 around the anchoring point 5 to complete the fourth wire row 602d. The orientation of the plate 460 when the wire guide 480 winds the continuous wire 600 around the anchoring point 5 can be quantified by the angle φ5 between the longitudinal plate axis D and the translation axis B. When the wire guide 480 winds the continuous wire 600 around the anchoring point 5, the position of the wire guide 480 can be quantified by the distance d5 between the rotation axis A and the wire guide 480 (e.g., the point where the continuous wire 600 exits the wire guide 480). d5 can represent the maximum distance that the wire guide 480 must travel from the rotation axis A while being restricted to a single axis to wind the continuous wire 600 around the anchoring point 5.

[0176] Between Figure 13A-13B and Figure 14A-14B , the plate 460 can rotate (e.g., counterclockwise) by an angle of φ5 - φ4, and the wire guide 480 can travel a distance of d4 - d5.

[0177] Although Figure 7A-14B illustrates the winding device 400 for winding four wire rows 602a - d, Figure 7A-14B illustrates the process for winding any number of wire rows 602 on the plate 460, e.g., the number of wire rows in the wire layer.

[0178] Figure 15 Represents a comparison table of the distance traveled by the wire guide 480 with the lengths of the first, second, third, and fourth wire guides 602a - d. When winding the first wire row 602a, the distance traveled by the wire guide 480 can be (d1 - d 1.5 ) + (d2 - d 1.5 ). In some embodiments, (d1 - d 1.5 ) + (d2 - d 1.5 ) can be less than the length of the first wire row 602a. For example, in some embodiments, (d1 - d 1.5 ) + (d2 - d 1.5 ) can be less than or equal to two-thirds of the length of the first wire row 602a.

[0179] When winding the second wire row 602b, the distance traveled by the wire guide 480 can be (d2 - d 2.5 ) + (d3 - d 2.5 ). In some embodiments, (d2 - d 2.5 ) + (d3 - d 2.5 ) can be less than the length of the second wire row 602b. For example, in some embodiments, (d2 - d 2.5 ) + (d3 - d 2.5 ) can be less than or equal to four-fifths of the length of the second wire row 602b.

[0180] When winding the third wire row 602c, the distance traveled by the wire guide 480 can be (d3 - d 3.5 ) + (d4 - d 3.5 ). In some embodiments, (d3 - d 3.5 ) + (d4 - d 3.5 ) can be less than the length of the third wire row 602c. For example, in some embodiments, (d3 - d 3.5 ) + (d4 - d 3.5 ) can be less than or equal to four-fifths of the length of the third wire row 602c.

[0181] When winding the fourth wire row 602d, the distance traveled by the wire guide 480 can be d4 - d5. In some embodiments, d4 - d5 can be less than the length of the fourth wire row 602d. For example, in some embodiments, d4 - d5 can be less than or equal to one-tenth of the length of the fourth wire row 602d.

[0182] When winding all of the first, second, third, and fourth wire rows 602a - d, the distance traveled by the wire guide 480 can be d1 - 2d 1.5 + 2d2 - 2d 2.5 + 2d3 - 2d 3.5 + 2d4 - d5. In some embodiments, d1 - 2d 1.5 + 2d2 - 2d 2.5 + 2d3 - 2d 3.5 + 2d4 - d5 can be less than the combined length of the first, second, third, and fourth wire rows 602a - d. For example, in some embodiments, d1 - 2d 1.5 + 2d2 - 2d 2.5 + 2d3 - 2d 3.5 + 2d4 - d5 can be less than or equal to eleven-twentieths of the combined length of the first, second, third, and fourth wire rows 602a - d, including the sub-range. For example, in some embodiments, d1 - 2d 1.5 + 2d2 - 2d 2.5 + 2d3 - 2d 3.5 + 2d4 - d5 can be less than or equal to five-sixths of the combined length of the first, second, third, and fourth wire rows 602a - d, less than or equal to three-fourths of the combined length of the first, second, third, and fourth wire rows 602a - d, or less than or equal to two-thirds of the combined length of the first, second, third, and fourth wire rows 602a - d.

[0183] Accordingly, the winding device 400 can wind a continuous length of wire 600 that is greater than the distance that the wire guide 480 moves during the winding of the continuous length of wire 600. Thus, rotation of the plate 460 below the wire guide 480 can reduce the amount of translation required of the wire guide 480 as compared to a device that includes a fixed plate 460 and a wire guide 480 that moves on multiple axes. This can enable the winding of the continuous wire 600 to produce wire layers more time-efficiently because the wire guide 480 travels a shorter distance. Additionally, since rotation of the plate 460 is more energy-efficient than translation of the wire guide 480, the configuration of a rotatable plate 460 and a translating wire guide 480 can result in reduced power consumption and production costs. Rotation of the plate 460 is more energy-efficient than translation of the wire guide 480 because in some embodiments, one or fewer rotations of the motor 422 can rotate the plate 460 fully, as described above, while more rotations of the motor 432 are required to move the wire guide 480 through the entire diameter of the plate 460 via the flexible coupling 434.

[0184] Figure 16 A winding device 400 is shown in accordance with some embodiments. In some embodiments, the winding device 400 can include a plurality of winding units 450. For example, the winding device 400 can include a first winding unit 450a, a second winding unit 450b, a third winding unit 450c, and a fourth winding unit 450d. Each of the first, second, third, and fourth winding units 450a-d can include all or a subset of the components described above with respect to Figure 4 While Figure 16 four winding units 450 are shown supported by the frame 410, the frame 410 can support fewer or more winding units 450, such as one, two, three, five, six, seven, eight, nine, or ten winding units 450.

[0185] As Figure 16As shown, in some embodiments, the first actuator 420 may be operatively connected to each of the plates 460a-d (e.g., via each of the shafts 452a-d). For example, a single torque generating element (e.g., motor 422) mechanically coupled to shaft 452a may be mechanically coupled to (in some cases via shaft 452a) shaft 452b, shaft 452c, and / or shaft 452d. In some embodiments, motor 422 may be coupled to the shafts 452 of each of the winding units 450 via one or more belts, chains, racks, or cables. Activation of the motor may cause all of the shafts 452a-d and plates 460a-d to rotate. In some embodiments, activation of the motor may cause all of the shafts 452a-d to rotate at substantially the same rotational speed and in the same direction of rotation. In some embodiments, due to changing the size and / or number of gears, pulleys, or sprockets included in the first actuator 420, activation of the motor 422 may cause the shafts 452a-d to rotate at different rotational speeds and / or in different directions.

[0186] In such embodiments, the first actuator 420 may include flexible couplings 1602a-c and wheels 1604a-f. In some embodiments, the flexible couplings 1602a-c may be belts, chains, racks, or cables. In some embodiments, the wheels 1604a-f may be gears, pulleys, or sprockets. As Figure 16 shown, wheel 1604a may be coupled to shaft 452a, and flexible coupling 1602a may engage with wheel 1604a. Flexible coupling 1602a may also engage with wheel 1604b coupled to shaft 452b. Flexible coupling 1602a may transfer the rotation of shaft 452a / wheel 1604a to wheel 1604b / shaft 452b such that shaft 452b rotates simultaneously with shaft 452a. Similarly, wheel 1604c may be coupled to shaft 452b, and flexible coupling 1602b may engage with wheel 1604c. Flexible coupling 1602b may also engage with wheel 1604d coupled to shaft 452c. Flexible coupling 1602b may transfer the rotation of shaft 452b / wheel 1604c to wheel 1604d / shaft 452c such that shaft 452c rotates simultaneously with shaft 452b. Finally, wheel 1604e may be coupled to shaft 452c, and flexible coupling 1602c may engage with wheel 1604e. Flexible coupling 1602c may also engage with wheel 1604f coupled to shaft 452d. Flexible coupling 1602c may transfer the rotation of shaft 452c / wheel 1604e to wheel 1604f / shaft 452d such that shaft 452d rotates simultaneously with shaft 452c. Thus, activation of the motor 422 may cause all of the shafts 452a-d and plates 460a-d to rotate.

[0187] Although Figure 16It is shown that shafts 452a-d are continuously coupled (e.g., shaft 452a is coupled to shaft 452b, which is then coupled to shaft 452c) to transfer the rotation of motor 422 to each of shafts 452a-d. However, in some embodiments, each of shafts 452a-d may be coupled to motor 422 via a single rotational transfer element (e.g., a belt, chain, rack, or cable). The single rotational transfer element may be coupled to all of shafts 452a-d, or each of shafts 452a-d may be coupled to motor 422 via a separate single rotational transfer element.

[0188] In some embodiments, a second actuator 430 may be operatively connected to each of the wire guides 480a-d. For example, a single translation generating element, such as an electromechanical linear actuator, a hydraulic linear actuator, or a member of a pneumatic linear actuator mechanically coupled to wire guide 480a, may be mechanically coupled to wire guide 480b, wire guide 480c, and / or wire guide 480d. For example, a single motor (e.g., motor 432) within the electromechanical linear actuator may be coupled to the wire guide 480 (e.g., using coupler 470) of each winding unit 450 via one or more belts, chains, racks, or cables, or via any other element for generating linear motion from rotational motion.

[0189] In some embodiments, the second actuator 430 may include a flexible coupler 434 (e.g., a belt, chain, rack, or cable) to which each of the wire guides 480a-d is attached (e.g., via coupler 470). In some embodiments, activation of the single translation generating element may move all of the wire guides 480a-d at substantially the same rate and in the same direction. In some embodiments, due to variations in the size and / or number of belts, chains, racks, or cables and gears, pulleys, or sheaves within the second actuator 430, activation of the translation generating element may move the wire guides 480a-d at different rates and / or in different directions.

[0190] In some embodiments, the first actuator 420 and / or the second actuator 430 are operatively coupled to the plurality of plates 460 and the plurality of threaders 480, respectively, which can reduce the complexity of the programming required to control the winding device 400. For example, a single set of instructions can be provided to the control system, which determines the winding pattern of all the winding units 450 during the production line layer or the wire pattern. Additionally, in some embodiments, the first actuator 420 and / or the second actuator 430 operatively coupled to the plurality of plates 460 and the plurality of threaders 480, respectively, can reduce the mechanical cost and complexity of the winding device 400, thereby requiring fewer components. Further, the first actuator 420 and / or the second actuator 430 operatively connected to the plurality of plates 460 and the plurality of threaders 480, respectively, can make the winding device 400 more energy-efficient because the winding device 400 can include fewer energy-consuming components (e.g., motors).

[0191] While the above discussion has focused on embodiments where the first actuator 420 and / or the second actuator 430 are operatively connected to the plurality of plates 460 and the plurality of threaders 480, respectively, in some embodiments, the winding device 400 can include a plurality of first actuators 420 and / or a plurality of second actuators 430, each actuator being operatively connected to a separate plate 460 and threader 480. In some embodiments, each of the plurality of first actuators 420 can be operatively coupled to the plate 460 via the shaft 452 of the winding unit 450. In some embodiments, each of the plurality of second actuators 430 is operatively coupled to the threader 480 of the winding unit 450. In such embodiments, the plurality of first actuators 420 can be independently controllable, and the plurality of second actuators 430 can be independently controllable. In such embodiments, a set of instructions can be provided to one or more control systems for each of the winding units 450 of the winding device 400. The set of instructions can determine the winding pattern of each winding unit 450 during the production line layer or the wire pattern. These embodiments can provide increased customization of the material wound using the winding device 400. For example, winding materials having different characteristics and properties can be produced using the same winding device 400.

[0192] In some embodiments where a plurality of first actuators 420 and / or a plurality of second actuators 430 are respectively operatively connected to a separate plate 460 and a separate wire guide 480, each first actuator 420 can be controlled by a separate control system, and each second actuator 430 can be controlled by a separate control system (where a pair of a first actuator 420 and a second actuator 430 that control the same winding unit 450 can be controlled by the same control system). In some embodiments, where a plurality of first actuators 420 and / or a plurality of second actuators 430 are each respectively operatively connected to a separate plate 460 and a separate wire guide 480, all of the first actuators 420 and second actuators 430 can be controlled by a single control system. In either case, the control system can include an interface (e.g., display interface 1102) with which a user can interact to provide instructions to the control system.

[0193] Figure 17 A method 1700 of manufacturing a garment article (e.g., garment article 100) is shown in accordance with some embodiments.

[0194] Unless otherwise specified, the steps of method 1700 need not be performed in the order set forth herein. Additionally, unless otherwise specified, the steps of method 1700 need not be sequential. These steps can be performed in a different order or simultaneously. As an example, step 1704 of method 1700 need not be performed before step 1706. Instead, step 1704 can be performed simultaneously with step 1706. As another example, step 1706 need not be performed after step 1702. Instead, step 1706 can be performed simultaneously with, before, or after step 1702. Additionally, method 1700 may not include all of the steps illustrated. For example, method 1700 may not include 1710.

[0195] Step 1702 can include rotating a plate (e.g., plate 460) about a rotational axis (e.g., axis A). In some embodiments, the plate can include a base (e.g., base 462) and a plurality of protrusions extending from the base (e.g., two or more anchoring points 464, which can be protrusions). In some embodiments, the plate can be rotated about the rotational axis by a shaft (e.g., shaft 452) coupled to the base. In some embodiments, step 1702 can include changing at least one of the rotational rate or the rotational direction of the plate. In some embodiments, step 1702 can include changing at least one of the rotational rate or the rotational direction of the plate while moving the wire guide (e.g., in the "simultaneous" or "partially continuous" modes as described above) or while the wire guide is stationary (e.g., in the "continuous" or "partially continuous" modes as described above).

[0196] In some embodiments, method 1700 may additionally or alternatively include changing at least one of the translation rate or the translation direction of the wire guide when the rotating plate or the plate is stationary. In some embodiments, changing the translation rate and / or the translation direction may change the winding pattern of the wire layer. In some embodiments, method 1700 may include changing one or more of the rotation rate, the rotation direction, the translation rate, or the translation direction while keeping one or more of the rotation rate, the rotation direction, the translation rate, or the translation direction constant.

[0197] Step 1704 may include dispensing a continuous wire (e.g., continuous wire 600) via a wire guide (e.g., wire guide 480). In some embodiments, the wire guide may move laterally along a lateral axis (e.g., wire guide translation axis C). In some embodiments, the lateral axis may pass above the axis. In some embodiments, the continuous wire may be fixed to the plate (e.g., at the anchor point 464) before dispensing the continuous wire and winding the continuous wire around an additional anchor point 464.

[0198] Step 1706 may include moving the wire guide to wind the continuous wire around a protrusion on the plate (e.g., around a plurality of protrusions). In some embodiments, moving the wire guide may include moving the wire guide along the lateral axis and between corresponding ones of the plurality of protrusions. In some embodiments, moving the wire guide may include moving the wire guide along only a single axis during the winding of the continuous wire. In some embodiments, moving the wire guide may include moving the wire guide while rotating the plate (e.g., in the "simultaneous" or "partially continuous" mode as described above). In some embodiments, moving the wire guide may include moving the wire guide when the plate is stationary (e.g., in the "continuous" or "partially continuous" mode as described above). In some embodiments, only the translation of the wire guide along the lateral axis and the rotation of the plate about the rotation axis are required to wind the continuous wire around a plurality of protrusions. In some embodiments, the length of the continuous wire wound around the plurality of protrusions is greater than the distance traveled by the wire guide during the length of the winding of the continuous wire, as described above with respect to Figure 7A-15 described.

[0199] As described herein, winding the continuous wire around a plurality of protrusions in step 1706 may form a wire layer (e.g., wire layer 120, 130, 140, 310, 320, or 330) including a plurality of wire rows (e.g., wire rows 204, 224, or 244), where each wire row extends between two corresponding ones of the plurality of protrusions and spans the plate.

[0200] In some embodiments, step 1706 may include winding a plurality of wire layers. In such embodiments, method 1700 may include winding a second continuous wire around a plurality of protrusions to form a second wire layer including a second plurality of wire rows, where each wire row in the second plurality of wire rows extends between two corresponding ones of the plurality of protrusions and spans the plate.

[0201] Step 1708 may include joining the rows of the wound continuous line (e.g., a row among multiple rows) to each other. In some embodiments, step 1708 may include joining the rows among the multiple rows while the wire layer is on the board.

[0202] In some embodiments, the rows may be joined within the wire layer or wire pattern (e.g., wire pattern 300). In some embodiments, the continuous line may be joined at the intersection between the rows by, for example, adhesives, joining layers, thermal (conduction or convection) heating (e.g., in a hot press or oven), IR (infrared) heating, laser heating, microwave heating, steam, mechanical fasteners (e.g., clips), hook-and-loop fasteners, needle punching, hydro entanglement, ultrasonic / vibrational entanglement, felting, knotting, chemical joining using a catalyst of a biological material, adhesive spraying (e.g., CNC adhesive spray deposition), or by pushing one row through other rows. In some embodiments, the continuous line may be directly joined at the intersection between the rows.

[0203] In some embodiments, the continuous line may be joined at the protrusion by, for example, adhesives, joining layers, thermal (conduction or convection) heating (e.g., in a hot press or oven), IR (infrared) heating, laser heating, microwave heating, steam, mechanical fasteners (e.g., clips), hook-and-loop fasteners, needle punching, hydro entanglement, ultrasonic / vibrational entanglement, felting, knotting, chemical joining using a catalyst of a biological material, adhesive spraying (e.g., CNC adhesive spray deposition), or by pushing one row through other rows. In some embodiments, the continuous line may be directly joined at the protrusion.

[0204] In some embodiments, the hot press may provide heat at a predetermined temperature equal to or higher than the melting point of the polymeric material of the polymeric wire of the wire layer or wire pattern. In some embodiments, the hot press may provide heat at a predetermined temperature lower than the melting point of the polymeric material of the polymeric wire of the wire layer or wire pattern, but high enough to cause the polymeric materials to bond (fuse) together, or to bond (fuse) to other materials of the wire layer or wire pattern.

[0205] Heat may be applied to the wire layer or wire pattern in one or more ways, such as, but not limited to, radio frequency heat sealing (welding), high frequency heat sealing (welding), infrared welding, and steam curing.

[0206] In some embodiments, joining can be facilitated by including steps 1702 - 1706 of winding and joining continuous lines. According to any of the methods described herein, the binding continuous line can be configured to be attached to other continuous lines within the line layer or line pattern. In some embodiments, the binding continuous line can include a material, such as a polymer material as described herein, which can be softened via heating or other treatment to attach to other continuous lines within the line layer or line pattern. In some embodiments, the binding continuous line can be wound through the same wire guide 480 simultaneously with the continuous line. In such embodiments, the binding continuous line can remain separate from the continuous line, while in some embodiments, the binding continuous line and the continuous line can be plied together to form a multifilament yarn wound as a single strand. In some embodiments, the continuous line can be wound into a line layer and a second line layer including the binding continuous line can be wound on top of the line layer including the continuous line, or vice versa.

[0207] In some embodiments, method 1700 can include a plurality of winding steps 1706 and a plurality of joining steps 1708. For example, a portion of the line pattern can be wound in a first winding step 1706 and then that portion can be joined in a first joining step 1708. Then, a second portion of the line pattern can be wound in a second winding step 1706 and then that portion can be joined in a second joining step 1708. In some embodiments, the joining step 1708 can include a preliminary joining step to hold the pattern of the line layer or line pattern until a final joining step is performed. For example, the preliminary joining step can allow the line layer or line pattern to be removed from the anchor point and then finally joined after the removal.

[0208] Step 1710 can include cutting the line layer. In some embodiments, step 1710 can include cutting the line layer while the line layer is on the plate. In some embodiments, the line layer can be cut adjacent to the protrusion. In some embodiments, the cutting in step 1710 can define all or a part of the line boundary (e.g., line boundary 250) for the line layer or line pattern.

[0209] In some embodiments, materials produced using all or a subset of steps 1702 to 1710 can be added to a garment article (e.g., garment article 100) or formed into a garment article. In some embodiments, forming the materials can include joining the materials to themselves at seams. In some embodiments, adding the materials produced using steps 1702 to 1710 to a garment article can include attaching the materials to one or more additional pieces of material to form the garment article. In some embodiments, attaching the materials to one or more additional materials can include joining the materials to one or more additional materials at one or more seams. In some embodiments, one or more of the additional pieces of material can be manufactured using method 1700. In some embodiments, one or more of the additional pieces of material can be pieces of material that do not have a wire layer or wire pattern as described herein.

[0210] Figure 18 Exemplary computer system 1800 is shown, and embodiments or portions thereof can be executed in the exemplary computer system as computer-readable code, according to some embodiments. For example, aspects of the methods discussed herein can be implemented in computer system 1800 using hardware, software, firmware, a tangible computer-readable medium having instructions stored thereon, or a combination thereof, and can be implemented in one or more computer systems or other processing systems.

[0211] If programmable logic is used, such logic can be implemented on commercially available processing platforms or dedicated devices. Those of ordinary skill in the art will appreciate that embodiments of the disclosed subject matter can be practiced with a variety of computer system configurations, including multi-core multi-processor systems, minicomputers, and mainframe computers, linked or clustered computers with distributed functionality, and pervasive or microcomputers that can be embedded in almost any device.

[0212] For example, at least one processor device and memory can be used to execute 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".

[0213] The various embodiments described herein can be implemented in accordance with the exemplary computer system 1800. After reading this specification, those skilled in the relevant art will understand how to implement one or more of the embodiments using other computer systems and / or computer architectures. Although operations may be described as sequential processes, some operations can actually be performed in parallel, simultaneously, and / or in a distributed environment, and program code can be stored locally or remotely for access by a single-processor 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.

[0214] The processor device 1804 can be a dedicated or general-purpose processor device. As will be appreciated by those skilled in the relevant art, the processor device 1804 can also be a single processor in a multi-core / multi-processor system, which operates alone or in a cluster or server farm in the manner of a cluster of computing devices. The processor device 1804 is connected to a communication infrastructure 1806, such as a bus, message queue, network, or multi-core message-passing scheme.

[0215] The computer system 1800 also includes a main memory 1808, such as random access memory (RAM), and may also include an auxiliary memory 1810. The auxiliary memory 1810 can include, for example, a hard disk drive 1812 or a removable storage drive 1814. The removable storage drive 1814 can include a floppy disk drive, tape drive, optical disk drive, flash memory, universal serial bus (USB) drive, and so on. The removable storage drive 1814 reads and / or writes to a removable storage unit 1818 in a well-known manner. The removable storage unit 1818 can include a floppy disk, tape, optical disk, etc., which are read and written by the removable storage drive 1814. As will be appreciated by those skilled in the relevant art, the removable storage unit 1818 includes a computer-usable storage medium in which computer software and / or data are stored.

[0216] The computer system 1800 (optionally) includes a display interface 1802 (which can include input and output devices, such as a keyboard, mouse, etc.), and the display interface 1802 forwards graphics, text, and other data from the communication infrastructure 1806 (or from a frame buffer not shown) for display on the display unit 1830.

[0217] In additional and / or alternative embodiments, the auxiliary memory 1810 can include other similar means for allowing computer programs or other instructions to be loaded into the computer system 1800. Such means can include, for example, a removable storage unit 1822 and an interface 1820. Examples of such means can include a program cartridge and cartridge interface (such as those found in video game devices), removable memory chips (such as EPROM (erasable programmable read-only memory) or PROM (programmable read-only memory)) and associated sockets, and other removable storage units 1822 and interfaces 1820 that allow software and data to be transferred from the removable storage unit 1822 to the computer system 1800.

[0218] The computer system 1800 may also include a communication interface 1824. The communication interface 1824 allows software and data to be transferred between the computer system 1800 and external devices. The communication interface 1824 may include a modem, a network interface (such as an Ethernet card), a communication port, a PCMCIA slot and card, and so on. The software and data transferred via the communication interface 1824 may be in the form of signals, which may be electrical, electromagnetic, optical, or other signals that can be received by the communication interface 1824. These signals may be provided to the communication interface 1824 via a communication path 1826. The communication path 1826 carries the signals and may be implemented using wires or cables, optical fibers, telephone lines, mobile phone links, RF links, or other communication channels.

[0219] As used herein, the terms "computer program medium" and "computer usable medium" generally refer to media such as removable storage units 1818, removable storage units 1822, and hard disks installed in hard disk drives 1812. Computer program media and computer usable media may also refer to memories such as main memory 1808 and auxiliary memory 1810, which may be memory semiconductors (e.g., DRAM, etc.).

[0220] The computer program (also referred to as computer control logic) is stored in main memory 1808 and / or auxiliary memory 1810. The computer program may also be received via the communication interface 1824. When executed, such a computer program enables the computer system 1800 to perform the embodiments discussed herein. In particular, when executed, the computer program enables the processor device 1804 to perform the methods of the embodiments discussed herein. Thus, such a computer program represents the controller of the computer system 1800. In cases where the embodiments are implemented using software, the software may be stored in a computer program product and loaded into the computer system 1800 using a removable storage drive 1814, an interface 1820, a hard disk drive 1812, or a communication interface 1824.

[0221] The embodiments described herein may also be directed to a computer program product that includes software stored on any computer usable medium. When executed in one or more data processing devices, such software causes the data processing devices to operate as described herein. The embodiments described herein may employ any computer usable or readable medium. Examples of computer usable media include, but are not limited to, main storage devices (e.g., any type of random access memory), auxiliary storage devices (e.g., hard disk drives, floppy disks, CD ROMs, ZIP disks, magnetic tapes, magnetic storage devices, and optical storage devices, MEMS, nanotechnology storage devices, etc.).

[0222] It should be appreciated 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 of the invention as contemplated by the inventor, and thus are not intended to limit the invention and the appended claims in any way.

[0223] The present invention has been described above in terms of functional building blocks that illustrate the implementation of specified functions and their relationships. For the sake of convenience, the boundaries of these functional building blocks have been arbitrarily defined herein. Alternative boundaries may be defined so long as the specified functions and their relationships are appropriately performed.

[0224] The description of the above specific embodiments will so fully reveal the general nature of the invention that others can, by applying the knowledge of those skilled in the art, readily modify and / or adapt these specific embodiments for various applications without undue experimentation, without departing from the general concept of the invention. Therefore, such changes and variations are intended to be within the meaning and equivalence of the disclosed embodiments, based on the teachings and guidance provided herein. It is to be understood that the language or terminology herein is for the purpose of description and not of limitation, such that the terminology or language of this specification is to be interpreted by those skilled in the art in light of the said teachings and guidance.

[0225] The breadth and scope of the present invention 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 winding device for manufacturing a clothing article, the winding device comprising: A winding unit comprising: A rotatable shaft, a wire guide movable along an axis perpendicular to the shaft, and a plate including a base coupled to the shaft and a plurality of protrusions extending from the base; a first actuator configured to rotate the shaft; and A second actuator is configured to move the wire guide along the axis and between corresponding ones of the plurality of protrusions.

2. The winding device according to claim 1, wherein: The wire guide is movable along the axis between points outside the perimeter of the plate regardless of the orientation of the plate.

3. The winding device according to claim 1, wherein: The base is coupled to the shaft near the center of mass of the plate.

4. The winding device according to claim 1, wherein: The axis passes over the shaft.

5. The winding device according to claim 1, wherein: The minimum diameter of the base is greater than or equal to half of the maximum diameter of the base.

6. The winding device according to claim 1, wherein: Each of the plurality of protrusions extends from the base at an angle of 90 to 175 degrees.

7. The winding device according to claim 1, comprising a plurality of winding units, wherein the shaft of each of the plurality of winding units is operatively connected to the first actuator, and the wire guide of each of the plurality of winding units is operatively connected to the second actuator.

8. The winding device according to claim 1, comprising: A plurality of winding units; a plurality of first actuators, each of the first actuators being operatively coupled to a shaft of a winding unit of the plurality of winding units; as well as a plurality of second actuators, each of the second actuators being operatively coupled to a wire guide of a winding unit of the plurality of winding units, Wherein the plurality of first actuators are independently controllable, and the plurality of second actuators are independently controllable.

9. The winding device according to claim 1, wherein: The wire guide is slidably coupled to the rod.

10. A method for making an article of clothing, the method comprising: rotating a plate on a rotation axis, the plate comprising a base and a plurality of protrusions extending from the base; dispensing a continuous wire via a wire guide, the wire guide being laterally movable along a transverse axis; as well as The wire guide is moved along the transverse axis and between corresponding ones of the plurality of protrusions to wind the continuous wire around the plurality of protrusions.

11. The method according to claim 10, wherein: Only translation of the wire guide along the transverse axis and rotation of the plate about the rotational axis are required to wind the continuous wire around the plurality of protrusions.

12. The method according to claim 10, wherein: The length of the continuous wire wrapped around the plurality of protrusions is greater than the distance the wire guide travels during winding of the length of the continuous wire.

13. The method according to claim 10, further comprising: While moving the wire guide, at least one of the rate of rotation or the direction of rotation of the plate is changed.

14. The method according to claim 10, wherein: Winding the continuous wire around the plurality of protrusions forms a wire layer including a plurality of wire rows, wherein each wire row extends between two corresponding protrusions of the plurality of protrusions and across the board.

15. The method according to claim 14, further comprising: The wire rows of the plurality of wire rows are connected to each other while the wire layer is on the board.

16. The method according to claim 14, further comprising: The wire layer is cut while the wire layer is on the board.

17. The method according to claim 14, further comprising: A second continuous wire is wound around the plurality of protrusions to form a second wire layer including a second plurality of wire rows, wherein each wire row of the second plurality of wire rows extends between two corresponding protrusions of the plurality of protrusions and across the board.

18. The method according to claim 10, wherein: The plate rotates on the rotation axis via a shaft coupled to the base, and wherein the transverse axis passes over the shaft.

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