Circular winding apparatus and method

Abstract

Winding apparatuses and methods for manufacturing an article of apparel. The winding apparatus can comprise a first rim and a second rim coupled to and spaced apart from each other and rotatable on a rotation axis. The winding apparatus can comprise a first plurality of projections coupled to and extending from a perimeter of the first rim and a second plurality of projections coupled to and extending from a perimeter of the second rim. A thread guide can be configured to dispense a continuous thread to wind one or more continuous threads around all or a subset of the first and second plurality of projections on the first and second rims.

What is claimed is: 
     
         1 . A winding apparatus for manufacturing an article of apparel, the winding apparatus comprising:
 a first rim;   a second rim coupled to and spaced apart from the first rim, the first and second rims rotatable on a rotation axis;   a first plurality of projections coupled to and extending from a perimeter of the first rim;   a second plurality of projections coupled to and extending from a perimeter of the second rim;   a thread guide configured to dispense a continuous thread, the thread guide moveable along a second axis parallel to the rotation axis;   a first actuator configured to rotate the first and second rims; and   a second actuator configured to move the thread guide along the second axis and between projections of the first and second pluralities of projections.   
     
     
         2 . The winding apparatus of  claim 1 , wherein the rotation axis is parallel or perpendicular to a gravity vector during operation. 
     
     
         3 . The winding apparatus of  claim 1 , further comprising:
 a first flexible chain comprising the first plurality of projections, the first flexible chain removably coupled to the first rim; and   a second flexible chain comprising the second plurality of projections, the second flexible chain removably coupled to the second rim.   
     
     
         4 . The winding apparatus of  claim 3 , wherein the first and second flexible chains are flexible between a linear state and a circular state to couple the first and second flexible chains to the first and second rims. 
     
     
         5 . The winding apparatus of  claim 1 , wherein the first and second rims are each coupled to a plurality of spokes. 
     
     
         6 . The winding apparatus of  claim 1 , wherein the first and second rims are spaced apart by a distance between 5 cm and 3 m. 
     
     
         7 . The winding apparatus of  claim 1 , wherein each projection of the first and second pluralities of projections extends at an angle relative to the rotation axis, the angle being from 45 degrees to 180 degrees. 
     
     
         8 . The winding apparatus of  claim 7 , wherein the angle is from 95 degrees to 175 degrees. 
     
     
         9 . The winding apparatus of  claim 1 , further comprising a support, the support comprising:
 a first end coupled to the first rim; and   a second end coupled to the second rim.   
     
     
         10 . The winding apparatus of  claim 1 , further comprising:
 a flexible sheet comprising the first plurality of projections and the second plurality of projections, the flexible sheet removably coupled to the first and second rims.   
     
     
         11 . The winding apparatus of  claim 10 , wherein the flexible sheet is flexible between a linear state and a circular state to couple the first and second pluralities of projections to the first and second rims. 
     
     
         12 . A method of making an article of apparel, the method comprising:
 rotating a first rim and a second rim coupled together and spaced apart by a support, the first rim coupled to a first plurality of projections that extend from a perimeter of the first rim, and the second rim coupled to a second plurality of projections that extend from a perimeter of the second rim;   dispensing a continuous thread via a thread guide; and   moving the thread guide along an axis parallel to the support and between projections of the first and second pluralities of projections to wind the continuous thread around a plurality of the first plurality of projections and around a plurality of the second plurality of projections.   
     
     
         13 . The method of  claim 12 , further comprising changing at least one of a rotation rate or a rotation direction of the first and second rims while moving the thread guide. 
     
     
         14 . The method of  claim 12 , further comprising rotating at least one of the first rim or the second rim independently from one another after winding the continuous thread around the plurality of the first plurality of projections and around the plurality of the second plurality of projections. 
     
     
         15 . The method of  claim 12 , wherein:
 a first flexible chain comprises the first plurality of projections, the first flexible chain removably coupled to the first rim; and   a second flexible chain comprises the second plurality of projections, the second flexible chain removably coupled to the second rim; and   wherein the method further comprises removing the first and second flexible chains from the first and second rims after winding the continuous thread around the plurality of the first plurality of projections and around the plurality of the second plurality of projections.   
     
     
         16 . The method of  claim 15 , wherein winding the continuous thread around the plurality of the first plurality of projections and around the plurality of the second plurality of projections forms a thread layer comprising a plurality of thread lines, with each thread line extending between one of the first plurality of projections and one of the second plurality of projections. 
     
     
         17 . The method of  claim 16 , further comprising bonding thread lines of the plurality of thread lines to one another after removing the first and second flexible chains from the first and second rims. 
     
     
         18 . The method of  claim 16 , further comprising cutting the thread layer after removing the first and second flexible chains from the first and second rims. 
     
     
         19 . The method of  claim 16 , further comprising winding a second continuous thread around the plurality of the first plurality of projections and around the plurality of the second plurality of projections to form a second thread layer comprising a second plurality of thread lines, with each thread line of the second plurality of thread lines extending between one of the first plurality of projections and one of the second plurality of projections.