BACKGROUND

[0001] Articles of manufacture may comprise materials with slits. The slits may be decorative or may serve functional purposes, such as to promote flexibility or ventilation of the materials. Current methods of forming slits in materials may suffer from inefficiencies.

Additionally, current methods of forming may leave the materials vulnerable to fraying or tearing.

SUMMARY

[0002] A sonic stamp may comprise a cutting component configured to cut a slit in a material. The slit may be sonically cut. The sonic stamp may comprise a welding component configured to sonically weld a region adjacent to the slit, contemporaneous to the cutting of the slit. The sonic welding and/or sonic cutting may improve the efficiency of slit forming methods by cutting slits through various layers or plies of material at a time. The sonic welding may improve slit forming methods by sealing the region adjacent the slit to prevent tearing or fraying. The sonic welding may bond various layers or plies of the material.

[0003] A sonic roller may comprise a plurality of sonic stamps. The sonic roller may be rolled across a material. The sonic roller may improve the efficiency of slit forming by eliminating the need to reposition the material or position the cutting component over a selected area of the material where the slit is to be formed.

BRIEF DESCRIPTION OF THE DRAWINGS

[0004] The following drawings illustrate generally, by way of example, but not by way of limitation, various examples discussed in the present disclosure. In the drawings:

[0005] FIG. 1 shows an example sonic stamp.

[0006] FIG. 2 shows an example sonic stamp.

[0007] FIG. 3 shows an example sonic roller.

[0008] FIG. 4 shows an example method.

[0009] FIG. 5 shows an example method. DETAILED DESCRIPTION

[0010] FIG. 1 shows an example sonic stamp 100. FIG. 1 A shows a top-down view of the sonic stamp 100. FIG. 1B shows a perspective view of the sonic stamp 100. The sonic stamp 100 may be connected to a source of electrical power. The electrical power may be converted to vibratory energy, such as by a transformer. The vibratory energy may have a frequency equal to or greater than 20 kHz The vibratory energy by be transmitted to a welding component 101. The welding component 101 may be configured to sonically or ultrasonically weld a portion of a material. The welding component 101 maybe configured to sonically weld material that is put in contact with the welding component 101.

[0011] Sonically welding may comprise using vibratory energy to cause localized heating or predetermined energy density in a region of the material or between two or more plies or layers of the material. Sonically welding the material may comprise bonding one or more plies of the material together. For example, if the material comprises one or more folded or superposed layers of the material, the welding component 101 may bond at least a portion of each of the layers together. If the material comprises one or more stacked plies of different materials, the welding component 101 may bond at least a portion of each of the plies together. Sonically welding the material may comprise sealing the regions of the material, such as to prevent fraying or tearing. Sealing the regions may comprise fusing fibers in the region.

[0012] The welding component 101 may comprise one or more faces 102. The faces may be joined by a side, a surface, or a wall 103. At least a portion of the side 103 may be curved. At least a portion of the side 103 may be straight. One of the faces l02a may be disposed adjacent a base 104 of the sonic stamp 100. The base 104 may comprise a planar surface. The base 104 may comprise a surface of a body, such as a three-dimensional body.

[0013] The sonic stamp 100 may comprise a cutting component 105. The vibratory energy may be transmitted to the cutting component 105. The cutting component 105 may be disposed adjacent the welding component 101. For example, the cutting component 105 may be protruding from the welding component 101. The cutting component 105 may be protruding from a face 102 of the welding component 101, such as the face l02b opposite the face l02a disposed adjacent the base 104. The cutting component 105 may protrude from a center of the face l02b of the welding component 101. [0014] The cutting component 105 may be configured to cut the material. The cutting component 105 may be configured to cut material that is put in contact with the cutting component. The cutting component 105 may be configured to cut a slit in the material. If the material comprises a plurality of plies, such as folded layers or stacked or superposed plies of different materials, the cutting component 105 may be configured to cut a list through each of the layers or plies.

[0015] The cutting component 105 may be configured to sonically or ultrasonically cut the material. The cutting component 105 may comprise a blade. Sonically or ultrasonically cutting the material may comprise vibrating the blade, such as at a frequency greater than or equal to 20 kHz. The blade may be vibrated by applying electric energy to a transducer or to a piezoelectric element configured to displace the transducer. An oscillator may be configured to drive the transducer. The blade may be vibrated at a selected amplitude, such as between 10-70 pm. The frequency and amplitude may be selected or controlled based on the material. For example, the frequency and amplitude may be selected based on a thickness of the material or type of the material.

[0016] The cutting component 105 or the blade may have a shape. As a non-limiting example, FIG. 1 shows the cutting component 105 having a linear shape. However, other shapes are possible, such as elliptical shapes, triangular shapes, quadrilateral shapes, star shapes, rounded shapes, or asymmetrical shapes, as examples. The shape of the cutting component 105 may be selected based on a desired property of the material or of an article comprising the material. Example properties include permeability, weight, waterproofing, insulation, or aesthetics. The property may comprise a pattern of slits or cuts in the material or article. The pattern may be selected based on a type of article to be manufactured using the material, such as outerwear, footwear, underwear, headwear, athletic wear, sporting equipment, outdoor equipment, or automotive accessories. For example, a linear shape may be selected for a cutting component 105 configured to cut a button hole for a waist area of pants. A round shape may be selected for a cutting component 105 configured to cut ventilation holes for a lining of a jacket.

A coil shape may be selected for a cutting component 105 configured to cut decorative holes in a pair of tights. A teardrop shape may be selected for a cutting component configured cut holes in the exterior fabric for a running shoe. The cutting component 105 may be configured to cut an opening in the material having a shape corresponding to the shape of the cutting component 105. [0017] The welding component 101 and the cutting component 105 may be configured to simultaneously cut and weld the material, respectively. The welding component 101 may be configured to weld a region of the material surrounding the slit in the material formed by the cutting component 105. The welding of the region may function to seal the region of the fabric, such as to prevent fraying of the material around a perimeter of the slit or to prevent tearing of the material. The welding of the material may bond a region of each of a plurality of plies of the material simultaneous to the cutting component 105 cutting a slit through each of the plies.

[0018] FIG. 2 shows an example sonic stamp 200. FIG. 2A shows a perspective view of the sonic stamp 200. FIG. 2B shows a top-down view of the sonic stamp 200. FIG. 2C shows a first side view of the sonic stamp 200. FIG. 2D shows a second side view of the sonic stamp 200. The sonic stamp 200 may be like the sonic stamp 100 in FIG. 1. The sonic stamp 200 may comprise a welding component 201 and a cutting component 205. The welding component may comprise faces 202. The faces 202 may be joined by a wall 203. FIG. 2C and 2D show the welding component 201 having an elongated shape with rounded ends. However, other shapes of the welding component 201 are possible. As non-limiting examples, the welding component 201 may have a quadrilateral shape, a round shape, a linear shape, a symmetrical shape, or an asymmetrical shape. The shape of the welding component 201 may be selected based on the shape of the cutting component 205. For example, the shape of the welding component 201 may be similar to the cutting component 205. The welding component 201 may have the same shape, but different dimensions than the cutting component 205.

[0019] FIG. 3 shows an example sonic roller 310. The sonic roller 310 may comprise a plurality of sonic stamps 300. The sonic stamps 300 may be like the sonic stamps 100 in FIG. 1 or 200 in FIG. 2. The sonic stamps 300 may be disposed adjacent a surface 304 of the sonic roller 310. The sonic roller 310 may comprise a three-dimensional body 306. The three- dimensional body 306 may comprise a cylindrical shape.

[0020] The sonic roller 310 may comprise shafts 307. The shafts 307 may be configured to be engaged by or coupled to a driver. The driver may be configured to rotate the sonic roller 310 about an“X” axis. The shafts 307 may be coupled to ends of the body 306. The shafts 307 may be components of or coupled to a rod traversing a cavity of the body 306. The cavity may pass from a first end 308a of the sonic roller 310 to a second end 309b of the sonic roller, opposite the first end 308a. The cavity may transverse a center of the body 306. The cavity may be cylindrical and may have a circumference. The circumference of the cavity may comprise an inner circumference of the body 306, which may be less than an outer circumference of the body 306. The rod may be cylindrical and may have a circumference less than the circumference of the cavity. The body 308 may be configured to rotate about the rod. For example, the body 308 may be configured to rotate about the rod when the body is put in contact with a material and when the rod is moved in a direction along a“y” axis orthogonal to the“x” axis.

[0021] The sonic stamps 300 may be arranged on the surface 304 randomly or in a pattern. The pattern may be selected based on a desired physical property of the material or of an article comprising the material. Example properties include permeability, weight,

waterproofing, insulation, or aesthetics. The property may comprise a pattern of slits or cuts in the material or article. The pattern may be selected based on type of article to be manufactured using the material, such as outerwear, footwear, underwear, headwear, athletic wear, sporting equipment, outdoor equipment, or automotive accessories.

[0022] FIG 4. shows an example method. At step 401, a material may be prepared for sonic slitting. The material may comprise a fabric, a knit material, or a woven material, as examples. The material may comprise one or more synthetic materials, such as a thermoplastic. The material may comprise a composite material, such as a material comprising a blend of fibers.

[0023] Preparing the material may comprise folding a piece of the material. Preparing the material may comprise stacking a plurality of plies of the material. Preparing the material may comprise stacking a plurality of plies of different materials. Preparing the material may comprise stretching the material. Preparing the material may comprise laying the material on a surface. The surface may comprise a surface with a hardness that is resistant to cutting, such as with the cutting component of the sonic roller. The surface may have a heat resistance such that heat from the welding component of the sonic roller will not melt the surface. Preparing the material may comprise securing one or more ends of the material.

[0024] At step 402, a sonic roller may be put in contact with the material. The sonic roller may be like the sonic roller 310 in FIG. 3. The sonic roller may be put in contact with a layer or ply of a plurality of layers or plies of the material. For example, the sonic roller may be put in contact with a layer or ply on top of a stacked, folded, or superposed layers or plies. The sonic roller may be put in contact with the material manually or by a machine. The machine may comprise a driver configured to move the sonic roller across the material. Pressure or a load may be applied to the sonic roller. The sonic roller may exert pressure on the material.

[0025] At step 403, the sonic roller may be moved relative to the material. The sonic roller may be rolled against the material. As the sonic roller is rolled, a plurality of sonic stamps of the sonic roller may be rolled over the material. Rolling the sonic roller, such as over stretched material, may comprise a more efficient way to form slits in a material, as compared to using a blade that must be repositioned over selected areas of the material where the slits are to be formed.

[0026] At step 404, when the sonic stamps come into contact with the material, the cutting components of the sonic stamps may cut the material at locations in the material at which the cutting components make contact. When the sonic stamps come into contact with the material, the welding components of the sonic stamps may sonically weld regions of the material at which the welding components make contact. Any of steps 402, 403, or 404 may be performed simultaneously or non-simultaneously.

[0027] FIG. 5 shows an example method. At step 501, a material may be prepared for sonic slitting. The material may comprise a fabric, a knit material, or a woven material, as examples. The material may comprise one or more synthetic materials, such as a thermoplastic. The material may comprise a composite material, such as a material comprising a blend of fibers.

[0028] Preparing the material may comprise folding a piece of the material. Preparing the material may comprise stacking a plurality of plies of the material. Preparing the material may comprise stacking a plurality of plies of different materials. Preparing the material may comprise stretching the material. Preparing the material may comprise laying the material on a surface. Preparing the material may comprise securing one or more ends of the material.

[0029] At step 502, a slit may be cut through the material. The slit may be cut by a cutting component of a sonic stamp, such as the sonic stamp 100 in FIG. 1, 200 in FIG. 2, or 300 in FIG. 3. The slit may be sonically cut. The slit may be cut through more than one layers or plies of the material. The slit may be cut by putting the cutting component in contact with the material or with a top layer or ply of a stack of materials or folded materials.

[0030] The slit may be cut in a shape corresponding to a shape of the cutting

component or to a blade of the cutting component. For example, the slit may have the same dimensions as the cutting component. The slit may be cut through more than one layers or plies of a stack of materials or folded materials, such as a subset of the layers or plies or all of the layers or plies.

[0031] At step 503, a region of the material adjacent to the slit may be welded. The region may be welded by a welding component of the sonic stamp, such as the welding component 101 in FIG. 1, 201 in FIG. 2, or FIG. 301 in FIG. 3. The region may surround the slit. A region of more than one layers or plies of a stack of materials or folded materials may be welded, such as a subset of the layer or plies or all of the layers or plies.

[0032] Welding the material may comprise sealing the material, such as to prevent fraying adjacent to the sealed region or tearing through the sealed region. Welding the material may comprise bonding one or more layers or plies of material. Steps 502 and 503 may be performed simultaneously or non-simultaneously.

[0033] The present disclosure comprises at least the following aspects.

[0034] Aspect 1. A sonic stamp comprising: a welding component; and a cutting component protruding from a face of the welding component; wherein the cutting component is configured to cut, through one or more plies of material, a slit having a shape of the cutting component; and wherein the welding component is configured to sonically weld a region of each of the one or more plies of material surrounding the slit.

[0035] Aspect 2. The sonic stamp of aspect 1, further comprising a transducer configured to ultrasonically vibrate the cutting component.

[0036] Aspect 3. The sonic stamp of aspect 1, further comprising a transducer configured to ultrasonically vibrate the welding component.

[0037] Aspect 4. The sonic stamp of aspect 1, wherein the cutting component is configured to cut the slit by sonically cutting the slit.

[0038] Aspect 5. The sonic stamp of aspect 1, wherein the shape of the cutting component comprise a linear shape.

[0039] Aspect 6. A sonic stamp comprising: a base; a welding component having a first face disposed adjacent the base and having a second face opposite the first face; and a cutting component protruding from the second face of the welding component; wherein the cutting component is configured to cut a slit through one or more plies of material; and wherein the welding component is configured to sonically weld a region of each of the one or more plies of material surrounding the slit. [0040] Aspect 7. The sonic stamp of aspect 6, wherein the base comprises a cylindrical roller.

[0041] Aspect 8. The sonic stamp of any of aspects 6 or 7, wherein the sonic stamp further comprises a plurality of welding components disposed adjacent the base.

[0042] Aspect 9. A sonic roller comprising: a base; and a plurality of sonic stamps coupled to the body, wherein each of the plurality of sonic stamps comprises: a welding component having a first face disposed adjacent the base and having a second face opposite the first face; and a cutting component protruding from the second face of the welding component; wherein the cutting component is configured to cut a slit through one or more plies of material; and wherein the welding component is configured to sonically weld a region of each of the one or more plies of material surrounding the slit.

[0043] Aspect 10. The sonic roller of aspect 9, wherein the base comprises a cylindrical body.

[0044] Aspect 11. The sonic roller of aspect 9, wherein the plurality of sonic stamps are arranged in a pattern on the base.

[0045] Aspect 12. The sonic roller of aspect 11, wherein the pattern is selected based on a type of article to be manufactured comprising the one or more plies of material.

[0046] Aspect 13. The sonic roller of aspect 11, wherein the pattern is selected based on a slit design for the one or more plies of material.

[0047] Aspect 14. The sonic roller of aspect 11, wherein the pattern is selected based on a physical property of an article to be manufactured comprising the one or more plies of material.

[0048] Aspect 15. The sonic roller of aspect 11, wherein the cutting component is configured to cut the slit having a shape of the cutting component.

[0049] Aspect 16. The sonic roller of aspect 15, wherein the shape comprises a linear shape.

[0050] Aspect 17. A method comprising: cutting, with a cutting component, a slit through one or more plies of a material; and contemporaneously, sonically welding, with a welding component coupled to the cutting component, a region of each of the one or more plies of the material surrounding the slit. [0051] Aspect 18. A method comprising rolling the sonic roller of aspect 9 against the one or more plies of material, wherein the each of the plurality of sonic stamps cuts and sonically welds the one or more plies of material when the each of the plurality of sonic stamps is disposed adjacent the one or more plies of material.

[0052] Aspect 19. A material comprising: one or more slits; and one or more welded regions each adjacent to at least one of the one or more slits; wherein the one or more slits and the one or more welded regions are formed using a sonic stamp comprising: a welding component configured to sonically weld the one or more regions, and a cutting component protruding from a face of the welding component and configured to cut the one or more slits.

[0053] Aspect 20. An article comprising the material of aspect 19.