Projection-Controlled Rotational Winding for Customizable Apparel Layers
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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 and method involving a rotatable shaft, a thread guide movable along a perpendicular axis, and a plate with projections, utilizing actuators to rotate the shaft and move the thread guide between projections to wind continuous threads, allowing for the creation of thread layers with customizable characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional weaving or knitting techniques are used to manufacture apparel materials, then the materials can be produced with established durability and comfort characteristics, but the manufacturing process is time-consuming and difficult to customize for large quantities
Solution Approach 1:
The apparatus segments the manufacturing process into discrete winding operations around multiple independently controllable projections, allowing different thread arrangements to be created efficiently for different apparel regions while maintaining high productivity through automated simultaneous operation
Solution Approach 2:
The system employs dynamically adjustable projections that can be repositioned or reconfigured during manufacturing, enabling customization of material characteristics for different use cases while maintaining efficient automated production across large quantities
2Manufacturing precision
If customized thread arrangements are created to achieve targeted apparel characteristics, then the material can be optimized for specific performance requirements, but the manufacturing complexity and time increase
Solution Approach 1:
The system changes parameters such as projection positions, thread tension, and winding patterns to achieve targeted material characteristics while maintaining efficient manufacturing through automated control, avoiding the time-consuming manual adjustment previously required
3Adaptability or versatility
If multiple actuators are used to control the winding process, then the thread arrangement can be precisely controlled for customized characteristics, but the device complexity increases
Solution Approach 1:
The apparatus employs multiple actuators that perform multiple functions - controlling projection positions, adjusting thread tension, and managing winding patterns - thereby achieving high adaptability for customized thread layers while minimizing overall device complexity through multi-functional integration
Data Source
Figure 1A~1B
Figure 2A
Figure 2B
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.