Tack-and-Drag Yarn Printing on Non-Flat Wearable Surfaces
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Solution Overview
Problem
Existing three-dimensional printing technologies face challenges in efficiently attaching and securing yarns to non-flat or textured surfaces without the need for a release layer or perfectly flat substrate, particularly in forming structures on articles of footwear and apparel.
Innovation Solution
A method and apparatus for tack and drag printing, utilizing an actuating system to move a nozzle along a base, securing a tagging segment of the yarn to the base while applying tension, and transitioning a heat moldable material from a solid to a liquid state to bond with the base, allowing for direct printing on textured surfaces without a release layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing three-dimensional printing technologies are used to attach yarns to non-flat or textured surfaces, then the printing process requires a release layer or perfectly flat substrate, but this increases device complexity and limits adaptability to various textile materials
Solution Approach 1:
The patent removes the release layer component from the printing system entirely. By using a nozzle that directly deposits heat-moldable material onto the substrate, the system eliminates the need for a separate release layer that would otherwise be required to facilitate yarn attachment and removal.
Solution Approach 2:
The patent changes the physical state parameter of the printing material by using heat-moldable material that transitions from a solid or semi-solid state during deposition to a molded state after cooling. This parameter change enables direct attachment to non-flat surfaces without requiring a release layer.
2Productivity
If existing three-dimensional printing technologies are used on textured surfaces, then the printing process requires additional layers or preparation, but this reduces productivity and increases manufacturing time
Solution Approach 1:
The patent performs preliminary heating of the heat-moldable material within the nozzle before deposition. This preliminary action prepares the material in advance for immediate attachment to the substrate upon contact, eliminating the need for post-deposition processing or additional preparation steps.
Solution Approach 2:
The heat-moldable material serves multiple functions simultaneously: it acts as both the printing material and the adhesive bonding agent. The material self-bonds to the substrate through its own thermal properties without requiring additional adhesives or preparation layers.
3Device complexity
If existing three-dimensional printing technologies are used to bond yarns to substrates, then the bonding process requires additional materials or steps, but this increases device complexity
Solution Approach 1:
The patent merges the functions of the printing material and the bonding agent into a single heat-moldable material. The material is deposited from the nozzle and simultaneously bonds to the substrate through controlled cooling and molding, combining what would traditionally be separate components into one integrated system.
Solution Approach 2:
The heat-moldable material acts as an intermediary between the nozzle and the substrate. It transfers the molding action from the nozzle to the substrate, enabling reliable bonding without requiring direct mechanical contact or additional bonding components.
4Adaptability or versatility
If existing three-dimensional printing technologies are used on flexible materials, then the printed structures may delaminate during flexing, but using rigid bonding methods would reduce adaptability to textile applications
Solution Approach 1:
The patent uses a dynamic bonding process where the heat-moldable material is deposited in a semi-molten state and then cooled to form a strong bond. The bonding strength develops dynamically during the cooling process, creating an attachment that can withstand subsequent flexing and mechanical stress.
Solution Approach 2:
The patent employs composite construction by integrating the heat-moldable material with the textile substrate through direct bonding. The resulting structure combines the properties of both materials, creating a composite that maintains the flexibility of the textile while achieving stable adhesion.
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 and secure attachment of yarns to non-flat surfaces, enhancing the versatility of three-dimensional printing on materials like textiles and fabrics, ensuring adhesion without delamination during flexing or assembly processes.
Implementation Method 1
transitioning a heat moldable material from a solid to a liquid state to bond with the base
Implementation Method 2
Enables direct and secure attachment of yarns to non-flat surfaces
Data Source
AI summary
A method and apparatus for bonding a yarn to a wearable article includes bonding the yarn to the wearable article at a first portion and a second portion. A first bonding location and a second bonding location are spaced apart from one another on a surface of the wearable article and an intermediate portion of the yarn extends contiguously between the first bonding location and the second bonding location and is not bonded to the wearable article.