Sock Printing Template for Flat Multi-Pair Inkjet Alignment
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Solution Overview
Problem
Current direct-to-garment digital inkjet printers face challenges in printing on socks due to their shape and size, requiring labor-intensive setup and resulting in inconsistent printing, which increases costs per pair.
Innovation Solution
A die-cut planar template is designed to be inserted inside socks, flattening them for consistent printing, with features like recesses and protrusions to secure the socks in place, allowing for efficient printing of multiple pairs simultaneously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If socks are printed individually on the printer tray, then printing can be performed, but the socks do not lay flat and labor and setup costs increase
Solution Approach 1:
The patent introduces a template as an intermediary device between the sock and the printer tray. The template has a recess that receives the sock opening and includes a flattening portion that presses the sock material flat against the recess walls, creating a stable printing surface without requiring manual labor to flatten each sock individually
Solution Approach 2:
The template is pre-configured with the recess and flattening portion structure before printing begins. This preliminary preparation allows multiple socks to be quickly inserted and automatically flattened without requiring manual intervention during the printing process, reducing both setup time and labor costs
2Productivity
If multiple pairs of socks are printed simultaneously, then productivity increases, but alignment and registration become more difficult
Solution Approach 1:
The template includes both the recess for receiving the sock opening and the flattening portion for securing the sock in a single integrated structure. This multi-functional design allows the same component to perform multiple functions (receiving, flattening, and positioning), ensuring consistent alignment while enabling batch printing of multiple pairs
Solution Approach 2:
The template is designed with specific local features including the recess geometry and flattening portion placement that are optimized for sock alignment. These localized structural qualities ensure precise positioning of each sock within the template, maintaining alignment precision even when multiple pairs are printed simultaneously
Data Source
AI summary
A template is provided to stretch socks out slightly so the surface of the socks are smooth and flat for printing. In order to make the process cost effective, the templates are designed to print either 2 or 3 pairs of socks at one time, the template comprises: a planar registration portion configured to assist a user to align the printing template with a printer tray; and first and second receiving portions orthogonally extending from the registration portion, each receiving portion configured to receive a garment opening and having a width configured to flatten a portion of the received sock for printing, wherein the first and second receiving portions extend in opposite direction of the planar registration portion.