Adhesive-Bonded Garment Web Handling for Automated Seam Joining
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Solution Overview
Problem
Garment manufacturing remains labor-intensive and inefficient due to reliance on manual labor and semi-manual material handling, with existing automated systems facing challenges in synchronization and material handling of pliable fabrics, leading to high production costs and low yield.
Innovation Solution
An automated garment manufacturing system using adhesive bonding and integrated mechanical processes to synchronize fabric webs, reduce manual handling, and enable both mass production and customization, incorporating programmable cutters and adhesive dispensers to form seams and joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If adhesive bonding is used to join fabric webs, then manufacturing precision and productivity are improved, but device complexity increases
Solution Approach 1:
The patent replaces traditional mechanical sewing systems with adhesive bonding systems to join fabric webs. This substitution eliminates the need for complex mechanical interlocking mechanisms while achieving continuous bonding, thereby improving productivity despite the introduction of adhesive application equipment.
Solution Approach 2:
The patent changes the joining method from mechanical (sewing) to chemical (adhesive bonding), fundamentally altering the parameters of the manufacturing process. This parameter change enables continuous web handling and eliminates discrete stitching operations, enhancing manufacturing efficiency.
2Extent of automation
If automated adhesive bonding systems are implemented, then labor intensity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent incorporates feedback mechanisms that monitor and adjust the positioning of fabric webs in real-time during the adhesive bonding process. This feedback control ensures precise alignment is maintained automatically, enabling high automation levels without sacrificing manufacturing precision.
Solution Approach 2:
The patent employs preliminary positioning and alignment actions before adhesive application to ensure precise registration of fabric patterns. This preliminary action establishes accurate alignment beforehand, allowing the automated bonding process to proceed without requiring high precision during the actual bonding operation.
3Productivity
If continuous web processing is used, then productivity increases, but device complexity increases
Solution Approach 1:
The patent merges multiple garment manufacturing operations into a single continuous web processing system. By combining cutting, adhesive application, and joining operations into one integrated process, the system achieves high productivity while managing complexity through consolidation rather than multiplication of separate devices.
Solution Approach 2:
The patent designs a universal web handling system that can process different fabric types and garment configurations through a single multi-functional platform. This universality allows the system to maintain high productivity across various applications without requiring complex specialized equipment for each specific task.
4Manufacturing precision
If adhesive bonding is used instead of sewing, then manufacturing precision is improved, but loss of substance increases
Solution Approach 1:
The patent applies adhesive bonding locally at specific joining points rather than uniformly across the entire fabric surface. This localized application minimizes adhesive consumption while maintaining precise bonding at critical locations, resolving the contradiction between bonding precision and substance loss.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enhances production efficiency, reduces defects, lowers costs, and allows for flexible, automated manufacturing of customized garments by minimizing manual intervention and improving synchronization of fabric movements.
Implementation Method 1
automated garment manufacturing system using adhesive bonding and integrated mechanical processes
Data Source
AI summary
A system for automated manufacturing of apparel that includes a fabric dispenser operable to dispense fabric. The system includes an adhesive dispenser configured to apply discrete non-contiguous adhesive masses to a first portion of the fabric. The discrete non-contiguous adhesive masses are deposited along a trajectory corresponding to seams of a first part of an apparel. The system includes one or more presses operable to join the first part of the apparel and a second part of the apparel along the seams. The system includes an energy source distinct from the one or more presses, wherein the energy source provides energy to cure the discrete non-contiguous adhesive masses. The system further includes a cutting tool operable to make cuts to the fabric along lines corresponding to features of the apparel.