Patent Application
20250003143
The present disclosure is generally related to apparatus, systems, and methods for manufacturing and joining fabric items, such as garments.
Despite technological advances and the introduction of automation in many types of manufacturing, the manufacturing of fabric items, such as garments, remains very labor-intensive. The process of producing large quantities of ready-to-wear apparel relies heavily on manual labor and remains inefficient relative to other industrial manufacturing processes. Garment manufacturing includes multiple steps including sizing, folding, fitting, cutting, sewing, and material handling. The unique and varied properties of individual fabrics, such as weight, thickness, strength, stretch, and drape, as well as the complex nature of certain tasks, complicates material handling and automated garment manufacturing.
Accordingly, there is a need for an automated system for manufacturing fabric items to improve manufacturing efficiency and variation reduction between individual manufactured fabric items.
In a particular implementation, a system or apparatus may include a fabric joining device. The fabric joining device may include a first section that is configured to releasably hold at least a first portion of a fabric item onto the surface of the first section. The first section may include a first plurality of sectors, where each sector is configured to selectively apply heat to the first portion of the fabric item. The fabric joining device may also include a second section that is configured to releasably hold at least a second portion of the fabric item onto a surface of the second section. The second section may include a second plurality of sectors, where each sector is configured to selectively apply heat to the second portion of the fabric item. The fabric joining device may also include one or more first actuators coupled to the first section or the second section. The one or more first actuators may be configured to rotate the first section about an axis of rotation (e.g., an axis orthogonal to a normal of the surface of the second section) to fold the first portion of the fabric item onto the second portion of the fabric item. The rotating of the first section to fold the fabric item may also result in pressing the first portion of the fabric item and the second portion of the fabric item together to join the first and second portions of the fabric item. The fabric joining device may further include a spacer positioned with respect to the first section and the second section to support a non-joint region of the first portion of the fabric item, a non-joint region of the second portion of the fabric item, or both. The support of the non-joint region may result in avoiding the formation of a crease.
In another particular implementation, the fabric joining device may further include an adhesive applicator that may be configured to, before rotation of the first section, apply an adhesive to a first joint region of the first portion of the fabric item, to a second joint region of the second portion of the fabric item, or both, such that pressing together the first portion of the fabric item and second portion of the fabric item adheres the first joint region and the second joint region to form a joint therebetween. The fabric joining device may also include a curing system that may be configured to cure the adhesive at the joint.
In another particular implementation, a method for manufacturing a fabric item may include mounting the first portion of the fabric item onto the surface of the first section of the fabric joining device. The method may also include mounting the second portion of the fabric item onto the surface of a second section of the fabric joining device. The method may further include rotating, using one or more first actuators of the fabric joining device, the first section about an axis of rotation (e.g., an axis orthogonal to a normal of the surface of the second section) to fold the first portion of the fabric item onto the second portion of the fabric item. The method may further include pressing, based on the rotating of the first section, the first portion of the fabric item and the second portion of the fabric item together to join the first portion of the fabric item and second portion of the fabric item.
In another particular implementation, the method may further include rotating, using one or more second actuators of the fabric joining device, one or more third sections to fold one or more third portions of the fabric item onto the first portion of the fabric item, the second portion of the fabric item, or both. The method may also include applying an adhesive to a first joint region of the first portion of the fabric item, to a second joint region of the second portion of the fabric item, or both, such that pressing together the first portion of the fabric item and second portion of the fabric item adheres the first joint region to the second joint region to form a joint therebetween.
The features, functions, and advantages described herein can be achieved independently in various implementations or may be combined in yet other implementations, further details of which can be found with reference to the following description and drawings.
Aspects disclosed herein present systems, apparatus, and methods for joining fabric items. Traditional manufacturing of fabric items is labor intensive and uses sewing machines, which were invented in the early nineteenth century. The laborers using these sewing machines manufactured fabric items by using the lock stitch sewing technique.
Today this same technology remains the foundation of fabric item manufacturing. The modern process of producing large quantities of ready-to-wear fabric items relies heavily on manual labor and remains inefficient relative to other industrial manufacturing processes. The manufacturing of fabric items includes multiple steps including, but not limited to, sizing, folding, fitting, cutting, sewing, and material handling. The unique and varied properties of individual fabrics, such as weight, thickness, strength, stretch, and drape, as well as the complex nature of certain tasks, complicates material handling and automated fabric item manufacturing.
In most small and large fabric item manufacturing factories, most of the material handling and fabric item manufacturing operations are conducted in a manual or semimanual manner. The fabric item manufacturing process may start with laying out a web of fabric for multiple hours to relax the fabric and remove wrinkles. Then, one or more layers of fabric may be cut based on patterns and dimensions matching the desired fabric item. Then, the cut fabric pieces are transferred from workstation to workstation, where at each workstation, one, two, or more pieces of fabrics are manually folded, overlapped along the seams, and fed into a sewing machine or serger machine (also referred to as an overlock machine). In addition, at these workstations one or more folds may create an unnecessary crease in the fabric, which will increase the amount of time to manufacture the fabric item as the crease will need to be removed.
Given the variety of fabrics, threads, seam types, and stitch types found in a finished garment, a large number of workstations with specialized tools and skilled operators may be required for assembling a fabric item. This results in fabrics or unfinished fabric items spending time in transit between workstations, which adversely affects the time required to complete a fabric item. Thus, traditional apparel manufacturing operations may include multiple sequential processes. Further, a time constant may be required between each operation to allow the fabric to relax or remove unnecessary creases, which further increases the time required to process a fabric item.
Accordingly, there is a need for an automated system for manufacturing fabric items to improve manufacturing efficiency and variation reduction between individual manufactured fabric items.
Described in this disclosure are techniques and systems for manufacturing a fabric item that improves manufacturing efficiency and variation reduction between individual manufactured fabric items. The system for manufacturing the fabric item may include a fabric joining device. The fabric joining device may include a work surface that includes multiple sections. For example, the fabric joining device may include a first section, a second section, a third section, and so forth. One or more of the sections (e.g., each of the sections) may be configured to releasably hold at least a portion of a fabric item onto a surface of the section. For example, a vacuum assembly may be coupled underneath the sections and configured to apply a vacuum which holds the fabric item in place.
The fabric joining device may include one or more actuators coupled to respective ones of the sections. The one or more actuators may be configured to rotate one or more of the sections. For example, at least one actuator may be coupled to the second section and configured to rotate the second section about an axis of rotation orthogonal to a normal of the surface of the first section to fold the second portion of the fabric item onto the first portion of the fabric item and to press the first portion of the fabric item and the second portion of the fabric item together to join the first portion and the second portion of the fabric item.
The fabric joining device may also include a spacer positioned with respect to the first section and the second section. The spacer may prevent an unnecessary crease from being formed in the fabric item by supporting a non-joint region of the first portion of the fabric item, a non-joint region of the second portion of the fabric item, or both.
In another implementation, the system or the fabric joining device may include an adhesive applicator. The adhesive applicator may be configured to apply an adhesive to a joint region of the fabric item. The fabric joining device may then rotate a section to press the joint region of the fabric item to another portion of the fabric item, thereby forming a joint therebetween. The joint formed may be a hem seam, butterfly joint, overlap joint, a lap joint, and so forth.
In another implementation, the system or the fabric joining device may include a curing system. The curing system may be configured to cure the adhesive at the joint.
The process of folding the fabric item, applying adhesive, and curing the adhesive is repeated until the particular fabric item is complete. For example, a completed fabric item may include, but is not limited to, a garment (e.g. a shirt, pants, socks, shoes, shorts, a coat, a jacket, a skirt, a dress, an undergarment, a hat, a headband, and the like), an accessory (e.g. a wallet, a purse, and the like), and homeware (e.g. artwork, upholstery, a towel, a bed linen, a blanket, a mat, and the like).
By using the techniques and systems described herein, the manufacturing efficiency for manufacturing a fabric item may improve because the steps of folding the fabric item, applying adhesive, and curing the adhesive may be performed at one workstation. The manufacturing efficiency may also improve because the formation of unnecessary creases is reduced based on the use of one or more spacers. By reducing unnecessary creases, the steps of removing those creases may be omitted in the manufacturing of the fabric item. This reduction of steps may yield improved efficiency of manufacturing time. The variation between individual manufactured fabric items may be reduced based on the fabric joint device applying the adhesive at the correct locations and with the correct amount for that particular fabric item. In addition, the variation between individual fabric items may be reduced based on the fabric joining device, applying the correct pressure at each of the joint regions, folding the fabric item correctly each time and avoiding creating unnecessary creases.
The figures and the following description illustrate specific exemplary implementations. It will be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described or shown herein, embody the principles described herein and are included within the scope of the claims that follow this description. Furthermore, any examples described herein are intended to aid in understanding the principles of the disclosure and are to be construed as being without limitation. As a result, this disclosure is not limited to the specific implementations or examples described below, but by the claims and their equivalents.
Particular implementations are described herein with reference to the drawings. In the description, common features are designated by common reference numbers throughout the drawings. In some drawings, multiple instances of a particular type of feature are used. Although these features are physically and/or logically distinct, the same reference number is used for each, and the different instances are distinguished by addition of a letter to the reference number. When the features as a group or a type are referred to herein (e.g., when no particular one of the features is being referenced), the reference number is used without a distinguishing letter. However, when one particular feature of multiple features of the same type is referred to herein, the reference number is used with the distinguishing letter. For example, referring to
As used herein, various terminology is used for the purpose of describing particular implementations only and is not intended to be limiting. For example, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. Further, some features described herein are singular in some implementations and plural in other implementations. To illustrate,
The terms “comprise,” “comprises,” and “comprising” are used interchangeably with “include,” “includes,” or “including.” Additionally, the term “wherein” is used interchangeably with the term “where.” As used herein, “exemplary” indicates an example, an implementation, and/or an aspect, and should not be construed as limiting or as indicating a preference or a preferred implementation. As used herein, an ordinal term (e.g., “first,” “second,” “third,” etc.) used to modify an element, such as a structure, a component, an operation, etc., does not by itself indicate any priority or order of the element with respect to another element, but rather merely distinguishes the element from another element having a same name (but for use of the ordinal term). As used herein, the term “set” refers to a grouping of one or more elements, and the term “plurality” refers to multiple elements.
As used herein, “generating,” “calculating,” “using,” “selecting,” “accessing,” and “determining” are interchangeable unless context indicates otherwise. For example, “generating,” “calculating,” or “determining” a parameter (or a signal) can refer to actively generating, calculating, or determining the parameter (or the signal) or can refer to using, selecting, or accessing the parameter (or signal) that is already generated, such as by another component or device. As used herein, “coupled” can include “communicatively coupled,” “electrically coupled,” or “physically coupled,” and can also (or alternatively) include any combinations thereof. Two devices (or components) can be coupled (e.g., communicatively coupled, electrically coupled, or physically coupled) directly or indirectly via one or more other devices, components, wires, buses, networks (e.g., a wired network, a wireless network, or a combination thereof), etc. Two devices (or components) that are electrically coupled can be included in the same device or in different devices and can be connected via electronics, one or more connectors, or inductive coupling, as illustrative, non-limiting examples. In some implementations, two devices (or components) that are communicatively coupled, such as in electrical communication, can send and receive electrical signals (digital signals or analog signals) directly or indirectly, such as via one or more wires, buses, networks, etc. As used herein, “directly coupled” is used to describe two devices that are coupled (e.g., communicatively coupled, electrically coupled, or physically coupled) without intervening components.
In addition, implementations presented in this disclosure generally relate to apparatus, systems, and methods for handling fabrics, such as textiles, such as sheet materials, such as leather, cloth, and the like, in the manufacture of items. Some examples of such items include, but are not limited to, garments (e.g. shirts, pants, socks, shoes, shorts, coats, jackets, skirts, dresses, underwear, hats, headbands, and the like), accessories (e.g. wallets, purses, and the like), technical textiles (e.g., for automotive applications, such as seats, interior, and the like), medical textiles (e.g., implants), geotextiles (e.g., reinforcement of embankments), agrotextiles (e.g., textiles for crop protection), boating industry textiles (e.g., sails, interiors and the like) and protective clothing (e.g., heat and radiation protection for fire fighter clothing, molten metal protection for welders, stab protection and bulletproof vests, and spacesuits), and homewares (e.g., artwork, upholstery, towels, bed linens, blankets, mats, and the like).
Some fabrics (so-called “single-faced fabrics”) may include a “right side” designated to be on show in the finished item, and a “wrong side” designated to be hidden in the finished item. When such fabrics include a printed design, typically the print is applied to the right side. Additionally, when such fabrics are joined, typically the join is made right side to right side, then the joined fabrics are reversed (for example by turning inside out) such that excess fabric at the join is hidden, and the right sides become facing outwards from each other. Some other fabrics (so-called “double-faced fabrics”) are created with two right sides and no wrong sides. Such fabrics are constructed such that either of the two right sides can be designated to be on show in the finished item. Each system and method of the present disclosure includes the performance of manufacturing operations on fabric items that may be right side facing upwards or wrong side facing upwards. In some implementations, a manufacturing operation may be performed on a fabric item that is oriented on the right side facing upwards. In some implementations, a manufacturing operation may be performed on a fabric item that is oriented wrong side facing upwards.
In some implementations of the systems of the present disclosure, fabric items may be transported to a sequence of stations (e.g., from a folding station to a curing station). In some such implementations, a conveyor transports individual fabric items between stations. In some implementations, a robot transports individual fabric items between stations. In some implementations, a robot transports individual fabric items between stations while the individual fabric items are secured in one or more frames. For example, the robot may pick up a frame that is holding a fabric item and move the frame with the fabric item between stations. At each station one or more operations are performed in the manufacture of a fabric item. The operations are performed on a work surface, such as a folding table, cutting table, printing table, and the like.
As one example of a mechanism to releasably hold portions of the fabric item, the one or more sections 104 may include perforations 106 coupled to a vacuum assembly. In this example, the vacuum assembly may be coupled underneath the one or more sections 104 to apply a suction to hold the portions of the fabric item in place. The one or more sections 104 and the vacuum assembly may be configured such that a vacuum applied through the perforations 106 of an individual one of the one or more sections 104, such as the first section 104A, may be controlled independently of a vacuum applied through the perforations 106 of another one of the one or more sections 104, such as the second section 104B. For example, a vacuum may be applied through the perforations 106 of the first section 104A while no vacuum is applied through the perforations 106 of the second section 104B. In another example, a vacuum may be applied through the perforations 106 of any one or more of the first section 104A, the second section 104B, the third section 104C, or the fourth section 104D, while no vacuum is applied through the perforations 106 of any one or more of the other sections 104. Additionally, a vacuum may apply through the perforations 106 of at least one of the one or more sections 104 at a first strength, while the vacuum applied through the perforations 106 of one or more other sections 104 is at a second strength, where the first strength and the second strength are different.
As another example of a mechanism to releasably hold portions of the fabric item, one or more of the sections 104 may include an electrostatic plate. In this example, a static electrical charge applied to the electrostatic plate may be turned on to hold a portion of the fabric item or off to release the portion of the fabric item. Other examples of mechanisms to releasably hold portions of the fabric item include, without limitation, a fold down frame assembly, a hook and loop fastener assembly, a releasable adhesive assembly, inertia, and so forth.
The fabric joining device 102 may include one or more spacers 108. In one implementation, a spacer 108A may be disposed within the second section 104B. In this implementation, the axis of rotation 118A of the second section 104B aligns with an edge of the spacer 108A. The spacer 108A may be configured to support a non-joint region of the first portion of the fabric item, a non-joint region of the second portion of the fabric item, or both. The support of the non-joint region may result in the avoidance of the formation of a crease in the fabric item. Although the spacer 108A in
In some implementations, the one or more spacers 108 may be disposed between two sections of the two or more sections 104. For example, the spacer 108B may be disposed between the third section 104C and the fourth section 104D. Although the spacer 108B in
The fabric joining device 102 may include a masking template 110. The masking template 110 may be configured to be complementary to a shape of the first portion of the fabric item, the second portion of the fabric item, or both. For example, the shape of the fabric item being manufactured may be a sleeve to a t-shirt. In this example, the masking template 110 may have a shape that corresponds to an outline of the shape of fabric used to form the sleeve for the t-shirt. The masking template 110 may be removable based on the size of the particular fabric item being manufactured. For example, the fabric item being manufactured may cover most or all of the one or more sections 104, in which case the masking template 110 may be removed to accommodate the large size of the fabric item. In another example, the fabric item being manufactured may be small, such as children's clothing. In this example, the size of the masking template 110 may be adjusted (or the masking template 110 may be replaced) to cover a majority of the perforations 106 on the one or more sections 104 to accommodate the small size of the fabric item. When air flow (e.g., vacuum) is used to retain the portions of the fabric item to the sections 104 of the fabric joining device 102, the masking template 110 is configured to block the airflow through particular portions of the fabric joining device 102 to focus the air flow in regions in which retention of the fabric item is desired.
In the example illustrated in
In some implementations, the fabric joining device 102 may include one or more hinges 114. The one or more hinges 114 may be configured to couple the one or more sections 104 to each other. For example, the hinge 114A may be configured to couple the second section 104B to the first section 104A. In other examples, the hinge 114B may be configured to couple the second section 104B to the third section 104C, and the hinge 114C may be configured to couple the fourth section 104D to the first section 104A. The hinge 114 may be configured to enable one or more of the sections 104 to rotate relative to one or more other sections 104. For example, the hinge 114A may be configured to enable the second section 104B to rotate about the axis of rotation 118A orthogonal to a normal of the surface of the first section 104A to fold the second portion of the fabric item onto the first portion of the fabric item. This action may also press the first portion of the fabric item and the second portion of the fabric item together to join the first and second portions of the fabric item. The rotation of the second section 104B may align an edge of the first portion of the fabric item and an edge of the second portion of the fabric item to form a butterfly joint therebetween. In another example, the hinge 114B and/or the hinge 114C may be configured to enable the third section 104C and/or the fourth section 104D to rotate about the axis of rotation 118B orthogonal to a normal of the surface of the first section 104A and/or the second section 104B to fold a portion of the fabric item onto another portion of the fabric item and to press those portions of the fabric item together. In other implementations, the axis of rotation 118 may be at an angle that corresponds to the type of fold necessary for a particular fabric item. In this implementation the angle of the axis of rotation 118 may be non-parallel to the surface of one or more of the sections 104.
In the example illustrated in
The controller 128 may be configured to monitor and control the operations of the fabric joining device 102 and the individual components of the fabric joining device 102. For example, the controller 128 may be configured to send control signals to the one or more actuators 116 during manufacturing of the fabric item that includes the first portion and the second portion. In other examples, the controller 128 may be configured to direct the placement apparatus 120. The controller 128 may include one or more software applications stored in memory and executed using one or more processors in a computing system. The controller 128 may receive data from one or more sensors, such as an alignment sensor, camera, a barcode reader, a quick response (QR) code reader, a radio frequency identification (RFID) tag reader, a proximity sensor, or the like. The one or more sensors are associated with the individual apparatuses of the fabric joining device 102. The controller 128 may be configured to process the data and direct the operation of one or more components of the fabric joining device 102.
The system 100 or the fabric joining device 102 may also include a cutter. The cutter may be configured to cut fabric into a shape that is associated with the fabric item being manufactured. For example, the cutter may cut the fabric into the shape of a t-shirt sleeve or into the shape associated with an undergarment, and so forth. The cutter may also be configured to make one or more intermediate cuts. For example, an intermediate cut may be associated with an eventual seam, neckline, armhole, or hemline of the fabric item. In some implementations, the one or more intermediate cuts may be omitted. In another implementation, the cutter may include a blade on a carrier that is movable with respect to the fabric while cutting the fabric.
In yet another implementation, the cutter is controlled by the controller 128. The cutter may have a sensor that may detect a feature associated with the fabric item. For example, a printed design or a fiducial can be on or in the fabric associated with the fabric item. The controller 128 may use information of the detected feature to direct or control the cutter to cut the fabric in a shape associated with the fabric item. For example, the controller 128 may direct the cutter to cut at specific locations, cut predetermined lengths, shapes, and so forth.
The system 100 or the fabric joining device 102 may include an adhesive applicator 130. The adhesive applicator 130 may include an articulated arm 132 attached to a dispensing nozzle 134. The dispensing nozzle 134 may be manipulated by the articulated arm 132 to perform dispensing of adhesive at one or more locations on the fabric item. The adhesive applicator 130 may also include a sensor 136. The sensor 136 may be configured to generate sensor data indicating location of where the adhesive was dispensed, particular pattern associated with the dispensing of the adhesive, amount of adhesive dispensed, and so forth.
The adhesive may be applied in the form of a liquid deposited onto the fabric item. The adhesive may permeate at least partially into the fabric of the fabric item. In other implementations, the adhesive may at least partially remain on a surface of the fabric of the fabric item. The adhesive may be configured to be cured by a curing system 138. The curing system 138 may be included in the fabric joining device 102 or may be a standalone device or part of another device. The curing system 138 may be configured to cure the adhesive by applying pressure, applying heat, applying moisture, exposing the adhesive to ambient conditions, or waiting for a predetermined duration of time. The application of heat may include a hot press (hot surface), heating paddles, hot air, infra-red (IR) radiation, microwave, and so forth. The curing of the adhesive results in a joint being formed. For example, the joint may be an overlap joint, a lap joint, a butterfly joint, a seam associated with a hem, and so forth.
In some implementations, the adhesive may be deposited onto the fabric item in one or more of a continuous line, a non-continuous line, one or more droplets, a single line, or multiple lines. In some implementations, lines or droplets may be deposited onto the fabric item according to one or more of uniform shape, uniform size, uniform separation between adjacent droplets, varying shape, varying size, or varying separation between adjacent droplets. The adhesive may also be deposited onto the fabric item in a pattern tailored according to any one or more of a hem, a desired seam size, a desired seam strength, or a desired accommodation of stretch of at least a portion of the fabric item.
In some implementations, the system 100 or the fabric joining device 102 may include a robot. The robot may include or correspond to the placement apparatus 120, the adhesive applicator 130, or a combination thereof. The robot may also be a standalone device or part of another device. The robot may be configured to move fabric items onto, and remove fabric items from, the one or more sections 104. In some implementations, the robot may be mounted on a gantry above the one or more sections 104. In other implementations, the robot may be freestanding. The robot may include an articulated arm attached to a head that may selectively hold and release the fabric item. In some implementations, the head may include clamps or other grippers that may selectively hold or release the fabric item. In other implementations, the head may include an electrostatic plate to selectively hold or release the fabric item. In some implementations, the head may include a vacuum assembly, such as a perforated plate coupled to a vacuum pump, to selectively hold or release the fabric item.
The robot may also include a sensor that may be used to assist with positioning of the head with respect to a fabric item on the one or more sections 104. For example, the sensor may include a camera. For instance, the camera may capture an image of the fabric item and relay the image to the controller. The controller 128 may determine the position, orientation, and/or extent of the fabric item on the one or more sections 104 with respect to the alignment indicia 112. The controller 128 may direct the head to the fabric item according to the determined position, orientation, and/or extent of the fabric item on the one or more sections 104 with respect to the alignment indicia 112. In some implementations, the controller 128 may use images captured by the one or more cameras in controlling operation of any one or more sections 104, the one or more actuators 116, the vacuum assembly, the adhesive applicator 130, the cutter, the robot, or any combination thereof.
In some implementations, one or more other finishing operations may be performed at the location of the fabric joining device 102 or at another workstation or another device. For example, one or more portions of the fabric item may be trimmed or hemmed. The system 100 or the fabric joining device 102 may include a printer. The printer may be configured to print a design onto the fabric item. The printer may include a printhead that is movable with respect to the fabric item while printing the design. The printer may include at least one of: a Direct To Garment (DTG) printer, a sublimation printer, or a screen-printing printer, or a combination thereof. In some implementations, the fabric item on which the printing is performed may be a single-color fabric, such as white color fabric, and the printer may print on part of or on the entire fabric to dye, colorize, or create a customized color and design pattern. In another implementation, the printing by the printer may be performed as an on-demand process, based on the requirements of the particular job. For example, the color(s) and/or pattern(s) applied by the printer may be tailored for the manufacture of each individual fabric item.
In some implementations, the fabric item may be transported to a packaging station at which the fabric item is packaged for further transportation.
By using the techniques and systems described herein, the manufacturing efficiency for manufacturing the fabric item may increase because multiple operating steps for manufacturing the fabric item may be performed at one location, such as at the fabric joining device 102. The manufacturing efficiency may also increase based on not having to perform the steps of removing the unnecessary creases. The variation between individual manufactured fabric items may also be reduced based on the fabric joining device 102 or the system 100 applying the adhesive at the correct locations and with the correct amount for that particular fabric item. In addition, the variation between individual fabric items may be reduced based on the fabric joining device 102 applying the correct pressure at each of the joint regions and folding the fabric item correctly each time.
The adhesive applicator 130, as described above, may apply an adhesive to the fabric item 202 at location 204. The one or more actuators 116 may be coupled to the one or more sections 104 via the hinge 114. The actuators 116B and 116C may rotate the third section 104C and the fourth section 104D about the axis of rotation 118 toward the first section 104A and the second section 104B. The rotation of the third section 104C and the fourth section 104D toward the first section 104A and the second section 104B may press the first portion of the fabric item 202 and the second portion of the fabric item 202 together to join the first and second portions of the fabric item 202 to create a hem.
Although the fabric item 202 in
In some implementations, once the rotation of the one or more sections 104 is complete the vacuum assembly may be configured to stop applying a vacuum to one or more of the sections 104 to release corresponding portions of the fabric item 202.
The fabric joining device 102 may include the masking template 110, as described above. The masking template 110 may be configured to be complementary to a shape of the first portion of the fabric item 202, the second portion of the fabric item 202, or both. For example, the masking template 110 may have a shape that corresponds to an outline of the shape of the sleeve for the t-shirt which creates an outline that is associated with the fabric item.
The one or more sections 104 may include the perforations 106 as described above. The perforations 106 may be coupled to the vacuum assembly. The vacuum assembly may be coupled underneath the one or more sections 104 to use airflow to hold a fabric item 202 in place on the one or more sections 104. For example, the vacuum may be applied through the perforations 106 of each of the one or more sections 104 to hold the fabric item 202 in place.
The fabric joining device 102 may include one or more spacers 108, as described herein. The one or more spacers 108 may be disposed within the one or more sections 104. The one or more spacers 108 may be configured to support one or more non-joint regions of the fabric item 202. The support of the one or more non-joint regions may result in the avoidance of the formation of one or more creases in the fabric item 202.
The adhesive applicator 130 may be configured to apply the adhesive, as described above, on the fabric item 202 at location 302. After the adhesive has been applied, the hinges 114A and 114B may be configured to rotate second section 104B about the axis of rotation 118A (e.g., using the one or more actuators 116) to fold the second portion of the fabric item 202 onto the first portion of the fabric item 202. This action may also press the first portion of the fabric item 202 and the second portion of the fabric item 202 together to join the first and second portions of the fabric item 202. The folding and joining of the fabric item 202 may result in the formation of a hem.
After the fabric joining device 102 has folded the fabric item 202, the adhesive applicator 130 may be further configured to apply the adhesive on the fabric item 202 at a location 304. After the adhesive has been applied the hinge 114C may be configured to rotate the third section 104C about the axis of rotation 118B (e.g., using the one or more actuators 116) to fold a third portion of the fabric item 202 onto a fourth portion of the fabric item 202. This action may also press the third portion of the fabric item 202 and the fourth portion of the fabric item 202 together to join the third and fourth portions of the fabric item 202. The folding and joining of the fabric item 202 results in the formation of a joint, such as an overlap joint, a lap joint, a butterfly joint, or the like. After the portions of the fabric item 202 have been joined, the curing system 138, as described herein, may be configured to cure the adhesive at each of the locations 302 and 304.
The adhesive applicator 130, as described in
At 406, the adhesive applicator 130 may be configured to apply the adhesive on the fabric item 202 at location 408. After the adhesive has been applied, the second section 104B may be rotated about an axis of rotation 118B (e.g., using the one or more actuators 116) toward the first section 104A to fold a third portion of the fabric item 202 onto a fourth portion of the fabric item 202. This action may also press the third portion of the fabric item 202 and the fourth portion of the fabric item 202 together to join the third and fourth portions of the fabric item 202. At 410, the folding and joining of the fabric item 202 results in the formation of a joint, such as an overlap joint, a lap joint, a butterfly joint, or the like. In one example, the formation of this joint results in the creation of a shirt sleeve. After the portions of the fabric item 202 have been formed, the curing system 138, as described above, may be configured to cure the adhesive at each of the locations 404 and 408.
At 506, after the adhesive has been applied, the first section 104A may be rotated about the axis of rotation 118A (e.g., using the one or more actuators 116) to fold a first portion of the fabric item 202 onto itself. The second section 104B may be rotated about the axis of rotation 118B (e.g., using the one or more actuators 116) to fold a second portion of the fabric item 202 onto the first portion of the fabric item 202. This action may also include pressing together the second portion of the fabric item 202 and the first portion of the fabric item 202 together to join the first portion of the fabric item 202 and the second portion of the fabric item 202 together therebetween.
At 512, the curing system 138 may be applied at location 514 to cure the adhesive and form a joint between the first portion of the fabric item 202 and the second portion of the fabric item 202.
The fabric joining device 102 may also include the one or more spacers 108. In one example, the spacer 108A may be disposed between the first section 104A and the second section 104B and the third section 104C. The spacer 108A may be configured to support a non-joint region of the first portion of the fabric item 202, a non-joint region of the second portion of the fabric item 202, or both. The support of the non-joint region may result in the avoidance of the formation of a crease in the fabric item 202. Although the spacer 108A in
The fabric joining device 102 may also include a spacer 108B. The spacer 108B may be disposed between the second section 104B and the third section 104C. Although the spacer 108B in
The fabric joining device 102 may also include the hinges 114. The hinges 114 may be configured to couple the one or more sections 104 to each other or to the one or more spacers 108. For example, the hinge 114A may couple the first section 104A to the spacer 108A. In another example, the hinge 114B may couple the second section 104B to the fourth section 104D. The hinge 114C may be configured to couple the third section 104C to the fifth section 104E. The hinges 114 may be configured to enable rotation of the one or more sections 104 toward each other to fold and/or press the fabric item 202. For example, the fourth section 104D may rotate about the non-parallel axis of rotation 118B to fold a third portion of the fabric item 202 onto the second portion of the fabric item 202. The fifth section 104E may rotate about the non-parallel axis of rotation 118C to fold a fourth portion of the fabric item 202 onto the second portion of the fabric item 202. In this example, the folds may result in the creation of one or more tabs. The adhesive applicator 130 may be configured to apply the adhesive at a location associated with the one or more tabs. Continuing this example, the first section 104A may rotate about the axis of rotation 18A to fold the first portion of the fabric item 202 onto the second portion, the third portion of the fabric item 202 and/or the fourth portion of the fabric item 202. This action may also press the first portion of the fabric item 202 to join the third portion of the fabric item 202 and the fourth portion of the fabric item 202. The curing system 138 may be configured to cure the adhesive at the joints where the first and third portion of the fabric item 202 were joined and the first and fourth portion of the fabric items were joined.
At 706, a second fabric item 708 may be placed at the location 704B. The second fabric item 708 may be pressed to join the fabric item 202. The curing system 138 may be used to cure the adhesive at the location 704B. In other implementations, the curing of the adhesive may be performed later. As illustrated in
At 710, one or more portions of the fabric item 202 are folded using the fabric joining device 102, as described in
At 714, the fabric joining device 102, as described in
At 716, the curing system 138, as described in
At 804, the alignment sensor 126 may be configured to generate sensor data indicating a first position of the fabric item 202 relative to the alignment indicia 112. The controller 128, as described in
At 806, one or more operations are performed on the fabric item 202, as described in
In the example illustrated in
At 810, the first section 104A may be transferred to the curing system 138. The curing system 138 may be configured to cure the adhesive by applying pressure, applying heat, applying moisture, exposing the adhesive to ambient conditions, or waiting for a predetermined duration of time. The application of heat may include a hot press (hot surface), heating paddles, hot air, infra-red (IR) radiation, microwave, and so forth. The curing of the adhesive results in a joint being formed between the portions of the fabric item 202.
At 812, the fabric item 202 may be transferred to another workstation where the fabric item 202 is used for the next manufacturing process. For example, the fabric item 202 may be a shirt sleeve. In this example, the fabric item 202 may be transferred to a workstation that attaches the shirt sleeve to a body of a shirt. In another example, the fabric item 202 may be placed in a holding area where the fabric item 202 may be retrieved at a later time to be used in the next manufacturing process. In another example, the fabric item 202 may be transferred to a workstation where the fabric item is packaged and placed into inventory.
The method 900 includes, at block 902, mounting a first portion of the fabric item onto a surface of a first portion of a fabric joining device. The method 900 may also include, at block 904, mounting a second portion of the fabric item onto a surface of a second portion of a fabric joining device. For example, the fabric joining device 102 can include the placement apparatus 120, which is configured to retrieve and place the first portion of the fabric item 202 on the first section 104A, the second portion of the fabric item 202 on the second section 104B, or both. Continuing this example, the fabric joining device 102 may further include an alignment sensor 126. The alignment sensor 126 may be configured to generate sensor data indicating a first position of the first portion of the fabric item 202 relative to the alignment indicia 112, a second position of the second portion of the fabric item 202 relative to the alignment indicia 112, or both. The placement apparatus 120, based on the sensor or direction from the controller 128, may be further configured to reposition the first portion of the fabric item 202, the second portion of the fabric item 202, or both, so that the fabric item 202 is positioned correctly relative to the alignment indicia 112.
The method 900, includes, at block 906, rotating, using one or more first actuators of the fabric joining device, the second section about an axis of rotation orthogonal to a normal of the surface of the first section to fold the second portion of the fabric item onto the first portion of the fabric item and to press the first portion of the fabric item and the second portion of the fabric item together to join the first portion of the fabric item and second portion of the fabric item. For example, using the one or more actuators 116 of the fabric joining device 102, the first section 104A may be rotated about the axis of rotation 118A orthogonal to a normal of the second section 104B to fold the first portion of the fabric item 202 onto the second portion of the fabric item 202 and to press the first portion of the fabric item 202 and the second portion of the fabric item 202 together to join the first portion of the fabric item 202 and second portion of the fabric item 202. In another implementation, the second section 104B may be rotated about the axis of rotation 118A orthogonal to a normal of the first section 104A to fold the second portion of the fabric item 202 onto the first portion of the fabric item 202 and to press the first portion of the fabric item 202 and the second portion of the fabric item 202 together to join the first portion of the fabric item 202 and second portion of the fabric item 202.
In some implementations, the method 900 for manufacturing the fabric item 202 may include using the one or more actuators 116 of the fabric joining device 102 to rotate one or more third sections 104C to fold one or more third portions of the fabric item 202 onto the first portion of the fabric item 202, the second portion of the fabric item 202, or both.
The method 900 for manufacturing the fabric item 202 may also include applying an adhesive to a first joint region of the first portion of the fabric item 202, to a second joint region of the second portion of the fabric item 202, or both. The method 900 may further include pressing together the first portion of the fabric item 202 and second portion of the fabric item 202 to adhere the first joint region to the second joint region to form a joint therebetween. The method 900 may also include removing the fabric item 202 and moving the fabric item 202 to a curing system to cure the adhesive. In another implementation, the removing step is omitted, and the adhesive is cured at the fabric joining device 102, as described herein.
Although one (1) fabric item 202 is illustrated or discussed in
As one example of a mechanism to releasably hold portions of the fabric item, the one or more sections 1004 may include perforations 1006 coupled to a vacuum assembly. In this example, the vacuum assembly may be coupled underneath the one or more sections 1004 to apply a suction to hold the portions of the fabric item in place. The one or more sections 1004 and the vacuum assembly may be configured such that a vacuum applied through the perforations 1006 of an individual one of the one or more sections 1004, such as the first section 1004A, may be controlled independently of a vacuum applied through the perforations 1006 of another one of the one or more sections 1004, such as the second section 1004B. For example, a vacuum may be applied through the perforations 1006 of the first section 1004A while no vacuum is applied through the perforations 1006 of the second section 1004B. In another example, a vacuum may be applied through the perforations 1006 of any one or more of the first section 1004A, the second section 1004B, the third section 1004C, the fourth section 1004D, the fifth section 1004E, or the sixth section 1004F while no vacuum is applied through the perforations 1006 of any one or more of the other sections 1004. Additionally, a vacuum may apply through the perforations 1006 of at least one of the one or more sections 1004 at a first strength, while the vacuum applied through the perforations 1006 of one or more other sections 1004 is at a second strength, where the first strength and the second strength are different.
As another example of a mechanism to releasably hold portions of the fabric item, one or more of the sections 1004 may include an electrostatic plate. In this example, a static electrical charge applied to the electrostatic plate may be turned on to hold a portion of the fabric item or off to release the portion of the fabric item. Other examples of mechanisms to releasably hold portions of the fabric item include, without limitation, a fold down frame assembly, a hook and loop fastener assembly, a releasable adhesive assembly, inertia, and so forth.
The one or more sections 1004 may include a plurality of individual sectors 1040. Each sector 1040 functions to selectively apply heat to targeted areas of the fabric item. In some embodiments, each sector 1040 integrates a printed circuit board (PCB) responsible for delivering heat to specific portions of the fabric. For example, the section 1004A includes sector 1040A, section 1004B includes sector 1040B, sections 1004C includes sector 1040C, section 1004D includes sector 1040D, section 1004E includes 1040E, and section 1004F includes 1040F. Each sector 1040 utilizes its PCB to apply heat to the joining regions of two fabric pieces, thereby forming a secure joint.
In some implementations, the system 1000 includes a vision system 1050. The vision system 1050 is configured to determine a location of the first portion of the fabric item, the second portion of the fabric item, or both. The vision system 1050 is further configured to determine one or more instructions that cause the first section, the second section, or both to move to a location to align the first portion of the fabric item with the second portion of the fabric item. To move to the location each of the one or more sections 1004 are configured to move along an X-Y-Theta planar space to facilitate the alignment of the second portion of the fabric item relative to the first portion of the fabric item prior to the one or more actuators 1016 moving one section (e.g., the first section 1004A) towards another section (e.g., the second section 1004B).
In some implementations, the fabric joining device 1002 may include a masking template 1010, as described in
In some implementations, the fabric joining device 1002 may include one or more hinges 1014. The one or more hinges 1014 may be configured to couple the one or more sections 1004 to each other. For example, the hinge 1014A may be configured to couple the second section 1004B to the first section 1004A. In other examples, the hinge 1014B may be configured to couple the fourth section 1004D to the third section 1004C, the hinge 1014C may be configured to couple the fifth section 1004E to the fourth section 1004D, and the hinge 1014D may be configured to couple the sixth section 1004F to the second section 1004B. The hinge 1014 may be configured to enable one or more of the sections 1004 to rotate relative to one or more other sections 1004. For example, the hinge 1014A may be configured to enable the first section 1004A to rotate about the axis of rotation 1018A orthogonal to a normal of the surface of the second section 1004B to fold the first portion of the fabric item onto the third portion of the fabric item. This action may also press the first portion of the fabric item and the third portion of the fabric item together to join the first and third portions of the fabric item. Additionally, this action may also cause the first sector 1040A, the second sector 1040B, or both to apply heat to cure the adhesive to form a scam between the first and third portions of the fabric item. The rotation of the first section 1004A may align an edge of the first portion of the fabric item and an edge of the third portion of the fabric item to form a butterfly joint therebetween.
In another example, the hinge 1014B may be configured to enable the third section 1004C to rotate about the axis of rotation 1018B orthogonal to a normal of the surface of the fourth section 1004D to fold the second portion of the fabric item onto the third portion of the fabric item. This action may also press the second portion of the fabric item and the third portion of the fabric item together to join the second and third portions of the fabric item. Additionally, this action may also cause the third sector 1040C, the fourth sector 1040D, or both to apply heat to cure the adhesive to form a seam between the second and third portions of the fabric item. The rotation of the third section 1004C may align an edge of the second portion of the fabric item and an edge of the third portion of the fabric item to form a butterfly joint therebetween.
In another example, the hinge 1014C and/or the hinge 114D may be configured to enable the fifth section 1004E and/or the sixth section 1004F to rotate about the axis of rotation 1018C orthogonal to a normal of the surface of the second section 1004B and/or the fourth section 1004D to fold a portion of the fabric item onto another portion of the fabric item and to press those portions of the fabric item together. This action may also cause the second sector 1040B, the fourth sector 1040D, the fifth sector 1040E, the sixth sector 1040F or a combination thereof, to apply heat to cure the adhesive to form a seam between the portions of the fabric item.
In other implementations, the axis of rotation 1018 may be at an angle that corresponds to the type of fold necessary for a particular fabric item. In this implementation the angle of the axis of rotation 1018 may be non-parallel to the surface of one or more of the sections 1004.
In the example illustrated in
The controller 1028 may be configured to monitor and control the operations of the fabric joining device 1002 and the individual components of the fabric joining device 1002. For example, the controller 1028 may be configured to send control signals to the one or more actuators 1016 during manufacturing of the fabric item that includes the first portion, the second portion, the third portion, or a combination thereof. In other examples, the controller 1028 may be configured to direct the placement apparatus 1020. The controller 1028 may include one or more software applications stored in memory and executed using one or more processors in a computing system. The controller 1028 may receive data from one or more sensors, such as an alignment sensor, the vision system 1050, a camera, a barcode reader, a quick response (QR) code reader, a radio frequency identification (RFID) tag reader, a proximity sensor, or the like. The one or more sensors are associated with the individual apparatuses of the fabric joining device 1002. The controller 1028 may be configured to process the data and direct the operation of one or more components of the fabric joining device 1002.
The system 1000 or the fabric joining device 1002 may also include a cutter. The cutter may be configured to cut fabric into a shape that is associated with the fabric item being manufactured. For example, the cutter may cut the fabric into the shape of a t-shirt sleeve or into the shape associated with an undergarment, and so forth. The cutter may also be configured to make one or more intermediate cuts. For example, an intermediate cut may be associated with an eventual seam, neckline, armhole, or hemline of the fabric item. In some implementations, the one or more intermediate cuts may be omitted. In another implementation, the cutter may include a blade on a carrier that is movable with respect to the fabric while cutting the fabric.
In yet another implementation, the cutter is controlled by the controller 1028. The cutter may have a sensor that may detect a feature associated with the fabric item. For example, a printed design or a fiducial on or in fabric associated with the fabric item. The controller 1028 may use information of the detected feature to direct or control the cutter to cut the fabric in a shape associated with the fabric item. For example, the controller 128 may direct the cutter to cut at specific locations, cut predetermined lengths, shapes, and so forth.
The system 1000 or the fabric joining device 1002 may include an adhesive applicator 1030. The adhesive applicator 1030 may include an articulated arm 1032 attached to a dispensing nozzle 1034. The dispensing nozzle 1034 may be manipulated by the articulated arm 1032 to perform dispensing of adhesive at one or more locations on the fabric item. The adhesive applicator 1030 may also include a sensor 1036. The sensor 1036 may be configured to generate sensor data indicating location of where the adhesive was dispensed, particular pattern associated with the dispensing of the adhesive, amount of adhesive dispensed, and so forth.
The adhesive may be applied in the form of a liquid deposited onto the fabric item. The adhesive may permeate at least partially into the fabric of the fabric item. In other implementations, the adhesive may at least partially remain on a surface of the fabric of the fabric item. The adhesive may be configured to be cured by a placement apparatus 1020, as described in more detail below. The adhesive may be deposited onto the fabric item in one or more of a continuous line, a non-continuous line, one or more droplets, a single line, or multiple lines. In some implementations, lines or droplets may be deposited onto the fabric item according to one or more of uniform shape, uniform size, uniform separation between adjacent droplets, varying shape, varying size, or varying separation between adjacent droplets. The adhesive may also be deposited onto the fabric item in a pattern tailored according to any one or more of a hem, a desired seam size, a desired seam strength, or a desired accommodation of stretch of at least a portion of the fabric item.
In some implementations, the system 1000 or the fabric joining device 1002 may include a robot. The robot may include or correspond to the placement apparatus 120, the adhesive applicator 130, or a combination thereof. The robot may also be a standalone device or part of another device. The robot may be configured to move fabric items onto, and remove fabric items from, the one or more sections 1004. In some implementations, the robot may be mounted on a gantry above the one or more sections 1004. In other implementations, the robot may be freestanding. The robot may include an articulated arm attached to a head that may selectively hold and release the fabric item. In some implementations, the head may include clamps or other grippers that may selectively hold or release the fabric item. In other implementations, the head may include an electrostatic plate to selectively hold or release the fabric item. In some implementations, the head may include a vacuum assembly, such as a perforated plate coupled to a vacuum pump, to selectively hold or release the fabric item.
The robot may also include a sensor that may be used to assist with positioning of the head with respect to a fabric item on the one or more sections 1004. For example, the sensor may include a camera. For instance, the camera may capture an image of the fabric item and relay the image to the controller. The controller 1028 may determine the position, orientation, and/or extent of the fabric item on the one or more sections 1004. The controller 1028 may direct the head to the fabric item according to the determined position, orientation, and/or extent of the fabric item on the one or more sections 1004. In some implementations, the controller 1028 may use images captured by the one or more cameras in controlling operation of any one or more sections 1004, the one or more actuators 1016, the vacuum assembly, the adhesive applicator 1030, the cutter, the robot, or any combination thereof.
In some implementations, one or more other finishing operations may be performed at the location of the fabric joining device 1002 or at another workstation or another device. For example, one or more portions of the fabric item may be trimmed or hemmed. The system 1000 or the fabric joining device 1002 may include a printer. The printer may be configured to print a design onto the fabric item. The printer may include a printhead that is movable with respect to the fabric item while printing the design. The printer may include at least one of: a Direct To Garment (DTG) printer, a sublimation printer, or a screen-printing printer. In some implementations, the fabric item on which the printing is performed may be a single-color fabric, such as white color fabric, and the printer may print on part of or on the entire fabric to dye, colorize, or create a customized color and design pattern. In another implementation, the printing by the printer may be performed as an on-demand process, based on the requirements of the particular job. For example, the color(s) and/or pattern(s) applied by the printer may be tailored for the manufacture of each individual fabric item.
The fabric joining device 1002 may include or be associated with a placement apparatus 1020 (e.g., a robot). The placement apparatus 1020 may include an articulated arm 1022 attached to a gripper 1024. The gripper 1024 may be manipulated by the articulated arm 1022 to perform operations on the fabric item. For example, the gripper 1024 may be configured to retrieve and place the first portion of the fabric item on the first section 1004A, the second portion of the fabric item on the third section 1004C, the third portion of the fabric item on the second section 1004B, the fourth section 1004D, the fifth section 1004E, the sixth section 1004F, or a combination thereof. Continuing this example, the placement apparatus 1020 may further include an alignment sensor 1026. The alignment sensor 1026 may be configured to generate sensor data indicating a position of the fabric item on the fabric joining device 1002. The placement apparatus 1020 may be further configured to, based on the sensor data, reposition, using the gripper 1024, the fabric item on the fabric joining device 1002. The gripper 1024 may further be configured to include one or more sectors, as further described in
In other implementations, the fabric joining device 1002 may include one or more spacers, as described in
In some implementations, the fabric joining device 1002 may include alignment indicia, as described in
In some implementations, the fabric item may be transported to a packaging station at which the fabric item is packaged for further transportation.
By using the techniques and systems described herein, the manufacturing efficiency for manufacturing the fabric item may increase because multiple operating steps for manufacturing the fabric item may be performed at one location, such as at the fabric joining device 1002. The manufacturing efficiency may also increase based on not having to perform the steps of removing the unnecessary creases. The variation between individual manufactured fabric items may also be reduced based on the fabric joining device 1002 or the system 1000 applying the adhesive at the correct locations and with the correct amount for that particular fabric item. In addition, the variation between individual fabric items may be reduced based on the fabric joining device 1002 applying the correct pressure and heat at each of the joint regions and folding the fabric item correctly each time.
The placement apparatus 1102 includes an articulated arm 1106 attached to a gripper 1104. The gripper 1104 includes one or more sectors 1108. Each of the sectors includes perforations 1106 coupled to a vacuum assembly. The vacuum assembly may be coupled underneath the one or more sectors 1108 to apply a suction to hold the portions of the fabric item in place. The one or more sectors 1108 and the vacuum assembly may be configured such that a vacuum applied through the perforations 1106 of an individual one of the one or more sectors 1108, such as a first sector 1108A, may be controlled independently of a vacuum applied through the perforations 1106 of another one of the one or more sectors 1108, such as the second sector 1108B. For example, a vacuum may be applied through the perforations 1106 of the first sector 1108A while no vacuum is applied through the perforations 1106 of a tenth sector 1108J. In another example, a vacuum may be applied through the perforations 1106 of any one or more of the first sector 1108A, the second sector 1108B, the third sector 1108C, the fourth sector 1108D, the fifth sector 1108E. the sixth sector 1108F, the seventh sector 1108G, the eight sector 1108H, the ninth sector 1108I, or the tenth sector 1108J while no vacuum is applied through the perforations 1106 of any one or more of the other sectors 1108. Additionally, a vacuum may apply through the perforations 1106 of at least one of the one or more sectors 1108 at a first strength, while the vacuum applied through the perforations 1106 of one or more other sectors 1108 is at a second strength, where the first strength and the second strength are different.
In some embodiments, the individual sectors 1108 can selectively apply pressure, heat, or both to specific areas of the fabric item. Each sector 1108 can include an actuator to ensure even pressure distribution when joining the first and second fabric portions together. Additionally, the heating element for each sector 1108 includes a Printed Circuit Board (PCB), enabling uniform heat distribution.
For example, the gripper 1104 positions the first fabric item (e.g., pocket, collar, sleeve, gusset) on the second fabric item (e.g., shirt, garment). The gripper 1104 can then activate specific sectors 1108 to apply both pressure and heat to that first fabric item, thereby joining it securely to the second fabric item. To illustrate, the gripper 1104 may activate sectors 1108C, 1108D, 1108E, and 1108F to deliver both pressure and heat, while the remaining sectors 1108A, 1108B, 1108G, 1108H, 1108I, and 1108J remain inactive.
The gripper 1104 may be manipulated by the articulated arm 1106 to perform operations on the fabric item. For example, the gripper 1104 may be configured to retrieve and place the first portion of the fabric item on the fabric joining device. Continuing this example, the placement apparatus 1102 may further include an alignment sensor, as described in
By using the techniques and systems described herein, the placement apparatus 1102 leverages the described techniques and systems to deliver several key advantages for precise fabric joining applications. These advantages work in concert to create a highly effective and versatile system. The gripper 1104 employs a modular design with individual sectors 1108. Each sector 1108 integrates dedicated actuators and PCB heating elements. This modularity allows for the selective activation of specific sectors 1108, enabling targeted pressure and heat application to precise areas of the fabric. This approach optimizes the joining process by focusing pressure and heat where needed, while minimizing potential damage to the fabric. Integrated actuators within each sector 1108 ensure consistent pressure distribution across the entire joining area. This uniformity minimizes the risk of fabric deformation or inconsistencies in seam quality, leading to reliable and robust joint formation. Further enhancing the capabilities of the placement apparatus 1102, PCB heating elements offer precise temperature control within each sector 1108. This level of control allows for tailoring the heat application to the specific requirements of different fabric types and joining techniques. By precisely controlling the heat, the placement apparatus 1102 ensures optimal results without compromising material integrity. This combination of modularity, precise pressure control, and targeted heating enhances the versatility of the placement apparatus 1102. This versatility allows the system 1100 to handle a wider range of fabric types and applications. By adapting to various garment construction needs, the system 1100 becomes a valuable tool for a broader range of manufacturing processes.
The fabric joining device 1202 includes one or more sections 1204. Each of the sections 1204 are configured to move along an X-Y-Theta planar space to facilitate alignment of a first portion of the fabric item relative to a second portion of the fabric item prior to the one or more actuators 1216 moving a section (e.g., a first section 1204A) toward another section (1204B).
The fabric joining device 1202 includes one or more sections 1204 configured to move along an X-Y-Theta planar space. This movement facilitates the alignment of a first portion of a fabric item relative to a second portion before joining them. For example, the fabric joining device 1202 can include a first section 120A, a second section 1204B, a third section 1204C, a fourth section 1204D, or a combination thereof. Each of these sections 1204 are configured to move along an X-Y-Theta planar space via one or more components 1220. The one or more components 1220 may be coupled to the fabric joining device 1202. For example, the one or more components 1220 can include, a first component 1220A, a second component 1220B, a third component 1220C, the fourth component 1220D, a fifth component 1220E, and so forth.
In some implementations, the fabric joining device 1202 may include one or more hinges 1214. The one or more hinges 1214 may be configured to couple the one or more sections 1204 to each other. For example, the hinge 1214 may be configured to couple the first section 1204A to the second section 1204B. In other examples, the hinge 1214 may be configured to couple one or more other sections 1204 to each other, as described in
The fabric joining device 1202 also includes one or more actuators 1216. The one or more actuators 1216 may comprise an electrically operated mechanism, such as one or more of a motor, solenoid, piezoelectric material, electroactive polymer, shape-memory alloy, and so forth. The one or more actuators 1216 may include, be coupled to, or in communication with a controller, as described in
The fabric joining device 1202 can include a vision system or an alignment sensor as described in
By using the techniques and systems described herein, the fabric joining device 1202 achieves several key technical advantages, such as enhanced alignment accuracy. The vision system and movable sections 1204 enable accurate alignment of the fabric portions before joining. This positioning minimizes inconsistencies and ensures optimal seam quality. Another technical advantage includes controlled pressure distribution. The combination of a gap and selectively actuated sections 1204 or sectors enables for targeted and even distribution of pressure across the joining area. This controlled pressure application minimizes fabric deformation and ensures strong, reliable seams. Another technical advantage includes secure bonding. Secure bonding is achieved through the one or more sections 1204 ability to rotate and achieve parallelism. This facilitates a secure pressing action between the fabric portions, and when combined with targeted pressure application, promotes strong and durable bonds. Another technical advantage includes adaptability to a wider range of fabric types, which is made possible by the selective pressure and heat application capabilities. By tailoring the joining process to specific fabric requirements, the fabric joining device 1202 ensures consistent results regardless of the fabric material.
At 1304, a controller, as described in
At 1306, the controller is configured to instruct the second section 1204B to rotate and translate along the X-Y-Theta planar space to align with the first section 1204A. In some implementations, after the vision system has confirmed that the sections are aligned, an adhesive applicator may be configured to apply the adhesive on the fabric item. The fabric joining device may fold the fabric item to form a joint. In other implementations, after the vision system has confirmed that the sections are aligned, one or more portions of the fabric item are folded using the fabric joining device, as described in
The actuator 1404 is configured to enable the section 1406 to selectively apply pressure, heat, or both to specific areas of the fabric item. The actuator 1404 is configured to move the section 1406 up and down in a linear motion. This movement facilitates the application of pressure to specific areas of the fabric during folding or seam creation. While
The fabric joining device 1502 is configured to include a first section 1506A, a second section 1506B and a pivot point 1504. The pivot point 1504 is configured to couple the first section 1506A to the second section 1506B. In some implementations, the pivot point 1504 includes a hinge and an actuator as described in
The fabric joining device 1510 includes a heated vacuum assembly 1510 and an actuator. The heated vacuum assembly 1510 can be the vacuum assembly 1402 of
Particular aspects of the disclosure are described below in sets of interrelated Examples:
According to Example 1, a fabric joining device includes a first section configured to releasably hold a first portion of a fabric item on a surface of the first section, wherein the first section comprises a first plurality of sectors, wherein each sector is configured to selectively apply heat to the first portion of the fabric item; a second section configured to releasably hold a second portion of the fabric item on a surface of the second section, wherein the second section comprises a second plurality of sectors, wherein each sector is configured to selectively apply heat to the second portion of the fabric item; and one or more first actuators coupled to the second section and configured to move the second section toward the first section to fold the second portion of the fabric item onto the first portion of the fabric item and to press the first portion of the fabric item and the second portion of the fabric item together to join the first and second portions of the fabric item.
Example 2 includes the fabric joining device of Example 1, wherein the first section, the second section, or both are further configured to move along an X-Y-Theta planar space to facilitate alignment of the second portion of the fabric item relative to the first portion of the fabric item prior to the one or more first actuators moving the second section toward the first section.
Example 3 includes the fabric joining device of any of Example 1 or Example 2, and further includes a vision system configured to determine a location of the first portion of the fabric item, the second portion of the fabric item, or both; and determine one or more instructions that cause the first section, the second section, or both to move to a location to align the first portion of the fabric item with the second portion of the fabric item.
Example 4 includes the fabric joining device of any of Example 1 to Example 3, wherein the second section includes a pivot point configured to rotate, via the one or more first actuators, the second section toward the first section until the second section is parallel to the first section with a gap between the second section and the first section.
Example 5 includes the fabric joining device of Example 4, wherein the gap enables a sector from the first plurality of sectors, the second plurality of sectors, or both, to be linearly actuated to facilitate equal pressure distribution and heat to join the first and second portions of the fabric item.
Example 6 includes the fabric joining device of any of Example 1 to Example 5 and further includes: one or more third sections configured to releasably hold one or more third portions of the fabric item to respective surfaces of the one or more third sections, wherein the third section comprises a third plurality of sectors, wherein each sector is configured to selectively apply heat to the one or more third portions of the fabric item; and one or more second actuators coupled to the one or more third sections and configured to move the one or more third sections to fold the one or more third portions of the fabric item onto the first portion of the fabric item, the second portion of the fabric item, or both, to position the one or more third portions of the fabric item for formation of a joint.
Example 7 includes the fabric joining device of Example 6, wherein each of the one or more third sections are further configured to move along an X-Y-Theta planar space to facilitate alignment of the one or more third sections of the fabric relative to the second portion of the fabric item, the first portion of the fabric item, or both prior to the one or more first actuators moving the second section toward the first section, the one or more second actuators moving the one or more third sections to fold the one or more third portions of the fabric item onto the first portion of the fabric item, the second portion of the fabric item, or both.
Example 8 includes the fabric joining device of Example 7, wherein the one or more third sections rotate about non-parallel axes of rotation.
Example 9 includes the fabric joining device of any of Example 1 to Example 8, wherein the one or more first actuators, one or more sectors of the first plurality of sectors, one or more sectors of the second plurality of sectors, or a combination thereof, are configured to apply a pressure to a joint region of the second portion of the fabric item and a joint region of the first portion of the fabric item to form a joint therebetween.
Example 10 includes the fabric joining device of Example 9 and further includes a spacer positioned with respect to the first section and the second section to support a non-joint region of the first portion of the fabric item, a non-joint region of the second portion of the fabric item, or both.
Example 11 includes the fabric joining device of any of Example 1 to Example 10 and further includes: one or more additional sections configured to releasably hold one or more additional portions of the fabric item, wherein the one or more additional sections comprise a plurality of one or more additional sectors, wherein each additional sector is configured to selectively apply heat to the one or more additional portions of the fabric item; and one or more additional actuators coupled to the one or more additional sections and configured to move the one or more additional sections to fold the one or more additional portions of the fabric item onto one or more third portions of the fabric item.
Example 12 includes the fabric joining device of any of Example 1 to Example 11 and further includes an adhesive applicator configured to, before movement of the second section, apply an adhesive to a first joint region of the first portion of the fabric item, to a second joint region of the second portion of the fabric item, or both, such that pressing together and heating the first portion of the fabric item and the second portion of the fabric item adheres the first joint region and the second joint region to form a joint.
Example 13 includes the fabric joining device of any of Example 1 to Example 12 and further includes an alignment sensor configured to generate sensor data indicating a first position of the first portion of the fabric item, a second position of the second portion of the fabric item, or both.
Example 14 includes the fabric joining device of Example 13, wherein the first section, the second section, or both are configured to move to a location to align the first portion of the fabric item with the second portion of the fabric item based on the sensor data.
Example 15 includes the fabric joining device of any of Example 1 to Example 14 and further includes a controller configured to send control signals to control the one or more first actuators, the first plurality of sectors, the second plurality of sectors, or a combination thereof, during manufacturing of the fabric item.
Example 16 includes the fabric joining device of any of Example 1 to Example 15, wherein the first section, the second section, or both, further comprise a retention mechanism to releasably hold a respective portion of the fabric item, wherein the retention mechanism includes one or more of: a vacuum assembly, a fold down frame assembly, a hook and loop fastener assembly, or a releasable adhesive assembly.
Example 17 includes the fabric joining device of any of Example 1 to Example 16 and further includes a placement apparatus comprising one or more sections configured to releasably hold and place the first portion of the fabric item, the second portion of the fabric item or both, onto the fabric joining device, wherein the one or more sections are further configured to include a third plurality of sectors, wherein each sector is configured to selectively apply heat to the first portion of the fabric item, the second portion of the fabric item, another portion of the fabric item, or a combination thereof.
According to Example 18, a method of manufacturing a fabric item, the method comprising: mounting a first portion of the fabric item on a surface of a first section of a fabric joining device; mounting a second portion of the fabric item on a surface of a second section of the fabric joining device; and moving, using one or more first actuators of the fabric joining device, the second section toward the first section to fold the second portion of the fabric item on top of the first portion of the fabric item and to press the first portion of the fabric item and the second portion of the fabric item together to join the first portion of the fabric item and second portion of the fabric item.
Example 19 includes the method of Example 18, and further includes moving, using one or more second actuators of the fabric joining device, one or more third sections to fold one or more third portions of the fabric item on top of the first portion of the fabric item, the second portion of the fabric item, or both.
Example 20 includes the method of any of Examples 18 to Example 19, and further includes: applying an adhesive to a first joint region of the first portion of the fabric item, to a second joint region of the second portion of the fabric item, or both, such that pressing together and heating the first portion of the fabric item and the second portion of the fabric item adheres the first joint region and the second joint region to form a joint.
Example 21 includes the method of any of Example 18 to Example 20, and further includes: generating sensor data indicating a first position of the first portion of the fabric item, a second position of the second portion of the fabric item, or both, relative to alignment indicia of the fabric joining device; and positioning the first section of the fabric joining device, the second section of the fabric joining device, or both, based on the sensor data.
According to Example 22, a system includes a fabric joining device includes a first section configured to releasably hold a first portion of a fabric item on a surface of the first section, wherein the first section comprises a first plurality of sectors, wherein each sector is configured to selectively apply heat to the first portion of the fabric item; a second section configured to releasably hold a second portion of the fabric item on a surface of the second section, wherein the second section comprises a second plurality of sectors, wherein each sector is configured to selectively apply heat to the second portion of the fabric item; and one or more first actuators coupled to the second section and configured to move the second section toward the first section to fold the second portion of the fabric item on top of the first portion of the fabric item and to press the first portion of the fabric item and the second portion of the fabric item together to join the first and second portions of the fabric item; and a placement apparatus comprising one or more sections configured to releasably hold and place the first portion of the fabric item, the second portion of the fabric item or both, onto the fabric joining device, wherein the one or more sections are further configured to include a third plurality of sectors, wherein each sector is configured to selectively apply heat to the first portion of the fabric item, the second portion of the fabric item, another portion of the fabric item, or a combination thereof.
The illustrations of the examples described herein are intended to provide a general understanding of the structure of the various implementations. The illustrations are not intended to serve as a complete description of all of the elements and features of apparatus and systems that utilize the structures or methods described herein. Many other implementations may be apparent to those of skill in the art upon reviewing the disclosure. Other implementations may be utilized and derived from the disclosure, such that structural and logical substitutions and changes may be made without departing from the scope of the disclosure. For example, method operations may be performed in a different order than shown in the figures or one or more method operations may be omitted. Accordingly, the disclosure and the figures are to be regarded as illustrative rather than restrictive.
Moreover, although specific examples have been illustrated and described herein, it should be appreciated that any subsequent arrangement designed to achieve the same or similar results may be substituted for the specific implementations shown. This disclosure is intended to cover any and all subsequent adaptations or variations of various implementations. Combinations of the above implementations, and other implementations not specifically described herein, will be apparent to those of skill in the art upon reviewing the description.
The Abstract of the Disclosure is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, various features may be grouped together or described in a single implementation for the purpose of streamlining the disclosure. Examples described above illustrate but do not limit the disclosure. It should also be understood that numerous modifications and variations are possible in accordance with the principles of the present disclosure. As the following claims reflect, the claimed subject matter may be directed to less than all of the features of any of the disclosed examples. Accordingly, the scope of the disclosure is defined by the following claims and their equivalents.
The present application claims the benefit of U.S. Provisional Patent Application No. 63/510,852 entitled “System and Method For Joining Fabric Items,” filed Jun. 28, 2023, which is expressly incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63510852 | Jun 2023 | US |
