Printed Appliqué Emblem With 3D Embroidered Appearance
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Solution Overview
Problem
Current methods for producing multi-colored printed appliqué emblems fail to accurately replicate a three-dimensional embroidered appearance due to difficulties in image manipulation and rendering, leading to loss of fine details and inferior durability.
Innovation Solution
A process involving design phase conversion from low-resolution raster to vector format, interpolation-to-embroidery phase mapping, raster editing for embroidery characteristics, and high-resolution printing, followed by heat or pressure sealing or sewing to create a three-dimensional embroidered appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional embroidery is used to create multi-colored designs, then aesthetic value and three-dimensional appearance are improved, but manufacturing complexity and time consumption increase significantly
Solution Approach 1:
The patent creates a printed representation that copies the visual appearance of embroidered stitches using digital printing technology. The system renders embroidery stitch patterns as printed images on fabric, capturing the three-dimensional look and texture of embroidery without requiring actual stitching. This allows multi-colored designs to be produced with the aesthetic quality of embroidery but with the simplicity of printing processes.
2Ease of manufacture
If screen printing is used for logo application, then manufacturing complexity is reduced, but the flat appearance and poor durability worsen
Solution Approach 1:
The patent applies different printing techniques to different regions of the design. Raised effect ink is used specifically for areas requiring three-dimensional appearance, while standard ink is used for other portions. This localized application of specialized materials allows the design to have both flat and raised elements, combining the simplicity of screen printing with the aesthetic quality of embroidery in specific critical areas.
3Shape
If high-resolution digital printing is used to replicate embroidery, then three-dimensional appearance is improved, but image manipulation complexity and detail loss increase
Solution Approach 1:
The patent performs preliminary rendering of the embroidery design into a digital format that preserves fine details before printing. The system uses specialized software to convert embroidery stitch data into high-resolution print-ready images, maintaining the integrity of fine details such as stitch lines, shading, and texture. This preliminary digital preparation ensures that when the design is printed at high resolution, the fine details are accurately reproduced without information loss.
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
Results in appliqué emblems with a realistic, three-dimensional embroidered appearance that can be easily applied to garments, offering improved durability and aesthetic value without the complexity of traditional embroidery.
Implementation Method 1
The adhesive layer is thermally activated or pressure sensitive
Implementation Method 2
The adhesive layer is thermally activated or pressure sensitive
Data Source
AI summary
An appliqué emblem having a three dimensional embroidered appearance for decoration and identification when applied to uniforms, fashion, “basic” and performance apparel, swimwear, and intimate apparel, as well as other textile products. The appliqué emblem being an alternative to direct embroidery, embroidered emblems, thermo-transfer films, silk screen or sublimated printing.