Method of producing a processed material

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Solution Overview

Problem

Conventional methods for producing pleated fabrics using shrink films are limited in expressing pleats and face difficulties in reliably removing the shrink film, making them cumbersome and in need of improvement.

Innovation Solution

A method involving applying a sizing agent containing a foaming agent to a cloth material, followed by pressing with a heated metal plate to foam the agent, and optionally using a second sizing agent with a coloring agent or sublimation transfer printing to create various concave-convex patterns and pleats.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If shrink film is used to produce pleated fabric, then pleats can be formed, but the shrink film is difficult to remove reliably and the method is troublesome

Engineering Contradiction:

Improvepleat formationVSAvoidshrink film removal

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The invention extracts and eliminates the shrink film component from the pleating process. Instead of using shrink film that needs to be removed, the patent applies a sizing agent directly to the fabric that creates pleats through its own structural properties, removing the need for a separate removable film layer entirely

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The sizing agent serves as an intermediary substance that mediates between the fabric and the pleating process. It is applied directly to the fabric surface and acts as the active agent that creates and maintains pleat structures through its molecular properties, replacing the need for shrink film

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If conventional shrink film method is used, then pleats can be produced, but the method is limited in expressing various pleat designs

Engineering Contradiction:

Improvepleat expressionVSAvoidpleat design variety

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The sizing agent can be applied locally to specific areas of the fabric, creating different pleat patterns and expressions in different regions. This allows for varied pleat designs across the same fabric piece, enabling complex patterns and expressions that were not achievable with uniform shrink film application

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention utilizes changes in the physical and chemical parameters of the sizing agent (such as molecular weight, flexibility, and reaction properties) to create different pleat expressions. By adjusting these parameters, various pleat designs can be achieved without changing the fundamental process methodology

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If shrink film is used for pleating, then fabric can be pleated, but the process becomes cumbersome and time-consuming

Engineering Contradiction:

Improvepleat formationVSAvoidprocess time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The sizing agent is applied to the fabric in advance before the pleating process. This preliminary application prepares the fabric surface with the necessary properties to form and hold pleats, eliminating the need for subsequent film removal steps and reducing overall process time

Inventive Principle:

Principle #10Preliminary action

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 allows for the reliable and simple formation of various concave-convex patterns and pleats on cloth materials, enabling more expressive designs while avoiding the challenges of working with shrink films.

Implementation Method 1

pressing the applied cloth material by means of a heated metal plate to foam the foaming agent

Methodology Applied

Scientific EffectFoaming: Foam

Implementation Method 2

pressing the applied cloth material by means of a heated metal plate to foam the foaming agent

Methodology Applied

Scientific EffectPhase change: Phase Change

Implementation Method 3

pressing the applied cloth material by means of a heated metal plate

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 4

pressing the applied cloth material by means of a heated metal plate to foam the foaming agent

Methodology Applied

Scientific EffectThermal energy transfer: Heat Exchanger

Implementation Method 5

applying a second sizing agent containing a coloring agent on the cloth material

Methodology Applied

Scientific EffectDeposition: Deposition (physical)

Implementation Method 6

pressing the washed cloth material again together with a transfer paper on which a sublimable (sublimating or sublimation) ink is printed

Methodology Applied

Scientific EffectSublimation: Sublimation

Data Source

PatentUS11332865B2Method of producing a processed material

Publication Date: 2022.05.17 MIYAKE DESIGN JIMUSHO

AI summary

To provide a method of producing a processed cloth capable of forming various concave-convex patterns on a cloth material in a simple manner. A method of producing a processed cloth comprising the steps of: preparing a cloth; printing a first sizing agent containing a foaming agent on at least a portion of the cloth material; and pressing the printed cloth with a heated metal plate to foam the foaming agent. The method of producing a processed cloth may further include a step of printing a second sizing agent containing a coloring agent on the cloth material. The method of producing the processed cloth may further include a step of sublimation transfer to the cloth material.