Thermal Transfer Yarn Coloring for Durable Woven QR Labels
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Solution Overview
Problem
Conventional methods for creating colored two-dimensional code fabrics are not wear-resistant, prone to fading, and lack anti-counterfeiting features, while also being environmentally harmful due to high water and fuel usage in dyeing processes and resulting in thick, uncomfortable fabrics with high production costs.
Innovation Solution
A system comprising an image processing device, yarn coloring mechanism, and weaving machine that transfers colors from colored papers onto yarns using thermal sublimation, allowing for the creation of colored woven labels with embedded two-dimensional codes without the need for multi-colored yarns, thus reducing fabric thickness and environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional dyeing methods are used to color yarns for two-dimensional code fabrics, then color variety is achieved, but environmental pollution increases due to water vapor, fuel consumption, and chemical waste
Solution Approach 1:
The patent replaces the conventional chemical dyeing process with a thermal transfer printing process. Instead of using chemical dyes and extensive water-based processing, the invention uses heat transfer technology to apply colors to the fabric surface, eliminating the need for harmful chemicals, reducing water consumption, and minimizing environmental pollution while maintaining color variety.
Solution Approach 2:
The invention changes the fundamental parameter of color application from chemical infiltration (dyeing) to thermal transfer deposition. By using heat as the transfer medium rather than chemical dyes, the process achieves color variety without the associated environmental harm of water vapor, fuel consumption, and chemical waste.
2Ease of manufacture
If multiple colored yarns are knitted into the fabric to enhance anti-counterfeiting effect, then color variety and anti-counterfeiting capability are improved, but fabric thickness increases resulting in poor softness
Solution Approach 1:
The patent extracts the color application step from the yarn preparation stage and applies it directly to the finished fabric surface. Instead of incorporating multiple colored yarns throughout the fabric structure, the invention applies color only where needed on the surface, maintaining fabric thinness and softness while achieving the desired anti-counterfeiting effect through visible color patterns.
Solution Approach 2:
The invention transitions from a three-dimensional color distribution (multiple colored yarns throughout the fabric bulk) to a two-dimensional surface application (thermal transfer printing on the fabric surface). This dimensional change reduces fabric thickness and maintains softness while still providing sufficient color variety for anti-counterfeiting purposes.
3Ease of manufacture
If multiple colored yarns are used to create colored two-dimensional code fabrics, then anti-counterfeiting effect is enhanced, but production cost increases due to larger raw material requirements
Solution Approach 1:
The patent uses thermal transfer printing to create precise color copies of the two-dimensional code pattern directly on the fabric surface. Instead of requiring multiple types of colored yarns as raw materials, the invention uses a single yarn type and applies color patterns through thermal transfer, significantly reducing raw material requirements and production costs while maintaining the anti-counterfeiting effect.
4Productivity
If printed labels are used for two-dimensional codes, then production cost is reduced, but wear-resistance and water-resistance are poor causing codes to blur or fade
Solution Approach 1:
The patent combines the advantages of both printed and woven approaches by using thermal transfer printing to apply color patterns to woven fabric. The base fabric provides the wear-resistance and structural integrity, while the thermal transfer color layer provides the durable, high-quality code pattern. This composite approach maintains code durability through washing while keeping production costs lower than conventional multi-yarn methods.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution results in a more durable, comfortable, and cost-effective colored woven label with improved anti-counterfeiting properties, while minimizing water and fuel usage, thereby reducing environmental harm and production costs.
Implementation Method 1
a portion of the inner colored paper is pressed against and covers a portion of the outer circumferential surface... transfer the colors of the inner and outer colored papers onto the yarn
Data Source
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AI summary
A system for colored woven label fabrication includes an image processing device (700), a yarn coloring mechanism (100) and a weaving machine (800). The yarn coloring mechanism (100) colors a yarn (13) to be woven into a colored woven label by the weaving machine (800) according to a weaving electronic file generated by the image processing device (700).