Selective attachment of a yarn structure
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Solution Overview
Problem
Current three-dimensional printing systems face challenges in efficiently bonding heat-moldable yarns to bases with varying surface geometries and materials, particularly in textile and apparel applications, where the yarns need to adhere without delamination under flexing or assembly processes.
Innovation Solution
A method and system that utilize a nozzle to dispense heat-moldable and melt-resistant materials in specific states, bonding the yarn to attachment regions on the base by transitioning the heat-moldable material from a liquid to a solid state while maintaining the melt-resistant material as a continuous segment, allowing for flexible attachment and detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heat-moldable material is used to bond yarn to base, then bonding strength is improved, but yarn delaminates under flexing or assembly processes
Solution Approach 1:
The yarn is constructed as a composite material containing both heat-moldable material (for bonding strength) and melt-resistant material (for structural integrity and delamination resistance). This composite structure allows the yarn to maintain strong bonding to the base while resisting delamination during flexing and assembly processes.
Solution Approach 2:
The bonding process applies heat locally at the attachment regions where the yarn contacts the base, allowing the heat-moldable material to bond only at specific locations while the melt-resistant material remains intact throughout the yarn structure, preventing delamination in non-bonded areas.
2Manufacturing precision
If nozzle moves into attachment region to bond yarn, then bonding precision is improved, but base thickness reduces by prodding distance
Solution Approach 1:
The system pre-compensates for the prodding distance by adjusting the nozzle's approach path or the base's positioning, ensuring that the temporary thickness reduction during bonding does not affect the final dimensional accuracy of the manufactured part.
3Ease of manufacture
If heat-moldable material is dispensed in liquid state, then bonding capability is improved, but material control becomes difficult
Solution Approach 1:
The system controls the temperature parameter of the heat-moldable material to maintain it in a liquid state during dispensing for optimal bonding capability, then rapidly cools it after deposition to solidify and lock the material in the precise desired position, achieving both bonding effectiveness and placement precision.
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 enables robust and flexible bonding of yarns to bases with varying geometries and materials, ensuring adherence without delamination, even under stress, and simplifies the manufacturing process by eliminating the need for release layers or perfect flatness.
Implementation Method 1
The heat moldable material bonds to the first attachment region during a transition of the heat moldable material from the liquid state to a solid state
Data Source
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AI summary
A method and system are disclosed. A method of printing onto a base (144) having an upper surface (148) spaced from a lower surface (150) by a base thickness (204) includes dispensing a yarn (151) from a nozzle (118) of a printing system and selectively attaching the yarn to a first attachment region (152). The step of dispensing the yarn includes dispensing a heat-moldable material (156) and a melt- resistant material (158). The step of selectively attaching the yarn to the first attachment region includes moving the nozzle into the first attachment region. The step of moving the nozzle into the first attachment region reduces the base thickness by a prodding distance (206). The heat-moldable material bonds to the first attachment region.