Rotational Thread Winding for Customizable Apparel Structures
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Solution Overview
Problem
Existing methods for manufacturing apparel lack the ability to efficiently produce materials with customizable characteristics in large quantities while maintaining durability and comfort, particularly for athletic and non-athletic activities.
Innovation Solution
A winding apparatus and method involving a rotatable shaft, thread guide, and actuators to move the thread guide along an axis, allowing for the winding of continuous threads around anchor points to create thread layers or patterns, which can be bonded to achieve desired characteristics such as strength, stiffness, and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional weaving or knitting methods are used to manufacture apparel, then production can be performed using established techniques, but the ability to efficiently produce materials with customizable characteristics in large quantities is limited
Solution Approach 1:
The apparatus segments the thread guide system into multiple independently controllable thread guides, each capable of being positioned and controlled separately. This allows different thread arrangements and material selections for different regions of the apparel material, enabling customization while maintaining efficient automated production through independent control of each segment
Solution Approach 2:
The patent implements dynamic control of thread guide positions and movements during the winding process. The thread guides can be moved along the axis and positioned at different locations, allowing the system to adapt and create varied thread arrangements on-the-fly, enabling customizable characteristics while maintaining high-speed automated manufacturing
2Adaptability or versatility
If thread guides are moved along an axis and between projections to wind continuous thread, then customizable thread arrangements can be created, but the device complexity increases with multiple actuators and moving components
Solution Approach 1:
The thread guide assembly is designed as a multi-functional unit that combines threading, guiding, and positioning capabilities in a single integrated structure. The same thread guide mechanism serves multiple purposes: guiding the continuous thread, being moved along the axis by the first actuator, and being positioned between projections by the second actuator, reducing the need for separate specialized components
Solution Approach 2:
The patent adds a vertical dimension to the thread guide movement by introducing projections that extend from the base. The thread guide can be positioned not only along the horizontal axis but also vertically between the projections, creating two-dimensional positioning capability that enables complex thread arrangements without requiring additional actuators in multiple directions
3Productivity
If multiple winding units are used with independently controllable actuators, then production efficiency and customization capability are improved, but the overall device complexity and cost increase
Solution Approach 1:
Multiple winding units are merged into a single integrated apparatus where the base, projections, and support structures are shared across all units. While each winding unit has its own thread guide and actuators for independent operation, the common structural elements reduce overall device complexity compared to having completely separate winding machines
Data Source
AI summary
Winding apparatuses and methods for manufacturing an article of apparel. A winding apparatus can comprise a winding unit comprising a rotatable shaft, a thread guide movable along an axis perpendicular to the shaft, and a plate comprising a base coupled to the shaft and a plurality of projections extending from the base. The winding apparatus can also comprise a first actuator configured to rotate the shaft and a second actuator configured to move the thread guide along the axis and between respective projections of the plurality of projections to wind a continuous thread around the plurality of projections.