Conveyor-Based Continuous Thread Winding for Customizable Apparel
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Solution Overview
Problem
There is a need for methods of making apparel that offer customizable characteristics while being efficiently manufactured in large quantities and sizes, addressing durability, comfort, and performance requirements.
Innovation Solution
A method involving a conveyor system that winds continuous threads around projection sets to form thread layers, which can include fusible materials, and allows for simultaneous operations such as loading, winding, and bonding, enabling efficient production of customizable apparel materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional weaving or knitting techniques are used to manufacture apparel, then the manufacturing process is well-established and reliable, but the ability to customize characteristics while maintaining efficient large-scale production is limited
Solution Approach 1:
The apparatus divides the manufacturing process into discrete modular components: projection sets with anchor points are segmented across multiple conveyors, allowing independent positioning and configuration. Each projection set can be customized with specific anchor point patterns while maintaining continuous high-speed production through the modular conveyor system.
Solution Approach 2:
The system employs dynamically adjustable conveyors that can change speed, position, and configuration during operation. The first and second conveyors can operate at different speeds and positions, allowing flexible adjustment of production parameters to accommodate various apparel designs while maintaining overall production efficiency.
2Adaptability or versatility
If complex apparel materials with customizable characteristics are produced, then adaptability and versatility improve, but device complexity and manufacturing process complexity increase
Solution Approach 1:
The projection sets serve multiple functions: they provide anchor points for thread winding, define the geometric pattern of the apparel, and act as temporary support structures during manufacturing. This multi-functionality reduces the need for separate specialized components, simplifying the overall system while enabling complex customizable designs.
Solution Approach 2:
The projection sets act as intermediary structures between the conveyors and the final apparel product. They temporarily hold the thread layers in the desired configuration during manufacturing, then facilitate easy removal and transfer to the final product, reducing direct complexity in the thread manipulation system.
3Manufacturing precision
If continuous threads are wound around projection sets to form thread layers, then manufacturing precision and material consistency improve, but the time required for winding and processing increases
Solution Approach 1:
The system maintains continuous thread winding action as conveyors continuously move projection sets through the winding zone. Threads are wound in an unbroken continuous process rather than discrete steps, eliminating idle time between operations while maintaining consistent thread layer formation through steady conveyor motion and continuous thread feed.
Solution Approach 2:
Projection sets are pre-configured with anchor points in the desired pattern before threading begins. This preliminary arrangement of anchor points allows threads to be wound directly into the final desired configuration without subsequent repositioning or adjustment, reducing processing time while maintaining precision.
4Strength
If fusible materials are used in continuous threads and bonding operations are performed, then material strength and durability improve, but additional processing steps and energy consumption increase
Solution Approach 1:
The bonding operation is merged with the existing conveyor system and thread winding process. As threads are wound around projection sets on the conveyors, bonding occurs simultaneously through the application of heat and pressure, eliminating the need for separate bonding equipment and reducing overall energy consumption compared to sequential processing.
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
Enables the production of customizable apparel materials with simultaneous operations, enhancing efficiency and reducing manufacturing costs and environmental impact.
Implementation Method 1
The respective continuous threads can comprise a fusible material, and the method can further comprise fusing the respective continuous threads after the winding
Implementation Method 2
moving a plurality of first projection sets positioned on a conveyor into a work zone
Data Source
AI summary
Methods of manufacturing an article of apparel that include moving a plurality of first projection sets positioned on a conveyor into a work zone. Each first projection set includes a plurality of projections disposed around a winding field. The methods include winding a respective continuous thread on each respective first projection set to form a thread layer including a plurality of thread lines, with each thread line extending between two respective projections and across the winding field. The methods also include, after winding the respective continuous threads, advancing the conveyor to move the first projection sets out of the work zone and to move a plurality of second projection sets into the work zone.