Selective Yarn Attachment to Textile Base Using FFF Printing

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Solution Overview

Problem

Current three-dimensional printing systems face challenges in printing directly onto textile and fabric materials without the need for a release layer or a perfectly flat substrate, and in maintaining attachment of printed materials when subjected to flexing, rolling, or assembly processes.

Innovation Solution

A three-dimensional printing system using fused filament fabrication (FFF) with a nozzle assembly that moves along x, y, and z axes to deposit yarn or heat-moldable materials directly onto textile surfaces, allowing for attachment and detachment from the substrate while maintaining structural integrity during assembly processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a release layer is used to prevent printed material from adhering to the substrate, then the printed material can be easily removed, but the printed material loses attachment and structural integrity during flexing and assembly processes

Engineering Contradiction:

Improveease of removing printed materialVSAvoidattachment of printed material during flexing

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The substrate is divided into attachment regions and non-attachment regions, allowing selective bonding in different areas. This segmentation enables the printed material to remain attached in critical areas while allowing removal in non-critical areas, resolving the contradiction between ease of removal and structural integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the substrate have different properties: attachment regions promote bonding while non-attachment regions prevent bonding. This local differentiation allows the printed material to be selectively attached where needed and easily removed where not needed, simultaneously achieving reliability during flexing and ease of manufacture.

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If the substrate surface is perfectly flat, then the printing process achieves high precision, but the system cannot accommodate curved and irregular surfaces commonly found in textile and fabric materials

Engineering Contradiction:

Improveprecision of printing processVSAvoidability to print on various surface geometries

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The printing system is made dynamic and adaptable by allowing the substrate to maintain its natural curved or irregular shape during printing. The selective attachment methodology adjusts to the substrate's geometry rather than requiring the substrate to conform to a flat printing surface, achieving both precision and versatility.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The printing system achieves universality by being able to print on multiple surface geometries (flat, curved, irregular) using the same methodology. The selective attachment regions work across different substrate types and shapes, making the system versatile while maintaining manufacturing precision through controlled bonding in specific areas.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of operation

If the printed material is selectively attached only in certain regions, then the material maintains flexibility and movement capability, but the overall structural integrity and attachment strength is reduced

Engineering Contradiction:

Improveflexibility and movement capabilityVSAvoidoverall attachment strength

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The attachment functionality is segmented into discrete regions rather than being distributed uniformly. This segmentation allows the printed material to be firmly attached in critical structural areas while remaining flexible and movable in non-critical areas, achieving both localized strength and overall flexibility.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the printed material have different attachment properties: high attachment strength in critical regions and low attachment strength (high flexibility) in non-critical regions. This local differentiation of quality allows the structure to maintain overall integrity while permitting necessary movement and flexibility in specific areas.

Inventive Principle:

Principle #3Local quality

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 direct printing on various surface geometries, including curved and irregular surfaces, without the need for a release layer, and ensures that printed materials remain attached and functional through flexing and assembly, enhancing the versatility and durability of printed articles.

Implementation Method 1

Methodology Applied

Scientific EffectHeat-moldable material extrusion: Melting

Implementation Method 2

ensures that printed materials remain attached and functional through flexing and assembly

Methodology Applied

Scientific EffectThermal adhesion: Adhesive

Data Source

PatentEP4159413B1Selective attachment of a yarn structure

Publication Date: 2024.03.20 NIKE INNOVATE CV

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AI summary

The claimed invention is directed to an article of apparel comprising a base having an upper surface, a yarn including a heat-moldable material and a melt-resistant material, a plurality of attachment regions in which the yarn is bonded to the base, the plurality of attachment regions comprising at least a first attachment region and a second attachment region, and at least one unattached region in which the yarn is detached from the unattached region.