Conveyor-Wound Thread Layers for Customizable Apparel Production
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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, allowing simultaneous operations such as winding, bonding, and unloading, using a conveyor system with projection sets and thread guides to create customizable thread patterns on 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 efficiently manufacturing in large quantities is limited
Solution Approach 1:
The apparel manufacturing process is segmented into discrete operational zones (winding zone, bonding zone, cooling zone, collection zone) that can independently process multiple projection sets simultaneously. Each zone performs a specific function, allowing parallel processing of multiple articles with different customization parameters without interfering with each other's production efficiency
Solution Approach 2:
The conveyor system is designed as a universal platform that can handle multiple types of projection sets with different configurations. The same conveyor infrastructure supports various winding patterns, thread types, and bonding parameters, enabling efficient production of diverse customized apparel products through a single multi-functional system
2Adaptability or versatility
If complex customization options are provided for apparel characteristics, then adaptability and versatility improve, but device complexity and manufacturing process complexity increase
Solution Approach 1:
Different sections of the conveyor system are equipped with specialized components tailored to specific operational requirements. The winding zone has thread guides and tensioning mechanisms, the bonding zone has heating elements, and the cooling zone has cooling elements. This localized specialization allows complex customization capabilities without requiring the entire system to be overly complex
Solution Approach 2:
Projection sets are pre-configured with specific patterns, anchor point arrangements, and material properties before entering the conveyor system. Thread types, tensions, and winding patterns are predetermined for each projection set. This preliminary preparation reduces the complexity of real-time decision-making and system coordination during the manufacturing process
3Productivity
If multiple operations are performed simultaneously on multiple projection sets, then productivity increases, but coordination and control complexity increases
Solution Approach 1:
The conveyor system operates with periodic cycles where projection sets move through standardized zones at controlled intervals. Each projection set spends a predetermined time in each zone (winding, bonding, cooling), creating a rhythmic production flow. This periodic operation simplifies coordination by establishing predictable timing patterns that reduce control system complexity
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 efficient and customizable manufacturing of apparel materials, allowing for simultaneous performance of multiple operations on multiple projection sets, enhancing durability and comfort characteristics.
Implementation Method 1
winding a respective continuous thread on each respective first projection set to form a thread layer on each first projection set
Implementation Method 2
moving a plurality of first projection sets positioned on a conveyor into a work zone
Implementation Method 3
the respective continuous threads can each comprise a fusible material, and the method can further comprise fusing the respective continuous threads after the winding
Data Source
Figure 1A
Figure 1B
Figure 1C
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.