WO2007015082A1 - Method of forming an article from layers of material - Google Patents
Method of forming an article from layers of material Download PDFInfo
- Publication number
- WO2007015082A1 WO2007015082A1 PCT/GB2006/002867 GB2006002867W WO2007015082A1 WO 2007015082 A1 WO2007015082 A1 WO 2007015082A1 GB 2006002867 W GB2006002867 W GB 2006002867W WO 2007015082 A1 WO2007015082 A1 WO 2007015082A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- article
- stock material
- stock
- juxtaposed
- garment
- Prior art date
Links
Classifications
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- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41H—APPLIANCES OR METHODS FOR MAKING CLOTHES, e.g. FOR DRESS-MAKING OR FOR TAILORING, NOT OTHERWISE PROVIDED FOR
- A41H42/00—Multi-step production lines for making clothes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
- B26F1/00—Perforating; Punching; Cutting-out; Stamping-out; Apparatus therefor
- B26F1/38—Cutting-out; Stamping-out
- B26F1/3806—Cutting-out; Stamping-out wherein relative movements of tool head and work during cutting have a component tangential to the work surface
- B26F1/3813—Cutting-out; Stamping-out wherein relative movements of tool head and work during cutting have a component tangential to the work surface wherein the tool head is moved in a plane parallel to the work in a coordinate system fixed with respect to the work
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/74—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area
- B29C65/745—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using a single unit having both a severing tool and a welding tool
- B29C65/7461—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using a single unit having both a severing tool and a welding tool for making welds and cuts of other than simple rectilinear form
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
- B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
- B29C66/112—Single lapped joints
- B29C66/1122—Single lap to lap joints, i.e. overlap joints
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
- B29C66/24—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight
- B29C66/244—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being non-straight, e.g. forming non-closed contours
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
- B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
- B29C66/43—Joining a relatively small portion of the surface of said articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
- B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
- B29C66/43—Joining a relatively small portion of the surface of said articles
- B29C66/431—Joining the articles to themselves
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- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- A41D2300/00—Details of garments
- A41D2300/50—Seams
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- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- A41D2300/00—Details of garments
- A41D2300/50—Seams
- A41D2300/52—Seams made by welding or gluing
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- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- A41D2500/00—Materials for garments
- A41D2500/10—Knitted
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- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- A41D2500/00—Materials for garments
- A41D2500/20—Woven
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- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- A41D2500/00—Materials for garments
- A41D2500/30—Non-woven
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2793/00—Shaping techniques involving a cutting or machining operation
- B29C2793/0009—Cutting out
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
- B29C65/1403—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the type of electromagnetic or particle radiation
- B29C65/1406—Ultraviolet [UV] radiation
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
- B29C65/16—Laser beams
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
- B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
- B29C65/483—Reactive adhesives, e.g. chemically curing adhesives
- B29C65/4845—Radiation curing adhesives, e.g. UV light curing adhesives
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
- B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
- B29C66/43—Joining a relatively small portion of the surface of said articles
- B29C66/432—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms
- B29C66/4322—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms by joining a single sheet to itself
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
- B29C66/729—Textile or other fibrous material made from plastics
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
- B29C66/729—Textile or other fibrous material made from plastics
- B29C66/7294—Non woven mats, e.g. felt
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
- B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
- B29C66/836—Moving relative to and tangentially to the parts to be joined, e.g. transversely to the displacement of the parts to be joined, e.g. using a X-Y table
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
- B29C66/84—Specific machine types or machines suitable for specific applications
- B29C66/863—Robotised, e.g. mounted on a robot arm
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
- B29K2105/0854—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns in the form of a non-woven mat
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2313/00—Use of textile products or fabrics as reinforcement
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2022/00—Hollow articles
- B29L2022/02—Inflatable articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2022/00—Hollow articles
- B29L2022/02—Inflatable articles
- B29L2022/027—Air bags
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/48—Wearing apparel
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/48—Wearing apparel
- B29L2031/4842—Outerwear
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/48—Wearing apparel
- B29L2031/4842—Outerwear
- B29L2031/4864—Gloves
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/48—Wearing apparel
- B29L2031/4871—Underwear
Definitions
- This invention relates to methods of forming articles such as garments and three dimensional preforms from stock material provided in sheet form. It has particular application to woven, knitted and non-woven fabrics, but can equaiiy be applied to ieather or synthetic sheet materials.
- the present invention constitutes a departure from the traditional practise of assembling and securing pre-cut elements into complete articles.
- stock material is presented to a forming station as a workpiece with at least two layers of material in juxtaposition.
- the juxtaposed layers are secured along at least one path to define the article by juxtaposed sections of material, and the article is completed by cutting the workpiece adjacent said at least one path to enable removal of material from the opposite side of the secured path relative to the juxtaposed sections.
- this last step is typically accomplished by withdrawing the formed garment from the stock material.
- the invention may be used to form articles, and particularly garments of many kinds, but can be particularly suited to garments having relatively complex shapes in two dimensions, such as gloves and three dimensionally wadding systems.
- the invention may also be used to form inflatable articles such as air bag systems for the automotive industry and parachutes for military, aerospace and leisure applications.
- the securing step in methods according to the invention is typically sewing, but any suitable method may be employed. Some alternatives are gluing or welding, for example with ultrasound. Others are spaced rivets or poppers.
- the removal step is accomplished by cutting, and numerous techniques are available. Lasers and water jets can be used. The means used to perform the securing and removal steps will of course be selected with reference to the nature of the stock material and the desired final edge effect. Cutting can be partial or intermittent, leaving critical regions. This can facilitate packaging and storage of multiple articles.
- the stock material can be presented to the forming station as a folded workpiece with material on either side of the fold in juxtaposition.
- the juxtaposed sections are of necessity, properly located one relative to the other.
- the fold can effectively take the place of a seam or line of securement in an article such as a garment formed by a more traditional method.
- the fold can define a section of the garment located at a shoulder portion thereof.
- Stock material used in the present invention can be embroidered for decorative or functional purposes, and the embroidery can be used also to secure juxtaposed material sections along a garment defining path.
- Stock material for use in the practice of the invention can also be manufactured in tubular form, and such material is ideally suited to the method of the present invention.
- the material can be delivered directly from the point of manufacture to the forming station in a method of the present invention as a substantially flat envelope bounded by two opposite folds.
- an article to be formed such as an upper body garment
- two articles may be formed from juxtaposed sections of material extending from opposite folds.
- two such garments can be aligned between the opposite folds or formed from adjacent lateral sections, or be staggered such that each interleaves with a pair from the opposite fold. It will be appreciated that the arrangement of the article sections can be selected to minimise waste material, and that the dimensions of the tubular stock material can also be selected with this consideration.
- Articles made according to the invention also include lower body garments.
- the or each fold at either side of the stock material can define a side of the garment made.
- the step of securing juxtaposed sections of workpiece material can be conducted before or simultaneously with any cutting of the material from the stock. Cutting or removing material at or from the fold region is of course not precluded, and for an upper body garment with the fold located at the shoulders, an opening will of course have to be cut to form the neck.
- Modern techniques in material handling enable the securing (sewing, welding etc.), cutting and finishing steps in methods of the invention to be conducted either simultaneously or in very quick succession. This enables such methods to be part of a continuous production process from the formation of the material to the finished garment.
- the process can include one or both of a folding and packaging process.
- Stock material including woven and knitted fabrics can be manufactured in flat or tubular form, and accordingly methods of the invention can be used with any form of material.
- laminated materials can be used, enabling the creation of lined garments, which can be from multiple layers of material manufactured simultaneously. Where the stock material is in tubular form, multiple layers can be created by the simultaneous delivery of two "tubes" of material, one inside the other and/or tubes being superimposed one on top of the other.
- Methods of the invention will normally be practised with devices conducting the securing, removal and if used a finishing step moving over the stock material in a forming station.
- a stationary tool through which the stock material is moved.
- the stock material would be located on a table movable under the tool in accordance with a suitable programme to enable the securing, removal or finishing step to follow the requisite path.
- This is particularly suited to methods in which a single tool assembly is adapted to perform more than one of the steps, and/or those in which the path or paths to be followed is or are complex, as in a glove or an air bag for example. In these circumstances it may well be more convenient to move the material on an X-Y table under a tool than move a tool over the material.
- Figure 1 is a plan view illustrating the manufacture of sleeved garments from tubular stock material
- Figure 2 shows a plan view of folded stock material with the outline of a glove to be formed therefrom;
- Figure 3 illustrates moving table apparatus for the manufacture of a glove from the stock material of the kind shown in Figure 2.
- stock material is delivered from station 2 in the form of a tube 4.
- the station 2 may be where the material is created, such as a circular, flat-bed and double needle bar warp knitting or weaving machine or, if the stock material is wholly synthetic it might be a plastics extruder.
- the tube is spread out and flattened by means of rollers 6 to form a flat envelope 8 when it reaches the forming station 10. If the stock material is created in plain sheet form, station 2 could encompass a unit for folding the sheet material to form the flat envelope 8.
- sew/cut devices 12 are programmed to sew the juxtaposed sections of material along the paths 14 to define the garment and its outline shape.
- the devices are also programmed to cut along these lines to separate the formed garment from the stock material, and along the lines 16 to open the lower end of the garment and form a neck opening as indicated.
- the devices 12 can also be adapted to produce finished edges as required.
- the completed garment 18 is removed from the remainder of the stock material which is itself discarded through opening 20.
- the completed garment may be folded and packaged directly thereafter.
- multi-layer, tubular or folded stock material is delivered to a forming station where a length is separated to form a separate workpiece.
- a forming station where a length is separated to form a separate workpiece.
- FIG 2. The workpiece in the form of a folded sheet 22 of fabric is disposed on a moving table under a tool which has adjacent securing and cutting mechanisms as shown in Figure 3.
- the table is moved under the tool in accordance with a preset programme, and the tool sews and cuts along substantially parallel paths 24 and 26 to create the garment; in this example, a glove 28.
- Figure 3 shows a moving table apparatus that can be used in the method of the present invention. It comprises a table 30 upon which the folded workpiece 22 is located under a securing and cutting tool 32.
- the table is mounted on a boss 34 movably surpported on a base 36.
- the boss 34, with table 30, is rotatable and translatable in a horizontal plane, and such movement is effected by a precision servo motor 38, the motor being controlled by a computer 40.
- the tool 32 has a welding arm 42, and a rotary cutter 44.
- the computer 40 is programmed to instruct the motor 38 to drive the boss 34 and thus the table 30 to move the foided sheet 22 such that the weld arm 42 and cutter 44 follow the substantially parallel paths 24 and 26 to create the glove.
- the welding arm 42 and the motor 38 are activated simultaneously and the procedure is got underway.
- Figure 3 shows the table 30 positioned with the tool 32 at the point 46 on the glove to be formed ( Figure 2) and the table will be moved in a generally anti-clockwise sense to secure and trim the stock material around first the thumb, then the four fingers and finally the opposite seam 48 of the glove.
- the welding arm will then be de-activated while the tool completes its return to point 46 with only the cutter operational, thereby creating the open wrist 50 of the glove.
- Figure 3 refers to a welding arm 42 and a rotary cutter 44. These devices are well suited for the manufacture of articles comprising plastics materials. For some fabrics sewing would be the preferred securement mechanism, and as an alternative to cutting a precision laser or a water jet may be preferred. Whatever mechanisms are used, the cutting step will never precede the securement step, be it sewing, welding or any other technique, but they may be effected simultaneously. Normally though, the securement step will precede the cutting step, with the respective mechanisms being suitably spaced from one another to avoid interference.
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Abstract
Stock material (4) is presented to a forming station as a workpiece (8, 22) with at least two layers of material in juxtaposition. The juxtaposed layers are secured along at least one path (14, 24, 26) to define the article by juxtaposed sections of material. The workpiece is then cut adjacent the path to enable removal of material from the opposite side of the secured path relative to the juxtaposed sections. This technique can be applied to stock material in multi-layer form, and stock material can suitably be provided in folded or tubular form.
Description
METHOD OF FORMING AN ARTICLE FROM LAYERS OF MATERIAL
This invention relates to methods of forming articles such as garments and three dimensional preforms from stock material provided in sheet form. It has particular application to woven, knitted and non-woven fabrics, but can equaiiy be applied to ieather or synthetic sheet materials.
Traditionally, garments formed from stock material in sheet form have comprised separate elements first cut to shape and then sewn together. This sequence of logical steps is straightforward, but time-consuming and labour- intensive. Cutting and sewing is conducted at separate locations, and an additional trimming step to remove surplus material is also sometimes required. Continuous processes following this technique are described in International Patent Specification No: WO 2001/094 674 and United States Patent No: 5 140 919.
The present invention constitutes a departure from the traditional practise of assembling and securing pre-cut elements into complete articles. According to the invention stock material is presented to a forming station as a workpiece with at least two layers of material in juxtaposition. The juxtaposed layers are secured along at least one path to define the article by juxtaposed sections of material, and the article is completed by cutting the workpiece adjacent said at least one path to enable removal of material from the opposite side of the secured path relative to the juxtaposed sections. Of course, this last step is typically accomplished by withdrawing the formed garment from the stock material. The invention may be used to form articles, and particularly garments of many kinds, but can be particularly suited to garments having relatively complex shapes in two dimensions, such as gloves and three dimensionally wadding systems. The invention may also be used to form inflatable articles such as air bag systems for the automotive industry and parachutes for military, aerospace and leisure applications.
The securing step in methods according to the invention is typically sewing, but any suitable method may be employed. Some alternatives are gluing or welding, for example with ultrasound. Others are spaced rivets or poppers. The removal step is accomplished by cutting, and numerous techniques are available. Lasers and water jets can be used. The means used to perform the securing and removal steps will of course be selected with reference to the nature of the stock material and the desired final edge effect. Cutting can be partial or intermittent, leaving critical regions. This can facilitate packaging and storage of multiple articles.
The stock material can be presented to the forming station as a folded workpiece with material on either side of the fold in juxtaposition. By presenting the stock material in this form, and securing the juxtaposed sections prior to cutting the material, the juxtaposed sections are of necessity, properly located one relative to the other. Additionally, the fold can effectively take the place of a seam or line of securement in an article such as a garment formed by a more traditional method. For example, where the article is an upper body garment, the fold can define a section of the garment located at a shoulder portion thereof. Stock material used in the present invention can be embroidered for decorative or functional purposes, and the embroidery can be used also to secure juxtaposed material sections along a garment defining path.
Stock material for use in the practice of the invention can also be manufactured in tubular form, and such material is ideally suited to the method of the present invention. The material can be delivered directly from the point of manufacture to the forming station in a method of the present invention as a substantially flat envelope bounded by two opposite folds. Where an article to be formed, such as an upper body garment, can most easily take advantage of only one fold, two articles may be formed from juxtaposed sections of material extending from opposite folds. Depending
upon dimensional requirements, and other aspects of the particular design, two such garments can be aligned between the opposite folds or formed from adjacent lateral sections, or be staggered such that each interleaves with a pair from the opposite fold. It will be appreciated that the arrangement of the article sections can be selected to minimise waste material, and that the dimensions of the tubular stock material can also be selected with this consideration.
Articles made according to the invention also include lower body garments. In such garments the or each fold at either side of the stock material can define a side of the garment made.
In the method of the invention the step of securing juxtaposed sections of workpiece material can be conducted before or simultaneously with any cutting of the material from the stock. Cutting or removing material at or from the fold region is of course not precluded, and for an upper body garment with the fold located at the shoulders, an opening will of course have to be cut to form the neck.
Modern techniques in material handling enable the securing (sewing, welding etc.), cutting and finishing steps in methods of the invention to be conducted either simultaneously or in very quick succession. This enables such methods to be part of a continuous production process from the formation of the material to the finished garment. The process can include one or both of a folding and packaging process. Stock material including woven and knitted fabrics can be manufactured in flat or tubular form, and accordingly methods of the invention can be used with any form of material. It will also be appreciated that laminated materials can be used, enabling the creation of lined garments, which can be from multiple layers of material manufactured simultaneously. Where the stock material is in tubular form, multiple layers can be created by the simultaneous delivery of two "tubes" of
material, one inside the other and/or tubes being superimposed one on top of the other.
Methods of the invention will normally be practised with devices conducting the securing, removal and if used a finishing step moving over the stock material in a forming station. However, there may be circumstances when at least one of these steps is performed by a stationary tool through which the stock material is moved. In such a variant the stock material would be located on a table movable under the tool in accordance with a suitable programme to enable the securing, removal or finishing step to follow the requisite path. This is particularly suited to methods in which a single tool assembly is adapted to perform more than one of the steps, and/or those in which the path or paths to be followed is or are complex, as in a glove or an air bag for example. In these circumstances it may well be more convenient to move the material on an X-Y table under a tool than move a tool over the material.
The invention will now be described by way of example and with reference to the accompanying schematic drawings which show two examples of a garment manufacturing process. In the drawings:
Figure 1 is a plan view illustrating the manufacture of sleeved garments from tubular stock material;
Figure 2 shows a plan view of folded stock material with the outline of a glove to be formed therefrom; and
Figure 3 illustrates moving table apparatus for the manufacture of a glove from the stock material of the kind shown in Figure 2.
As shown in the Figure 1 , stock material is delivered from station 2 in the form of a tube 4. The station 2 may be where the material is created, such as a circular, flat-bed and double needle bar warp knitting or weaving
machine or, if the stock material is wholly synthetic it might be a plastics extruder. The tube is spread out and flattened by means of rollers 6 to form a flat envelope 8 when it reaches the forming station 10. If the stock material is created in plain sheet form, station 2 could encompass a unit for folding the sheet material to form the flat envelope 8.
At the forming station 10 sew/cut devices 12 are programmed to sew the juxtaposed sections of material along the paths 14 to define the garment and its outline shape. The devices are also programmed to cut along these lines to separate the formed garment from the stock material, and along the lines 16 to open the lower end of the garment and form a neck opening as indicated. The devices 12 can also be adapted to produce finished edges as required.
The completed garment 18 is removed from the remainder of the stock material which is itself discarded through opening 20. The completed garment may be folded and packaged directly thereafter.
In an alternative arrangement, multi-layer, tubular or folded stock material is delivered to a forming station where a length is separated to form a separate workpiece. Such an arrangement is illustrated in Figure 2. The workpiece in the form of a folded sheet 22 of fabric is disposed on a moving table under a tool which has adjacent securing and cutting mechanisms as shown in Figure 3. The table is moved under the tool in accordance with a preset programme, and the tool sews and cuts along substantially parallel paths 24 and 26 to create the garment; in this example, a glove 28.
Figure 3 shows a moving table apparatus that can be used in the method of the present invention. It comprises a table 30 upon which the folded workpiece 22 is located under a securing and cutting tool 32. The table is mounted on a boss 34 movably surpported on a base 36. The boss 34, with table 30, is rotatable and translatable in a horizontal plane, and such
movement is effected by a precision servo motor 38, the motor being controlled by a computer 40.
The tool 32 has a welding arm 42, and a rotary cutter 44. In use, the computer 40 is programmed to instruct the motor 38 to drive the boss 34 and thus the table 30 to move the foided sheet 22 such that the weld arm 42 and cutter 44 follow the substantially parallel paths 24 and 26 to create the glove. The welding arm 42 and the motor 38 are activated simultaneously and the procedure is got underway. Figure 3 shows the table 30 positioned with the tool 32 at the point 46 on the glove to be formed (Figure 2) and the table will be moved in a generally anti-clockwise sense to secure and trim the stock material around first the thumb, then the four fingers and finally the opposite seam 48 of the glove. The welding arm will then be de-activated while the tool completes its return to point 46 with only the cutter operational, thereby creating the open wrist 50 of the glove.
The above description of Figure 3 refers to a welding arm 42 and a rotary cutter 44. These devices are well suited for the manufacture of articles comprising plastics materials. For some fabrics sewing would be the preferred securement mechanism, and as an alternative to cutting a precision laser or a water jet may be preferred. Whatever mechanisms are used, the cutting step will never precede the securement step, be it sewing, welding or any other technique, but they may be effected simultaneously. Normally though, the securement step will precede the cutting step, with the respective mechanisms being suitably spaced from one another to avoid interference.
Claims
1. A method of forming an article from stock material, which method comprises presenting the material to a forming station as a workpiece with at least two layers of material in juxtaposition; securing the juxtaposed layers along at ieast one path to define the article by juxtaposed sections of material extending from the fold; and cutting the workpiece adjacent said at least one path to enable removal of material from the opposite side of said at least one path relative to the juxtaposed sections, the cutting step being simultaneous with or after the securing step.
2. A method according to Claim 1 wherein the article is a garment and the juxtaposed sections form the front and the back of the garment to be formed.
3. A method according to Claim 1 wherein the article is a three dimensional preform and the juxtaposed sections form the front and the back of the preform to be formed.
4. A method according to Claim 1 wherein the article is an inflatable product and the juxtaposed sections form the front and the back of the product to be formed.
5. A method according to Claim 1 or Claim 2 wherein the juxtaposed material is secured along two paths to define the juxtaposed sections therebetween.
6. A method according to any preceding Claim wherein the stock material is in the form of folded stock, and presented to the forming station as a substantially flat envelope bounded by a fold along one side.
7. A method according to Claim 6 wherein the article is an upper body garment and wherein the fold defines a section of the garment located at a shoulder portion thereof.
8. A method according to any of Claims 1 to 5 wherein the stock material is in the form of tubuiar stock, and presented to the forming station as a substantially flat envelope bounded by two opposite folds.
9. A method according to Claim 8 wherein two articles are formed from said juxtaposed sections extending from opposite folds.
10. A method according to Claim 9 wherein said two articles are aligned between the opposite folds.
11. A method according to Claim 9 wherein said two articles are formed from adjacent lateral sections of the tubular stock.
12. A method according to Claim 11 wherein the sections overlap.
13. A method according to Claim 6 or Claim 8 wherein the article is a lower body garment and wherein the or each fold defines a side section of the garment.
14. A method according to any preceding Claim wherein the folded workpiece is disposed on a table at the forming station, which table is movable in a two-dimensional plane under a tool for performing at least one of the securing and removal steps, and wherein said at least one step is conducted by movement of the table according to a program to have the tool follow said at least one path.
15. A method according to any preceding Claim wherein the securing step is immediately succeeded by the removal step in a continuous process.
16. A method according to any preceding Claim wherein the stock material is a fabric, the securing step comprises sewing, and the removal step comprises laser cutting.
17. A method according to any preceding Claim wherein the stock material is a fabric, the securing step comprises one of gluing, sewing, ultrasonic welding and laser welding; and the removal step comprises one of laser cutting and water jet cutting.
18. A method according to Claim 17 wherein the securing step comprises the application of a UV curable glue.
19. A method according to any preceding Claim wherein the stock material is a folded or a tubular knitted fabric.
20. A method according to any of Claims 1 to 18 wherein the stock material is a folded or a tubular woven fabric.
21. A method according to any of Claims 1 to 18 wherein the stock material is a folded or a tubular non-woven sheet.
22. A production process comprising a method according to any preceding Claim and at least one of a folding and a packaging step applied to the formed article.
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB0515828.2 | 2005-08-01 | ||
GB0515828A GB0515828D0 (en) | 2005-08-01 | 2005-08-01 | Methods of forming garments |
GB0611050A GB0611050D0 (en) | 2006-06-05 | 2006-06-05 | Methods of forming garments |
GB0611050.6 | 2006-06-05 |
Publications (1)
Publication Number | Publication Date |
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WO2007015082A1 true WO2007015082A1 (en) | 2007-02-08 |
Family
ID=37401225
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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PCT/GB2006/002867 WO2007015082A1 (en) | 2005-08-01 | 2006-08-01 | Method of forming an article from layers of material |
Country Status (1)
Country | Link |
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WO (1) | WO2007015082A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP1859696A3 (en) * | 2006-05-23 | 2008-02-27 | Bha Group, Inc. | Waterproof breathable garment with tape-free seams |
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GB1500967A (en) * | 1974-06-28 | 1978-02-15 | Ikeda Bussan Co | Inflatable protector bag for vehicle safety device and method of producing same |
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US2526634A (en) * | 1946-02-28 | 1950-10-24 | Chavannes Ind Synthetics Inc | Method for producing articles from film-forming materials |
US2650182A (en) * | 1951-06-14 | 1953-08-25 | Charles V Green | Method of forming waterproof garments |
US2903704A (en) * | 1956-11-23 | 1959-09-15 | Jr John D Plant | Method and apparatus for making wearing apparel |
US2961661A (en) * | 1959-02-13 | 1960-11-29 | Jasik Andre | Pleated gloves and methods of and apparatus for making the same |
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