Reflective Motif Template Sewing Without Laser Cutting
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Solution Overview
Problem
The existing methods for producing textile products with reflective motifs are complex and expensive due to the need for multiple process steps, including cutting and sewing, which are time-consuming and costly, especially for small series production.
Innovation Solution
A method involving sewing a pre-designed motif template onto a textile substrate, where the template is perforated to allow easy removal of excess material, followed by permanent fixation, eliminating the need for expensive cutting tools and simplifying the process by integrating sewing and perforation in a single step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser cutting is used to cut out motifs from reflective transfer films, then precise motif shapes are achieved, but production cost and process complexity increase significantly
Solution Approach 1:
The motif template is segmented into two parts: the desired motif area and the excess template material. The perforation line separates these segments, allowing the excess material to be easily removed after sewing, achieving precise motif shapes without complex cutting processes
Solution Approach 2:
The motif template is pre-perforated along the motif boundary during the sewing process itself. This preliminary perforation enables easy separation of the excess template material after sewing, eliminating the need for subsequent laser cutting while maintaining precise motif shapes
2Manufacturing precision
If multiple process steps including cutting and sewing are used to produce reflective motifs, then precise motif application is achieved, but production time increases
Solution Approach 1:
The perforation process and sewing process are merged into a single operation. The sewing machine needle creates both the permanent attachment stitches and the perforation holes along the motif boundary simultaneously, eliminating separate cutting and sewing steps while maintaining precise motif application
Solution Approach 2:
The template is pre-perforated during sewing, preparing it for easy removal of excess material. This preliminary action during the sewing process itself enables rapid completion without requiring separate cutting operations, significantly reducing production time
3Manufacturing precision
If expensive laser devices are used for cutting work, then precise motif shapes are achieved, but production cost increases
Solution Approach 1:
The motif template is designed as a disposable item that can be easily discarded after use. The excess template material is removed after sewing and discarded, eliminating the need for expensive laser cutting devices while maintaining precise motif shapes through the simple perforation-and-tear process
Solution Approach 2:
The expensive laser cutting system is replaced with a simple mechanical sewing process. The sewing machine needle creates perforations that enable easy manual removal of excess template material, achieving the same motif shape precision without requiring costly laser equipment
Data Source
Figure 1
Figure 2a~2c
Figure 2d~2f
AI summary
The invention relates to a method for producing a textile product, wherein the method comprises the following steps: placing a flat motif template (10) on a textile substrate (30), sewing the motif template (10) onto the textile substrate (30) so that a perforation adjacent to a desired motif is created in the motif template (10), removing the part (10b) of the motif template (10) located outside of the motif limited by the perforation and permanently attaching the remaining part (10a) of the motif template (10) comprising the motif to the textile substrate (30).