Projecting finishing pattern with correction onto three-dimensional surface

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The traditional process of producing jeans with finishing patterns is resource-intensive, time-consuming, and costly, requiring significant water and chemical usage, which has a high environmental impact.

Innovation Solution

A software and laser-based system that allows users to create, preview, and apply finishing patterns on jeans, using a laser to burn designs onto the fabric, reducing the need for water and chemicals while maintaining the desired aesthetic.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If traditional water and chemical-based finishing processes are used, then finishing patterns can be achieved on jeans, but significant water and chemical resources are consumed, leading to high environmental impact

Engineering Contradiction:

Improvewater and chemical usageVSAvoidenvironmental impact

Core Design Contradiction:

Loss of substanceVSEase of manufacture

Solution Approach 1:

The patent replaces traditional water-based chemical finishing processes with a laser-based physical system. The laser beam directly ablates or heats the denim fabric to create finishing patterns without requiring water, chemicals, or ozone, thereby eliminating the harmful substance consumption associated with conventional methods

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the fundamental parameter of the finishing process from chemical/water-based to energy-based (laser). By controlling laser parameters such as power, speed, and pattern, the system achieves the same aesthetic finishing effects without the environmental drawbacks of traditional substance-intensive methods

Inventive Principle:

Principle #35Parameter changes

2Productivity

If traditional finishing processes are used, then finishing patterns can be produced, but the process takes significant time and is resource-intensive

Engineering Contradiction:

Improveprocessing timeVSAvoidresource consumption

Core Design Contradiction:

ProductivityVSQuantity of substance

Solution Approach 1:

The laser-based system replaces slow, multi-step mechanical and chemical processes with a rapid energy delivery system. The laser can quickly scan and treat large areas of denim fabric, significantly reducing processing time while consuming minimal resources compared to water immersion and chemical treatment methods

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The laser finishing process enables continuous treatment of denim fabric as it moves through the system, rather than requiring batch processing with multiple intermediate steps. This continuous action increases productivity while maintaining low resource consumption throughout the process

Inventive Principle:

Principle #20Continuity of useful action

3Adaptability or versatility

If traditional finishing methods are used, then various finishing patterns can be achieved, but the process is costly and environmentally harmful

Engineering Contradiction:

Improvedesign varietyVSAvoidenvironmental harm

Core Design Contradiction:

Adaptability or versatilityVSObject-generated harmful factors

Solution Approach 1:

The laser system allows dynamic adjustment of finishing patterns through software control. Different patterns (combs, honeycombs, whiskers, stacks, train tracks) can be programmed and applied on-demand without changing physical tools or chemicals, providing design versatility while eliminating the environmental harm associated with multiple chemical treatment processes

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The single laser device serves multiple functions: it can create various finishing patterns, adjust intensity levels, and treat different areas of the jeans. This universal tool replaces multiple specialized chemical processes, reducing environmental harm while maintaining adaptability for diverse design requirements

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

This method reduces processing time and costs, minimizes environmental impact, and allows for efficient production of various designs from a single fabric template, enhancing productivity and inventory management.

Implementation Method 1

A laser beam is scanned across a surface of the denim to finish the denim

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

A laser beam is scanned across a surface of the denim to finish the denim

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS11549211B2Projecting finishing pattern with correction onto three-dimensional surface

Publication Date: 2023.01.10 STRAUSS LEVI & CO

AI summary

A system allows a user to create new designs for apparel and preview these designs before manufacture. Software and lasers are used in finishing apparel to produce a desired finishing pattern or other design. The system provides three-dimensional previews of their designs on a mannequin, using light projection techniques.