Reflective Motif Sewing Process Without Laser Cutting
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Solution Overview
Problem
The existing processes for producing textile products with reflective motifs are complex and costly due to the need for cutting and applying reflection transfers, which require expensive laser equipment and multiple process steps.
Innovation Solution
A process involving sewing a motif template onto a textile substrate with a perforation that allows for the removal of excess template material, using a reflection transfer with a specific layer structure that permits sewing and permanent fixing, eliminating the need for cutting and reducing the number of process steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If cutting operations are used to create motifs on textile products, then manufacturing precision is improved, but device complexity and cost increase due to expensive laser apparatuses
Solution Approach 1:
The patent combines multiple operations into a single sewing process. The sewing machine simultaneously attaches the motif template to the textile substrate and creates the perforation defining the motif boundary, eliminating the need for separate cutting operations and expensive laser apparatuses while maintaining manufacturing precision
Solution Approach 2:
The patent replaces the mechanical cutting system (laser apparatus) with a sewing-based system. The sewing machine needle creates both the attachment stitches and the motif-defining perforation through a single mechanical operation, simplifying the device complexity while achieving the desired motif precision
2Manufacturing precision
If multiple process steps are used for transferring reflecting motifs, then manufacturing precision is improved, but productivity decreases due to time-consuming operations
Solution Approach 1:
The patent merges the template attachment operation and the motif definition operation into a single sewing step. The perforation is created during the sewing process itself, eliminating subsequent cutting steps and reducing the overall number of process steps, thereby increasing productivity while maintaining motif accuracy
Solution Approach 2:
The motif template is pre-configured with the desired motif design, allowing the sewing machine to directly create the final motif shape through a single operation. This preliminary preparation eliminates the need for multiple subsequent steps to achieve the desired motif accuracy, improving production speed
3Manufacturing precision
If laser cutting is used for motif production, then manufacturing precision is improved, but loss of time increases due to complex cutting operations
Solution Approach 1:
The patent combines template attachment and motif cutting into one simultaneous sewing operation. The sewing machine needle creates both the securing stitches and the perforation that defines the motif boundary in a single pass, eliminating the time-consuming separate cutting operation while maintaining cutting precision
Solution Approach 2:
The patent skips the intermediate cutting step entirely by creating the motif perforation directly during the sewing operation. This eliminates the time loss associated with complex cutting operations while achieving the same motif precision through the integrated sewing process
Data Source
AI summary
A process for the production of a textile product includes placing a flat motif template on a textile substrate, sewing the motif template onto the textile substrate in such a way that a perforation defining a desired motif in the motif template is produced, removing the part of the motif template, that is outside the motif defined by the perforation, and permanently fixing the remaining part, having the motif, of the motif template to the textile substrate.