Letter Jacket Patch Edge Curling Prevention
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Solution Overview
Problem
Current patch manufacturing methods for letter jackets result in edge curling due to unsecured felt edges and manual cutting inaccuracies, along with color mismatch issues between felt and chenille yarn.
Innovation Solution
Replacing the upper felt layer with a stitched outer border of thread, which secures the edges and allows for precise cutting and color matching using a computer numerical control machine for stitching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the upper felt layer is used with manual cutting, then the patch can be manufactured with traditional materials, but the edges curl apart and cutting accuracy is poor
Solution Approach 1:
The patent replaces manual mechanical cutting with computer numerical control (CNC) machine cutting. The CNC system uses programmed instructions to automatically control the cutting tool, achieving high precision cutting accuracy while eliminating the manual cutting process that causes edge curling and inconsistency.
2Manufacturing precision
If felt and chenille yarn are used together, then the patch has traditional appearance, but color matching between the two materials is difficult to achieve
Solution Approach 1:
The patent changes the material parameter by replacing felt with thread for the outer border. This parameter change allows for precise color matching between the outer border and inner fill areas, as both can be made from the same or coordinated thread materials, eliminating the color mismatch problem inherent in combining felt and chenille yarn.
3Stability of the object's composition
If the upper felt layer is stitched to the lower felt layer, then the patch structure is formed, but the edges outside the stitching are not secured and tend to curl
Solution Approach 1:
The patent replaces traditional stitching with a combination of CNC cutting and bonding techniques. The CNC machine cuts precise shapes and the bonding process secures the edges to the base felt layer, providing stable edge attachment without the complexity of traditional stitching structures.
Data Source
AI summary
A patch comprising a lower layer of felt material, and an inner area stitched to the felt and having a desired shape. A first stitched border surrounds the central area, and a second stitched border surrounds the first border.