Patent Application
20250188657
This application claims priority to German Patent Application No. 10 2023 134 475.1, filed Dec. 8, 2023, which is incorporated by reference herein in its entirety.
The present disclosure relates a method of manufacturing a textile element comprising a thread arranged in a thread pattern and an apparatus for manufacturing the textile element.
A variety of products are at least partially formed from textile elements. For example, articles of apparel, such as sports apparel but also shirts, pants, jackets, footwear or others in general are often formed from various textile elements. Each of these components is generally adapted to provide various desired characteristics, such as cushioning, stability, moisture management, durability, abrasion resistance, stretch, etc. In recent years, textile manufacturers developed a new technique in which at least a part of a textile element is manufactured by winding one or more threads or strands around predefined anchor points. By this, various desired characteristics can be provided and individually adjusted based on the winding pattern of the threads or strands.
However, designing and manufacturing a frame having the required anchor points for each textile component is labor intensive, complicated and results in an immense amount of frames that need to be stored. Moreover, individual adaptations of the thread pattern are limited by the shape or form of the frame. Further, after the winding of the thread pattern has been completed, further manufacturing steps are required for resulting in a textile element ready to be used in manufacturing a final product. For example, the excess thread material of the loop wound around the anchor point may need to be cut or otherwise removed from the textile element.
Thus, known processes of winding a thread in a thread pattern are generally less suitable for individual adaptations, result in waste production based on the cut excess material, and are mostly labor intense and less cost efficient. Therefore, a continuing need exists for innovations in the manufacturing of textile elements.
Embodiments according to the present disclosure improve manufacturing methods of textiles and apparatuses for manufacturing such textiles so that the above outlined disadvantages are at least partly overcome.
The above-mentioned problems are solved by the subject matter of the at least the following embodiments.
A first embodiment (1) of the present disclosure is directed to a method of manufacturing a textile element, the method comprising: outputting a thread; heating the thread; and arranging the heated thread in a thread pattern.
In a second embodiment (2), the method according to the first embodiment (1) comprises applying pressure to at least a portion of the thread pattern.
In a third embodiment (3), applying pressure according to the second embodiment (2) comprises using a first circular object following a path of the thread pattern.
In a fourth embodiment (4) applying pressure according to the third embodiment (3) further comprises applying an essentially constant first pressure on at least a first portion of the thread pattern using the first circular object.
In a fifth embodiment (5), the method according to the third embodiment (3) or the fourth embodiment (4) further comprises cooling the first circular object.
In a sixth embodiment (6), applying pressure according to any one of embodiments (3)-(5) comprises applying pressure using a second circular object following the path of the thread pattern, and the second circular object is arranged before the first circular object along the path.
In a seventh embodiment (7), the method according to the sixth embodiment (6) further comprises heating the second circular object.
In an eighth embodiment (8), applying pressure according to the sixth embodiment (6) or the seventh embodiment (7) further comprises applying an essentially constant second pressure on at least a second portion of the thread pattern using the second circular object.
In a ninth embodiment (9) the heating according to any one of embodiments (1)-(8) further comprises softening or melting at least a portion of the thread. In some embodiments, the method comprising softening or melting a sheath portion of the thread.
In a tenth embodiment (10), the heating according to any one of embodiments (1)-(9) further comprises heating the thread by means of at least one of: a laser, a heat gun, a fan, heating plates, or a radiation emitting device. In some embodiments, the radiation emitting device is adapted for emitting at least one of: electromagnetic radiation, radio frequency radiation, microwave radiation, infrared radiation, or ultraviolet radiation.
In an eleventh embodiment (11), the heating according to any one of embodiments (1)-(10) further comprises heating the thread and at least a portion of the thread pattern simultaneously.
In a twelfth embodiment (12), the heating according to any one of embodiments (1)-(11) further comprises heating the thread prior to arranging the thread.
In a thirteenth embodiment (13), the arranging according to any one of embodiments (1)-(12) comprises overlapping at least a portion of the thread pattern with the heated thread.
In a fourteenth embodiment (14), the arranging according to any one of embodiments (1)_(13) comprises refraining from winding the thread around anchor points.
In a fifteenth embodiment (15), the method according to any one of embodiments (1)-(14) further comprises arranging at least a first layer of the thread pattern on a substrate.
In a sixteenth embodiment (16), the thread pattern according to the fifteenth embodiment (15) is removably attached to the substrate such that the thread pattern of at least the first layer is maintained.
In a seventeenth embodiment (17), the method according to the fifteenth embodiment (15) or the sixteenth embodiment (16) further comprises removing the thread pattern from the substrate.
In an eighteenth embodiment (18), the outputting according to any one of embodiments (1)-(17) comprises outputting the thread prior to heating the thread.
In a nineteenth embodiment (19), the thread according to any one of embodiments (1)-(18) comprises a thermoplastic material. In some embodiments, the thermoplastic material may be a thermoplastic polyurethane, a co-polyester, or a co-polyamide.
In a twentieth embodiment (20), the thread according to any one of embodiments (1)-(19) comprises a non-thermoplastic material. In some embodiments, the non-thermoplastic material may be a thermoset polyester, a synthetic thread material, or a natural thread material.
In a twenty-first embodiment (21), the thread according to the twentieth embodiment (20) comprises a core comprising the non-thermoplastic material.
In a twenty-second embodiment (22), the thread according to any one of embodiments (19)-(21) comprises a sheath comprising the thermoplastic material.
A twenty-third embodiment (23) of the present disclosure is directed to an apparatus for manufacturing a textile element, the apparatus comprising: means for outputting a thread; means for heating the thread; and means for arranging the heated thread in a thread pattern.
In a twenty-fourth embodiment (24), the apparatus according to the twenty-third embodiment (23) further comprising means for applying pressure to at least a portion of the thread pattern.
In a twenty-fifth embodiment (25), the means for applying pressure according to the twenty-fourth embodiment (24) comprises a first circular object arranged to follow a path of the thread pattern.
In a twenty-sixth embodiment (26), the means for applying pressure according to the twenty-fifth embodiment (25) further comprises means for applying an essentially constant first pressure on at least a first portion of the thread pattern using the first circular object.
In a twenty-seventh embodiment (27), the apparatus according to the twenty-fifth embodiment (25) or the twenty-sixth embodiment (26) further comprises means for cooling the first circular object.
In a twenty-eighth embodiment (28), the means for applying pressure according to any one of embodiments (24)-(27) further comprises a second circular object arranged to follow a path of the thread pattern, and the second circular object is arranged before the first circular object.
In a twenty-ninth embodiment (29), the apparatus according to the twenty-eighth embodiment (28) further comprising means for heating the second circular object.
In a thirtieth embodiment (30), the means for applying pressure according to the twenty-eighth embodiment (28) or the twenty-ninth embodiment (29) further comprises means for applying an essentially constant second pressure on at least a second portion of the thread pattern using the second circular object.
In a thirty-first embodiment (31), the means for heating according to any one of embodiments (23)-(30) is adapted to soften or melt at least a portion of the thread, In some embodiments, the means for heating softens or melts a sheath portion of the thread.
In a thirty-second embodiment (32), the means for heating the thread according to any one of embodiments (23)-(31) comprises at least one of: a laser, a heat gun, a fan, heating plates, or a radiation emitting device. In some embodiments, the radiation emitting device is adapted for emitting at least one of: electromagnetic radiation, radio frequency radiation, microwave radiation, infrared radiation, or ultraviolet radiation.
In a thirty-third embodiment (33), the means for heating the thread according to any one of embodiments (23)-(32) is adapted to heat the thread and at least a portion of the thread pattern simultaneously.
In a thirty-fourth embodiment (34), the means for heating the thread according to any one of embodiments (23)-(33) is further adapted to heat the thread prior to arranging the thread in a thread pattern.
In a thirty-fifth embodiment (35), the means for arranging according to any one of embodiments (23)-(34) further comprises means for overlapping at least a portion of the thread pattern with the heated thread.
In a thirty-sixth embodiment (36), the means for arranging according to any one of embodiments (23)-(35) is adapted to refrain from winding the thread around anchor points.
In a thirty-seventh embodiment (37) the apparatus according to any one of embodiments (23)-(36) further comprises a substrate, and the means for arranging is adapted to arrange at least a first layer of the thread pattern on the substrate.
In a thirty-eighth embodiment (38) the thread pattern according to the thirty-seventh embodiment (37) is removably attached to the substrate such that the thread pattern of at least the first layer is maintained.
In a thirty-ninth embodiment (39), the apparatus according to the thirty-seventh embodiment (37) or the thirty-eighth embodiment (38) further comprising means for removing the thread pattern from the substrate.
In a fortieth embodiment (40), the means for outputting according to any one of embodiments (23)-(39) is adapted to output the thread prior to a heating of the thread.
In a forty-first embodiment (41), the thread according to any one of embodiments (23)-(40) comprises a thermoplastic material. In some embodiments, the thermoplastic material may be a thermoplastic polyurethane, a co-polyester, or a co-polyamide.
In a forty-second embodiment (42), the thread according to any one of embodiments (23)-(41) comprises a non-thermoplastic material. In some embodiments, the non-thermoplastic material may be a thermoset polyester, a synthetic thread material, or a natural thread material.
In a forty-third embodiment (43), the thread according to the forty-second embodiment (42) comprises a core comprising the non-thermoplastic material.
In a forty-fourth embodiment (44), the thread according to any one of embodiments (41)-(43) comprises a sheath comprising the thermoplastic material.
Possible embodiments of the present disclosure will be further described in the following detailed description with reference to the following figures. The accompanying figures, which are incorporated herein, form part of the specification and illustrate embodiments of the present disclosure. Together with the description, the figures further serve to explain the principles of and to enable a person skilled in the relevant art(s) to make and use the disclosed embodiments. These figures are intended to be illustrative, not limiting. Although the disclosure is generally described in the con-text of these embodiments, it should be understood that it is not intended to limit the scope of the disclosure to these particular embodiments. In the drawings, like reference numbers indicate identical or functionally similar elements.
In the following, exemplary embodiments of the present disclosure are described in more detail, with reference to an apparatus for and a method of manufacturing a textile element. While specific feature combinations are described in the following with respect to the exemplary embodiments, it is to be understood that the disclosure is not limited to such embodiments. In particular, not all features have to be present for realizing various embodiments, and the embodiments may be modified by combining certain features of one embodiment with one or more features of another embodiment.
The present disclosure provides a method of manufacturing a textile element. The method comprises the steps of outputting a thread, heating the thread, and arranging the heated thread in a thread pattern.
The present disclosure therefore provides a textile element in which the thread may be first heated and then arranged in a thread pattern. In other words, the heating may comprise heating the thread prior to arranging the thread. By this, a winding of threads around anchor points and a subsequent heating step for connecting the wound threads to each other to form a thread pattern, as known in the art, can be omitted. Instead, the present disclosure provides a method of arranging the heated thread in which a winding around anchor points may be omitted. This is possible at least in part because the thread is heated when it is arranged in a thread pattern. In contrast, in the prior art, heating is done after winding the threads around anchor points. However, according to the present disclosure, anchor points can be omitted because the heated thread adheres at least in part to the underlying substrate, parts of the thread already laid out or other threads already laid out. Thus, the heated thread itself provides for the necessary “anchor points”.
Moreover, in this manner, the design or shape of the thread pattern can be individually adjusted. The design or shape of the thread pattern may merely depend on the arranging of the heated thread. The term “thread pattern” according to the present disclosure may comprise a pattern of a thread laid out on top of already laid out threads. The threads of the thread pattern may be attached to each other. For example, the thread or multiple threads may be bonded at least one intersection point within the thread pattern. By this, the thread pattern may lack any of the known mechanical manipulation techniques of threads or yarns, such as weaving, knitting, stitching, and others.
In some embodiments, the method may comprise applying pressure to at least a portion of the thread pattern. By applying pressure after arranging the heated thread in a thread pattern, bonding strength or quality of the heated thread with the thread pattern already arranged can be increased. Thus, additional components adapted for maintaining a shape or form of the thread pattern may be omitted.
Applying pressure may comprise using a first circular object following a path of the thread pattern. The circular object may, for example, be a cylinder or a sphere. By following the path of the thread pattern, the circular object may be adapted to apply the required amount of pressure to the thread pattern, in particular to the recently arranged portion of the thread pattern. For example, the pressure may be applied using the circular object directly after arranging the heated thread in the thread pattern. By this, the thread may still be heated, i.e. at least above ambient temperature, when being pressed onto the already arranged thread pattern. This may greatly increase the bonding of the heated thread with the thread pattern already arranged.
Additionally, applying pressure may further comprise applying an essentially constant first pressure on at least a first portion of the thread pattern using the first circular object. The term “essentially constant” is to be understood as encompassing small pressure deviations introduced by a manufacturing apparatus. For example, deviations in pressure of up to 5% may be understood as “essentially constant”. Based on the essentially constant first pressure, a minimum pressure required for resulting in a high-quality bonding of the heated thread with the thread pattern already arranged can be ensured. Additionally or alternatively, the first pressure can be maintained essentially constant independent of the thickness of the thread pattern already arranged.
In some embodiments, the method may comprise cooling the first circular object. By this, a duration of cooling the recently arranged heated yarn, for example below a glass transition temperature of a thread material, may be reduced. By this, an unintended detaching or debonding of the arranged heated thread from the thread pattern after applying the pressure using the first circular object may be omitted. Thus, a high quality and stable bonding of the arranged thread to the thread pattern may be provided.
In some embodiments, applying pressure may further comprise applying pressure using a second circular object following the path of the thread pattern. The second circular object may be arranged before the first circular object along the path. In other words, the second circular object may be arranged along the path of the thread pattern in between the heated thread to be arranged and the first circular object. The second circular object may have a size smaller than the first circular object. By this, the second circular object may apply the pressure more precisely to the recently arranged heated thread and an area of the thread pattern already arranged.
Additionally, the method may comprise heating the second circular object, in particular above ambient temperature. By this, the second circular object may prevent the heated thread from being cooled down too quickly based on a contacting of the heated thread with a second circular object having ambient or a lower temperature. In this manner, a cooling of the heated thread prior to establishing a bond with the thread pattern already arranged can be omitted. Thus, a high quality and stable bonding of the arranged thread to the thread pattern may be ensured.
Applying pressure may comprise applying an essentially constant second pressure on at least a second portion of the thread pattern using the second circular object. Based on the essentially constant second pressure, a minimum pressure required for resulting in a high-quality bonding of the heated thread to the thread pattern already arranged can be ensured. Additionally or alternatively, the second pressure can be maintained essentially constant independent of the thickness of the thread pattern already arranged. The essentially constant second pressure may be larger than the essentially constant first pressure. By this, the heated second circular object may ensure a stable bonding of the heated thread and the thread pattern already arranged while the first circular object, which may be cooled, may ensure that the already established bonds may be maintained or may not debond unintendedly.
Additionally or alternatively, heating may further comprise softening or melting at least a portion of the thread, in particular a sheath portion of the thread. In this manner, the heated thread can be attached to the thread pattern already arranged without requiring additional adhesive means, such as an adhesive.
Heating may comprise heating the thread by means of at least one of a laser, a heat gun, a fan, heating plates, or a radiation emitting device. The radiation emitting device may be adapted for emitting at least one of: electromagnetic radiation, radio frequency radiation, microwave radiation, infrared radiation, or ultraviolet radiation. Depending on the textile element to be manufactured, a corresponding heating area may be required. A heat gun, fan or heating plates, for example, may heat a larger area compared to a laser. Thus, if a highly precise and small heating area compared to a heating area of a fan, heat gun or heating plates is required, the laser may be advantageously selected. On the other hand, if a larger heating area compared to the heating area of the laser is required, the fan, heat gun or heating plates may be advantageously selected. In some embodiments, the laser may comprise multiple beams and/or at least one defocused/widened beam. The radiation emitting device provides the advantage that the emitted radiation can be specifically selected based on a material of the thread to be heated.
Heating may comprise heating the thread and at least a portion of the thread pattern simultaneously. By arranging the heated thread on a portion of the thread pattern, which also has a temperature above ambient temperature, a high quality and stable bonding of the arranged thread with the thread pattern may be provided. In these embodiments, the heating may comprise heating the thread and at least a portion of the thread pattern simultaneously using the same heating means.
Arranging the heated thread may comprise overlapping at least a portion of the thread pattern with the heated thread. In this manner, the heated thread may be bonded to at least the portion of the thread pattern, with which it overlaps. Based thereon, after consolidation or cooling down to ambient temperature of the recently arranged heated thread, this recently arranged heated thread will be part of the thread pattern.
Arranging the heated thread may comprise refraining from winding the thread around anchor points. As noted above, embodiments according to the present disclosure provide the advantage that anchor points may not be required for arranging a thread pattern. Thus, additional steps of removing any excess material of the thread pattern, which was required for maintaining a shape of the thread pattern until fixation as known in the art, for example the part of the thread wound around the anchor points, can be omitted. This may result in a more cost-efficient manufacturing of textile elements with less excess material.
In some embodiments, the method may further comprise arranging at least a first or initial layer of the thread pattern on a substrate. At the start of manufacturing a new thread pattern, there is no part of the thread pattern already arranged on which the heated thread can be arranged and bonded to. Thus, a non-bonding substrate may be required. In some embodiments, the thread pattern may be removably attached to the substrate such that the thread pattern of at least the first or initial layer can be maintained. For example, the substrate may comprise a layer of a non-bonding material, such as polytetrafluoroethylene (PTFE), from which the arranged and cooled first or initial layer of the thread pattern can be removed, in particular without damaging the thread pattern. Alternatively, the substrate may be resolvable in a liquid. By this, a frame or anchor points can also be omitted for manufacturing the first or initial layer of the thread pattern. In these embodiments, the method may comprise removing the thread pattern from the substrate.
Outputting the thread may comprise outputting the thread prior to heating the thread. For example, a nozzle may be used to output and guide the thread in a direction onto the thread pattern already arranged or onto the substrate in case of arranging the first or initial layer of the thread pattern. The heating of the thread may be directed to the portion of the thread between the nozzle and the thread pattern or substrate. Thus, by heating the thread right before the thread contacts the thread pattern or substrate, an unintended bonding to parts of the arranging means, such as parts of the nozzle, can be prevented. Additionally or alternatively, by heating the thread right before the thread contacts the thread pattern or substrate, a time for cooling of the thread is reduced. Thus, an amount of excessive heat above the desired temperature applied to the thread for taking the time of cooling of the thread until the arranging into account is essentially zero. In other words, since the thread may be heated right before the heated thread is arranged, the temperature difference of the thread between the maximum temperature after the heating and the temperature during the arranging may be essentially zero. The term “essentially zero” as used herein should be understood as including small deviations in temperature which have no influence on the bonding strength between the thread and the thread pattern.
In some embodiments, the thread may comprise a thermoplastic material, for example at least one of: a thermoplastic polyurethane, a co-polyester, or a co-polyamide.
In some embodiments, the thread may comprise a non-thermoplastic material, for example at least one of: a thermoset polyester, a synthetic thread material, or a natural thread material. Examples of natural thread materials comprise cotton, silk, linen, bamboo, wool, or cashmere. Examples of synthetic thread materials comprise rayon, nylon, or acrylic.
In some embodiments, the thread may comprise a core comprising the non-thermoplastic material. By this, a risk of tearing the heated thread apart during the arranging can be significantly reduced compared to a thread without a core comprising the non-thermoplastic material. Additionally or alternatively, the thread may comprise a sheath comprising the thermoplastic material. In this manner, at least the sheath may be softened based on the heating. Further the heated sheath may be adapted to bond to the thread pattern already arranged.
Embodiments according to the present disclosure are also directed to an apparatus for manufacturing a textile element. The apparatus may comprise means for performing any method as described herein. In particular, the apparatus may comprise means for outputting a thread, means for heating the thread, and means for arranging the heated thread in a thread pattern.
The various advantages, embodiments and functions of the present disclosure, as discussed above with regard to a method of manufacturing a textile element, also apply analogously to embodiments of an apparatus for manufacturing the textile element and are not repeated here for reasons of brevity.
In some embodiments, the apparatus may comprise means for applying pressure to at least a portion of the thread pattern. The means for applying pressure may comprise a first circular object arranged to follow a path of the thread pattern. The means for applying pressure may further comprise means for applying a first constant pressure on at least a first portion of the thread pattern using the first circular object. The apparatus may further comprise means for cooling the first circular object.
In some embodiments, the means for applying pressure may further comprise a second circular object arranged to follow the path of the thread pattern, wherein the second circular object may be arranged before the first circular object. The apparatus may further comprise means for heating the second circular object. The means for applying pressure may further comprise means for applying a second constant pressure on at least a second portion of the thread pattern using the second circular object.
The means for heating may be adapted to soften or melt at least a portion of the thread, for example a sheath portion of the thread.
The means for heating the thread may comprise at least one of: a laser, a heat gun, a fan, heating plates, or a radiation emitting device. The radiation emitting device may be adapted for emitting at least one of: electromagnetic radiation, radio frequency radiation, microwave radiation, infrared radiation, or ultraviolet radiation.
In some embodiments, the means for heating the thread may be adapted to heat the thread and at least a portion of the thread pattern simultaneously.
In some embodiments, the means for heating the thread may be further adapted to heat the thread prior to arranging the thread in the thread pattern.
The means for arranging may further comprise means for overlapping at least a portion of the thread pattern with the heated thread.
The means for arranging may be adapted to refrain from winding the thread around anchor points.
In some embodiments, the apparatus may further comprise a substrate, and the means for arranging may be adapted to arrange at least a first layer of the thread pattern on the substrate.
In such embodiments, the thread pattern may be removably attached to the substrate such that the thread pattern of at least the first layer may be maintained after removing the thread pattern from the substrate.
In some embodiments, the apparatus may further comprise means for removing the thread pattern from the substrate. Exemplary means for removing the thread pattern from the substrate comprise the following. (1) Reverse processing of thread application through a heat source (e.g., heat source 220). In such embodiments, separation of different threat types is possible by adjusting the heat source temperature to the melt temperature of the thread. (2) A mechanical device (for example, a thin blade-like plate, a hook, or a gripper device) capable of manual or robotic removal of the thread pattern from the substrate before full hardening or crystallization of the heated thread. In some embodiments, the mechanical device can be connected to the apparatus for manufacturing a textile element via an additional arm to remove the thread pattern simultaneously while placing final threads. In some embodiments, the mechanical device can be moveably attached on the apparatus and activated by a switch, spring, or programmed sensor at the start of the placing the final thread. (3) Mechanical, hydraulic, or pneumatic arms with a gripper fixed on the aparatus and capable of grabbing and lifting of thread pattern from the substrate. In such embodiments, the gripper can be activated by a sensor or switch.
In some embodiments, the means for outputting may be adapted to output the thread prior to a heating of the thread.
In some embodiments, the thread for use in the apparatus may comprise a thermoplastic material, for example at least one of: a thermoplastic polyurethane, a co-polyester, and co-polyamide. Examples of natural thread materials comprise cotton, silk, linen, bamboo, wool, or cashmere. Examples of synthetic thread materials comprise rayon, nylon, or acrylic.
In some embodiments, the thread for use in the apparatus may comprise a non-thermoplastic material, for example, at least one of: a thermoset polyester, a synthetic thread material, and a natural thread material.
In some embodiments, the thread may comprise a core comprising the non-thermoplastic material. Additionally or alternatively, the thread may comprise a sheath comprising the thermoplastic-material.
The nozzle 130 may further be used as a means for arranging the heated thread 110 in a thread pattern 160. One or more mechanical actuators, for example an electromechanical linear actuator (for example, a motor coupled to a belt, chain, cable, or rack), a hydraulic linear actuator, or a pneumatic linear actuator, operatively coupled to nozzle 130 can move nozzle 130 so that the heated thread 110 is arranged in the thread pattern 160.
The apparatus 100 further comprises means for applying pressure to at least a portion of the thread pattern 160, for example a pressing cylinder 140 attached at the end of an arm 150. In some embodiments, the opposite end of arm 150 is attached to a side of nozzle 130. In some embodiments, the arm 150 may be configured to apply an essentially constant first pressure with the pressing cylinder 140 onto a first portion of thread pattern 160, namely the portion in contact with pressing cylinder 140. In some embodiments, the pressing cylinder 140 can be made with a steel, polytetrafluoroethylene (PTFE), or polyvinylidene fluoride (PVDF).
Nozzle 130, heating source 120 and arm 150 with pressing cylinder 140 may together form part of a moving assembly 170 (the means for arranging the heated thread 110 in a thread pattern 160), which may be adapted to be movably arranged above a surface, on which thread pattern 160 can be arranged. Thus, by moving the moving assembly 170 over the surface while nozzle 130 outputs the heated thread 110, the heated thread 110 can be arranged in a desired pattern of thread pattern 160. The surface may for example be a non-bonding substrate onto which an initial or first layer of thread pattern 160 can be removably arranged without damaging the pattern of thread pattern 160. Moreover, since pressing cylinder 140 may also be a part of moving assembly 170, the pressing cylinder 140 immediately follows the path of thread pattern 160. Based on the essentially constant pressure applied by pressing cylinder 140, the recently arranged heated thread 110 can be pressed onto the already arranged thread pattern 160 or onto the non-binding substrate in case of the first or initial layer of thread pattern 160 is arranged. Since at least a portion of thread 110 is softened or molten, the applied pressure of pressing cylinder 140 results in a high-quality bonding between the recently arranged heated thread 110 and the already arranged thread pattern 160. For improving a cooling and consolidating of the recently bonded heated thread 110 with thread pattern 160, pressing cylinder 140 can be cooled below ambient temperatures. In such embodiments, apparatus 100 may comprise a means for cooling the pressing cylinder 140, such as an air or liquid coolant channel running through the cylinder 140. In some embodiments, the air or liquid coolant channel can run through arm 150. In some embodiments, a pressurized air system capable of blowing air through holes in the cylinder 140 can additionally or alternatively be used to directly cool the thread. In such embodiments, the pressurized air system can be coupled to arm 150.
In this manner, apparatus 100 provides an improved manufacturing process of a textile element without requiring anchor points around which the thread 110 has to be wound for forming a thread pattern. It should be noted that in other embodiments the assembly 170 could be fixed and a table or substrate is moved under assembly 170 to produce the thread pattern 160. In such embodiments, the table or substrate may comprise all or part of the means for arranging the heated thread 110 in a thread pattern 160.
However, in contrast to apparatus 100, in apparatus 200, heating source 220 is arranged outside of nozzle 230. More specifically, heating source 220 is arranged on a second arm 255 with an opposite end, which can be attached to nozzle 230 or to moving assembly 270 in general. By this, thread 210 is first output from nozzle 230 prior to a heating. After outputting thread 210, heat 225 is applied to thread 210 immediately before thread 210 is being pressed onto thread pattern 260, or onto the non-binding substrate in case of the first or initial layer of thread pattern 260 is arranged. This may advantageously reduce a maximum temperature applied to thread 210, since an excess amount of heat necessary in apparatus 100 when considering the time required for heated thread 110 to pass through nozzle 130 after being heated until being pressed onto a substrate, in which thread 110 starts to cool, can be reduced. In addition, heat source 220 not only applies heat 225 onto thread 210 but also applies heat to a portion of thread pattern 260 onto which heated thread 210 will be pressed. This may further increase a bonding strength and bonding quality between thread 210 and thread pattern 260 compared to an embodiment with a not-heated thread pattern. Moreover, arm 255 may comprise a computer-controlled actuator for tuning a position and direction of heat source 220. By this, arm 255 can advantageously be used for efficiently controlling the portion of thread pattern 260 and of thread 210 onto which heat 225 will be applied. Again, it should be noted that, in other embodiments, the assembly 270 could be fixed and a table or substrate is moved under assembly 270 to produce the thread pattern 260.
However, in apparatus 300, heat source 320 is arranged on the same side of moving assembly 370 as arm 350 and pressing cylinder 340. In this manner, heat source 320 can also be adapted to simultaneously apply heat to thread 310 and at least a portion of thread pattern 360 onto which heated thread 310 will be pressed, like in apparatus 200. However, an additional arm, like second arm 255 in apparatus 200 can be omitted. This may reduce a size and/or costs of apparatus 300. Again, it should be noted that in other embodiments the assembly 370 could be fixed and a table or substrate is moved under assembly 370 to produce the thread pattern 360.
However, in addition to pressing cylinder 440, apparatus 400 further comprises a second pressing cylinder 445 attached to a second arm 455. Pressing cylinder 445 is arranged in between pressing cylinder 440 and nozzle 430. By this arrangement, pressing cylinder 445 first applies a second pressure onto thread pattern 460 and the recently arranged thread 410 prior to cylinder 440 applying a first pressure onto thread 410 already bonded to thread pattern 460.
Contrary to pressing cylinder 440, which as described above may be cooled, second pressing cylinder 445 may be heated above ambient temperature. In such embodiments, apparatus 400 comprises means for heating the second pressing cylinder 445. Exemplary means for heating the second pressing cylinder 445 comprise the following. (1) A heated air or liquid channel running through the cylinder 445. (2) A heating element coupled to the pressing cylinder 445, for example an electromagnetic heater or an infrared heater.
In this manner, a cooling of already heated thread 410 prior to being pressed onto the also already heated portion of thread pattern 460 can be omitted. In such embodiments, second heated pressing cylinder 445 can further increase and improve a bonding strength between thread 410 and thread pattern 460. Since the heated and recently bonded thread pattern 460 may be prone to debonding if the tension applied by moving assembly 470 on thread 410 is too high, an immediate cooling of the recently bonded portion of the thread pattern may be advantageous. For this, pressing cylinder 440 is provided in apparatus 400. Pressing cylinder 440 ensures to maintain the bonding and, since pressing cylinder 440 can be cooled, the temperature of the recently bonded portion of thread pattern 460 can be reduced such that a debonding can be prevented.
It may be noted that a second pressing cylinder, like pressing cylinder 445 as shown in
While various embodiments have been described herein, they have been presented by way of example, and not limitation. It should be apparent that adaptations and modifications are intended to be within the meaning and range of equivalents of the disclosed embodiments, based on the teaching and guidance presented herein. It therefore will be apparent to one skilled in the art that various changes in form and detail can be made to the embodiments disclosed herein without departing from the spirit and scope of the present disclosure. The elements of the embodiments presented herein are not necessarily mutually exclusive, but can be interchanged to meet various situations as would be appreciated by one of skill in the art.
The examples are illustrative, but not limiting, of the present disclosure. Other suitable modifications and adaptations of the variety of conditions and parameters normally encountered in the field, and which would be apparent to those skilled in the art, are within the spirit and scope of the disclosure.
It is to be understood that the phraseology or terminology used herein is for the purpose of description and not of limitation. The breadth and scope of the present disclosure should not be limited by any of the above-described exemplary embodiments, but should be defined in accordance with the following claims and their equivalents.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2023 134 475.7 | Dec 2023 | DE | national |
