Damage process for a textile product
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Solution Overview
Problem
Current methods for decolorizing dyed cotton fabrics, such as denim, are time-consuming and costly due to their manual and water-intensive nature, requiring extensive labor and large water consumption.
Innovation Solution
A method involving laser irradiation to burn the fabric surface, followed by ozone treatment and agitation with artificial stones and scourers to shave the surface, reducing the need for water and labor through a more efficient process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual dry processes and water-intensive wet processes are used for decolorization, then the fabric can be effectively decolorized, but the process becomes time-consuming and costly with extensive labor and large water consumption
Solution Approach 1:
The patent replaces manual mechanical processes (hand shaving, hand-sand rubbing) with automated laser beam irradiation to burn the fabric surface and create patterns, significantly reducing labor time and operational complexity while maintaining decolorization effectiveness
Solution Approach 2:
The patent utilizes phase transition of water to steam through laser heating, where the laser beam rapidly heats and vaporizes moisture on the fabric surface, creating the desired decolorization and texture effects without requiring extensive water-intensive wet processing steps
2Measurement precision
If manual dry processes and water-intensive wet processes are used for decolorization, then the fabric can be effectively decolorized, but the process becomes costly with extensive labor and large water consumption
Solution Approach 1:
The patent replaces labor-intensive manual operations with automated laser processing and machine agitation systems, eliminating the need for extensive manual labor while reducing water consumption by avoiding traditional wet processing steps, thereby significantly lowering operational costs
Solution Approach 2:
The patent extracts and eliminates the water-intensive wet processing steps from the traditional decolorization process, using only dry laser processing and air agitation with artificial stones, which removes the associated costs of water consumption, wastewater treatment, and extensive labor
3Shape
If traditional stone washing methods are used, then the fabric achieves a used and abused appearance, but the process damages or excessively wears the fabric
Solution Approach 1:
The patent changes the physical parameters of the abrasion process by using controlled laser burning to create patterns and using machine agitation with artificial stones instead of traditional heavy stones, achieving the desired used appearance while controlling the intensity to prevent excessive fabric damage
Solution Approach 2:
The patent introduces artificial stones as an intermediary material that provides controlled abrasion surfaces, creating the desired fabric texture and appearance without the uncontrolled damage caused by traditional natural stones, while the laser beam serves as an intermediary for precise pattern creation
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
Significantly reduces water consumption and operational time, lowering costs while achieving effective decolorization and texture modification, with estimated costs reduced by approximately 65% per piece of fabric.
Implementation Method 1
irradiating a laser beam onto a surface region of a textile product which is dyed, to burn the surface region
Implementation Method 2
exposing the textile product to an ozone gas; and agitating the textile product together with at least one of: pieces of one or more solid materials having uneven surfaces and one or more abrasives of artificial fibers
Implementation Method 3
agitating the textile product together with at least one of: pieces of one or more solid materials having uneven surfaces and one or more abrasives of artificial fibers to allow the surface region to be shaved
Data Source
Figure 1
Figure 2
AI summary
A damage process for a textile product is provided. The process includes agitating a textile product having a moist surface together with one or more abrasives of artificial fibers to allow the moist surface to be shaved by the one or more abrasives of artificial fibers.