Fabric Assembly Frames for Automated Bonding and Cutting

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Solution Overview

Problem

The garment manufacturing industry remains labor-intensive due to the inefficiencies of traditional sewing technologies, which rely heavily on manual labor and sequential processes, struggling to automate tasks that require hand-eye coordination and varying fabric properties.

Innovation Solution

A system that unwinds fabric, applies adhesive, and uses sensors and frames with fiducials to automate cutting and bonding processes, enabling robotic handling and precise operations on fabric items, reducing manual labor and increasing throughput.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional sewing machines and manual processes are used, then flexibility in handling various fabric properties is maintained, but productivity and automation level remain low

Engineering Contradiction:

Improveability to handle various fabric propertiesVSAvoidproduction rate

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent replaces traditional mechanical sewing systems with an automated system that uses adhesive application and ultrasonic welding. This substitution enables higher productivity through automation while maintaining the ability to handle various fabric properties through programmable control and sensor feedback

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system changes the bonding method from mechanical stitching to adhesive bonding and ultrasonic welding, altering the physical parameters of the joining process. This allows for automated operation while adapting to different fabric weights, thicknesses, and material compositions through adjustable process parameters

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If multiple sequential workstations are used, then specialized operations can be performed, but material handling time and production cycle increase

Engineering Contradiction:

Improvespecialized operations capabilityVSAvoidmaterial handling time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The patent merges multiple sequential operations (fabric positioning, adhesive application, bonding, and cutting) into a single integrated automated workstation. The fabric remains on the frame throughout the process, eliminating transfer time between stations while maintaining specialized operations through programmable control

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The system enables continuous operation by keeping the fabric mounted on the frame throughout the entire manufacturing process. The automated adhesive applicator and cutter operate sequentially without requiring fabric removal or repositioning, maintaining continuous useful action and eliminating idle transfer time

Inventive Principle:

Principle #20Continuity of useful action

3Productivity

If automated systems are introduced, then productivity increases, but complexity of handling varied fabric properties and tasks increases

Engineering Contradiction:

Improveproduction rateVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent introduces a frame as an intermediary carrier that holds the fabric throughout the manufacturing process. This simple mechanical element mediates between the automated adhesive applicator and cutter, enabling complex automated operations without requiring complex fabric handling mechanisms

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system uses sensors to detect fiducial markers on the frame and creates a digital map of the fabric layout. This copying approach allows the automated system to understand fabric position and properties without physical contact or complex mechanical adaptation, simplifying the automation while maintaining productivity

Inventive Principle:

Principle #26Copying

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

This automated system enhances factory efficiency by minimizing manual handling and reliance on human labor, improving production rates through automated cutting, bonding, and assembly processes.

Implementation Method 1

applying adhesive to the portion of the unwound fabric and positioning a fabric item onto the portion of the unwound fabric, thereby adhering the fabric item to the portion of the unwound fabric

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS11793258B1Using a frame to assemble a fabric article

Publication Date: 2023.10.24 CREATEME TECHNOLOGIES LLC

AI summary

Systems and methods facilitate automated manufacture of fabric articles. In an example operation, a first fabric portion is mounted in a first frame, and a second fabric portion is mounted in a second frame. The first and second frames with the corresponding fabric portions are transported to a sequence of stations at which one or more operations are performed on the first and/or second fabric portion. The operations include applying an adhesive to one of the fabric portions, and then joining the first and second fabric portions by bringing the first and second frames together. The operations include cutting the joined first and second fabric portions to create corresponding joined first and second components of a fabric article.