Textile Element Manufacturing Without Anchor Points
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Solution Overview
Problem
Existing methods for manufacturing textile elements by winding threads around anchor points are labor-intensive, costly, and limited in individual adaptation, resulting in waste production and inefficiency.
Innovation Solution
A method involving the outputting, heating, and arranging of threads in a thread pattern without the need for anchor points, utilizing heated threads that adhere to substrates or existing threads, and applying pressure with circular objects to enhance bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If threads are wound around anchor points to form textile elements, then the textile structure can be formed, but the manufacturing process becomes labor-intensive and costly
Solution Approach 1:
The patent removes the frame with anchor points from the manufacturing process entirely. Instead of winding threads around fixed anchor points, the method directly deposits melted thread material in the desired pattern onto a substrate, eliminating the frame structure and anchor points that caused labor-intensive operations and high costs.
Solution Approach 2:
The patent replaces the mechanical winding process around anchor points with a thermal deposition process. A heating element melts the thread material, which is then deposited directly onto the substrate in the desired pattern, substituting mechanical manipulation with thermal processing for more efficient manufacturing.
2Adaptability or versatility
If frames with anchor points are designed for each textile component, then individual adaptations are possible, but the device complexity and storage requirements increase immensely
Solution Approach 1:
The patent extracts and eliminates the frame structure from the system. By removing the frame with anchor points, the method achieves individual adaptations through direct digital patterning of thread deposition without requiring complex physical frameworks or extensive frame storage.
Solution Approach 2:
The patent changes the manufacturing approach from mechanical frame-based positioning to thermal deposition with programmable patterning. By controlling the heating element's movement and deposition parameters, individual adaptations are achieved through software control rather than physical frame modifications, reducing device complexity.
3Ease of manufacture
If excess thread material is cut or removed after winding, then the textile element is finalized, but waste production increases
Solution Approach 1:
The patent performs preliminary action by precisely depositing the exact amount of thread material needed in the desired pattern during the manufacturing process itself. By controlling the heating element to melt and deposit thread only where and when needed, the method eliminates subsequent cutting operations and prevents material waste from the beginning.
Solution Approach 2:
The patent replaces the mechanical cutting and trimming process with a precision thermal deposition process. The heating element is controlled to deposit thread material exactly where needed, eliminating the need for post-manufacturing cutting operations and reducing material waste.
4Productivity
If traditional winding methods are used, then textile elements can be manufactured, but further manufacturing steps are required after winding
Solution Approach 1:
The patent merges multiple manufacturing steps into a single integrated process. The heating element simultaneously melts, deposits, and bonds the thread material to the substrate in one continuous operation, eliminating separate winding, cutting, and finishing steps that characterize traditional methods.
Solution Approach 2:
The patent replaces the multi-step mechanical winding and finishing process with a single thermal deposition process. By using heat to melt, place, and bond the thread material in one operation, the method reduces the number of manufacturing steps and increases productivity.
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 approach reduces labor and costs, allows for individual adjustments in thread patterns, minimizes waste, and eliminates the need for anchor points, resulting in a more efficient and adaptable textile manufacturing process.
Implementation Method 1
heating the thread
Implementation Method 2
softening or melting at least a portion of the thread
Implementation Method 3
arranging the heated thread in a thread pattern
Data Source
AI summary
Methods of manufacturing a textile element comprising the steps of outputting a thread, heating the thread, and arranging the heated thread in a thread pattern. The methods may further comprise applying pressure to at least a portion of the thread pattern. The present disclosure further relates to an apparatus for manufacturing the textile element according to the methods described.