Laser finishing method for providing a finishing pattern on a fabric
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Solution Overview
Problem
Current laser finishing methods for fabrics, particularly denim, fail to accurately replicate a faded or worn appearance due to uniform removal of yarns, leading to unrealistic visual effects and environmental concerns from chemical use in traditional techniques.
Innovation Solution
A method utilizing a laser apparatus with a control unit and moving means to scribe patterns on fabric based on a 2D or 3D model of the article, allowing precise alignment and adjustment of the finishing pattern to match the fabric's weave and geometry, thereby replicating a realistic worn appearance without chemicals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional chemical finishing techniques are used to achieve a faded or worn appearance, then a realistic visual effect is obtained, but environmental damage and chemical harm occur
Solution Approach 1:
The patent replaces chemical finishing processes with a laser-based mechanical/thermal system. The laser beam selectively removes dye from the fabric through controlled thermal energy, achieving the faded or worn appearance without using harmful chemicals. This substitution eliminates environmental and human harm while maintaining the realistic visual effect.
2Reliability
If laser finishing is applied to assembled clothing articles, then the process accounts for seams and hidden portions, but the pattern reproduction accuracy decreases due to complex geometry
Solution Approach 1:
The patent applies the finishing pattern to the fabric before the clothing article is assembled into its final three-dimensional form. By treating the flat fabric in advance, the laser can accurately reproduce the pattern without the complications of seams, hidden portions, and complex geometry that arise during final assembly. The fabric is then cut and sewn into the clothing article, preserving pattern accuracy.
Solution Approach 2:
The patent separates the finishing process from the final assembly process. The fabric is first finished with the laser pattern while still in a flat, accessible state, then subsequently cut and assembled into the three-dimensional clothing article. This segmentation allows the laser to work on a simple two-dimensional surface, ensuring pattern accuracy without needing to account for complex final geometry.
3Ease of manufacture
If laser lines are scribed perpendicular or parallel to warp yarns, then the laser processing is simplified, but the finishing pattern does not provide the desired visual effect on diagonal weave fabrics
Solution Approach 1:
The patent changes the angular parameter of the laser lines from the conventional perpendicular/parallel orientation to an oblique angle that aligns with the diagonal weave pattern of the fabric. This parameter adjustment allows the laser to follow the natural diagonal structure of twill or denim fabrics, creating a realistic faded or worn appearance that matches the fabric's inherent pattern, while still maintaining relatively simple laser processing.
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 method achieves a high-quality, realistic faded or worn finish on fabrics by accurately aligning the laser-scribed patterns with the fabric's weave, reducing environmental impact and avoiding the use of chemicals, while ensuring correct positioning on complex clothing articles.
Implementation Method 1
the localized thermal effect of the laser beam selectively removes dyes, paints or breaks yarns
Implementation Method 2
the localized thermal effect of the laser beam selectively removes dyes
Data Source
Figure 1a
Figure 1b
Figure 2a~2b
AI summary
It is disclosed a method for providing a finishing pattern (3) on a fabric (20) by a laser apparatus (1) comprising at least one laser source (10) generating an output laser beam (11) and moving means (12) for said laser beam and a control unit (200), the fabric (20) being suitable to be used for assembling an article, preferably a clothing article (20a), the method comprising the steps of providing at least one predetermined finishing pattern (3, 3', 3", 3"') to be scribed on said fabric (20); the step of providing an input model (2, 2') of at least one portion of the article (20a) to be scribed with said predetermined finishing pattern (3), said model (2) comprising at least one portion or surface (2b - 2i) corresponding to a portion or surface (20b - 20i) of the article (20a) to be scribed; the step of combining said predetermined finishing pattern (3, 3', 3", 3"') to be scribed on said fabric (20) and said input model (2, 2') of the article (2b - 2i) to be scribed, in an output model (5, 5') of at least one scribed portion of said article (20a), said output model comprising at least one scribed portion or surface (5b - 5i) corresponding to a portion (20b - 20i) of the article (20a) scribed with the predetermined finishing pattern (3, 3', 3", 3"'); the step of providing command instructions (100) for operating said laser apparatus (1) for scribing said predetermined finishing pattern (3, 3', 3", 3"') on said fabric (20) according to said output model (5, 5') and operating said laser source (10) and said moving means (12) for generating said output laser beam (11) for scribing lines and/or dots (13) forming the predetermined finishing pattern (3, 3', 3", 3"') on said fabric (20) according to said command instructions (100).