Circular Winding with Rotatable Rims for Custom Apparel Materials
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Solution Overview
Problem
There is a need for methods of making apparel materials that are customizable and efficiently manufacturable in large quantities, while providing durable, comfortable, and performance-enhancing characteristics for various use cases.
Innovation Solution
A winding apparatus comprising rotatable rims with projections and a thread guide is used to wind continuous threads around anchor points, allowing for customizable thread patterns and layers that can be efficiently produced, with features like flexible chains and actuators for precise control over thread movement and bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional weaving or knitting techniques are used to manufacture apparel materials, then the materials can be produced with established methods, but the manufacturing process is time-consuming and lacks customization flexibility
Solution Approach 1:
The apparatus divides the manufacturing process into discrete winding operations around multiple independently controllable rims. Each rim can be rotated independently to create different thread patterns, allowing customization without restarting the entire manufacturing process. The thread guide can be positioned at multiple locations to wind threads around different rims in sequence, enabling rapid pattern changes.
Solution Approach 2:
The system employs dynamically controllable rim rotations where each rim's speed and direction can be independently adjusted during operation. The thread guide position is also dynamically changeable, allowing the system to adapt thread winding patterns in real-time without fixed tooling, thus achieving customization while maintaining continuous production.
2Adaptability or versatility
If complex thread patterns and layers are created to achieve customizable apparel characteristics, then the material properties can be tailored, but the manufacturing complexity increases
Solution Approach 1:
Multiple rims serve universal functions by all being capable of receiving thread from the same thread guide and creating different pattern sections. The same basic winding mechanism is replicated across multiple rims, each performing the same function but with independently controllable parameters, simplifying the overall system architecture while enabling complex patterns.
Solution Approach 2:
The system adds the dimension of multiple rims arranged in space, allowing thread patterns to be created across multiple spatial dimensions. Instead of complexing a single winding mechanism, the invention distributes the winding function across multiple rims, creating complex 3D thread architectures through coordinated rotation of multiple simpler components.
3Productivity
If large quantities of apparel materials are produced efficiently, then manufacturing throughput increases, but maintaining customization and quality control becomes difficult
Solution Approach 1:
The system replaces manual or semi-automated quality control with a mechanically controlled winding system where rim rotation speeds, directions, and thread guide positions are precisely controlled. This mechanical precision ensures consistent thread tension, spacing, and pattern repetition across large production volumes, maintaining quality control through repeatable mechanical operations rather than inspection.
Data Source
AI summary
Winding apparatuses and methods for manufacturing an article of apparel. The winding apparatus can comprise a first rim and a second rim coupled to and spaced apart from each other and rotatable on a rotation axis. The winding apparatus can comprise a first plurality of projections coupled to and extending from a perimeter of the first rim and a second plurality of projections coupled to and extending from a perimeter of the second rim. A thread guide can be configured to dispense a continuous thread to wind one or more continuous threads around all or a subset of the first and second plurality of projections on the first and second rims.