Methods for distressing fabrics or garments using polysaccharide particles

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Solution Overview

Problem

Existing methods for distressing fabrics, such as sandblasting, are hazardous to workers and can damage metal parts, and alternative methods like dry ice blasting and air blasting have limitations including high costs, noise, and equipment wear, while also causing premature wear to washing equipment.

Innovation Solution

Using polysaccharide particles with a Mohs hardness of at least 1.5, suspended in a gas and projected onto the fabric or garment, which are water-soluble and can be reused, allowing for controlled distressing with reduced damage and easier cleaning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If sandblasting is used to distress fabrics, then the distressing effect is achieved, but worker health is damaged due to inhalation of silica or cellulose fibers

Engineering Contradiction:

Improvedistressing processVSAvoidworker health

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The invention changes the material parameter of the abrasive grit from traditional sand/silica to organic-based materials with lower Mohs hardness (3.0-5.0), transforming the process from hazardous to safe while maintaining distressing effectiveness

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses disposable organic-based grit media that can be used once and then discarded or composted, eliminating the health hazards associated with reusable inorganic abrasives like sand and silica

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Ease of manufacture

If sand or silica is used for sandblasting, then distressing is achieved, but metal parts such as rivets or zippers are damaged creating a frosted artificial look

Engineering Contradiction:

Improvedistressing effectVSAvoidmetal parts

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The invention changes the hardness parameter of the abrasive grit to a lower range (Mohs 3.0-5.0) that is sufficient for fabric distressing but too soft to damage metal components, thereby preserving the natural shine of rivets and zippers

Inventive Principle:

Principle #35Parameter changes

3Productivity

If aluminum oxide is used as abrasive grit, then distressing is achieved, but fabric is overly abraded leading to poorer control of distressing design

Engineering Contradiction:

Improvedistressing speedVSAvoiddistressing design control

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The invention optimizes the hardness parameter of the grit media to a specific range (Mohs 3.0-5.0) that provides sufficient abrasiveness for efficient distressing while maintaining enough softness to allow precise control over the distressing pattern and prevent excessive fabric damage

Inventive Principle:

Principle #35Parameter changes

4Object-affected harmful factors

If sodium bicarbonate is used as grit medium, then distressing is achieved, but the process becomes very expensive because the grit can be projected only once due to its fragility

Engineering Contradiction:

Improvefabric damageVSAvoidprocess cost

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

The invention uses inexpensive organic-based grit media that can be disposed of after single use or composted, eliminating the high costs associated with recovering and reusing fragile materials like sodium bicarbonate

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

5Ease of manufacture

If dry ice blasting is used to distress fabrics, then distressing is achieved, but high pressures create loud noises requiring hearing protection and additional cold protection is needed

Engineering Contradiction:

Improvedistressing processVSAvoidsafety equipment requirements

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The invention changes the operating pressure parameter from high pressure (60-100 psi for dry ice) to low pressure (5-20 psi), eliminating the need for hearing protection and cold protection equipment while maintaining distressing effectiveness

Inventive Principle:

Principle #35Parameter changes

6Ease of manufacture

If air blasting is used to distress fabrics, then distressing is achieved, but fine particles infiltrate the fabric requiring thorough cleaning that causes premature wear to washing equipment

Engineering Contradiction:

Improvedistressing processVSAvoidwashing equipment

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The invention changes the material composition parameter of the grit media to organic-based materials with lower hardness (Mohs 3.0-5.0) that are less abrasive to washing equipment, reducing premature wear while still achieving effective fabric distressing

Inventive Principle:

Principle #35Parameter changes

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 effectively distresses fabrics with better control and reduced structural damage, while being safer for workers and more environmentally friendly, with the added benefit of being able to recycle and reuse the polysaccharide particles, and incorporating dye for aesthetic or anti-counterfeit effects.

Implementation Method 1

The fine particles impact the fabric, discharging kinetic energy on the fabric

Methodology Applied

Scientific EffectKinetic energy:

Implementation Method 2

suspending polysaccharide particles in a gas, creating a suspension

Methodology Applied

Scientific EffectSuspension: Suspension

Data Source

PatentEP3063325B1Methods for distressing fabrics or garments using polysaccharide particles

Publication Date: 2021.08.18 ARCHER DANIELS MIDLAND CO

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AI summary

The present disclosure relates to methods for distressing an object by projecting polysaccharide particles onto a surface of the object. The present disclosure relates also to methods for cleaning the distressed fabric or garment and optionally methods for recycling the polysaccharide particles. In one embodiment, a method for distressing an object comprises suspending polysaccharide particles in a gas, creating a suspension, and projecting the suspension onto an object.