Custom Embroidery Frame with Adjustable Receiving Cavity
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Solution Overview
Problem
Traditional embroidery techniques rely on static-sized and static-shaped tensioning members, leading to inefficiencies such as excess material usage, increased manufacturing steps, and resource wastage, particularly when dealing with irregularly shaped or sized materials.
Innovation Solution
A custom embroidery frame with a receiving cavity sized and shaped to match the specific dimensions of the material to be embroidered, optionally using a gasket for compression, allowing for precise alignment and tensioning of composite materials during the embroidery process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional fixed-size tensioning members are used, then the embroidery process can be performed with standard equipment, but excess material is needed and multiple manufacturing steps are required
Solution Approach 1:
The tensioning member is designed with adjustable dimensions, allowing it to be dynamically resized to match the exact boundaries of the material to be embroidered. This eliminates the need for fixed-size hoops and enables the member to adapt to different material sizes and shapes, thereby reducing material waste while maintaining ease of manufacture
Solution Approach 2:
The invention changes the size parameter of the tensioning member from fixed to variable. By enabling continuous adjustment of the member's dimensions, the system can optimize the fit around the material boundaries, reducing excess material requirements while keeping the manufacturing process simple through a single integrated device
2Productivity
If fixed-size maintaining members are used, then standard equipment can be utilized, but multiple facilities and manufacturing steps are needed
Solution Approach 1:
The adjustable tensioning member serves multiple functions: it acts as both the maintaining member and the boundary definition tool, eliminating the need for separate cutting and embroidery facilities. This multi-functional design consolidates multiple manufacturing steps into one, improving productivity while managing device complexity through a single versatile component
Solution Approach 2:
The invention merges the functions of the tensioning member with the material boundary definition. By combining what were previously separate operations (defining material boundaries and providing tension) into a single adjustable member, the system reduces the number of manufacturing steps and facilities needed, thereby improving overall manufacturing efficiency
3Reliability
If oversized material cuts are made to accommodate fixed maintaining members, then the material can be tensioned properly, but excess material must be sent to multiple facilities
Solution Approach 1:
The adjustable tensioning member allows the system to dynamically adapt to the exact size and shape of the material to be embroidered. This eliminates the need to cut oversized material in advance, as the member can be resized to fit the actual material boundaries, thereby maintaining proper tensioning quality while reducing manufacturing cycle time by eliminating unnecessary cutting and transport steps
Data Source
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AI summary
Aspects of the present invention relate to systems and methods of utilizing a custom embroidery system. A custom embroidery frame is comprised of a custom receiving cavity sized and shaped to receive a composite piece for embroidery. The size and the shape of the custom receiving cavity correspond with a size and a shape of the portion of the composite piece onto which an embroidery device will embroider. Additionally, a gasket with a size and a shape adapted to be inserted into the receiving cavity and around the portion of the composite piece may optionally be utilized.