Solid-State Laser Marker for Over-Pigmented Denim Finishing
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Solution Overview
Problem
Existing CO2 gas laser markers are expensive, less energy-efficient, and limited in power for denim garment finishing, while fabrics dyed with pure indigo are non-reactive to fiber solid-state lasers, leading to increased production costs and environmental impact.
Innovation Solution
A solid-state laser marker using a near-infrared fiber optic laser irradiates textile materials with an over-pigmentation composition to selectively remove dye and base pigment, reproducing design patterns with precise discolouration, utilizing wavelengths between 1,060 to 1,090 nm and a modulated continuous wave laser beam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If CO2 gas laser is used for denim garment finishing, then the laser can effectively mark and fade denim fabric, but the equipment cost is high, energy efficiency is low, and production space requirement increases
Solution Approach 1:
The patent changes the fundamental parameter of laser wavelength from CO2 (10.6 μm) to fiber laser (1.07 μm), enabling effective denim marking with a more compact, energy-efficient system that maintains marking effectiveness while reducing equipment complexity and cost
Solution Approach 2:
The patent substitutes the CO2 gas laser system with a fiber optic laser system, replacing a complex gas-based optical system with a more efficient solid-state laser that delivers the same functional outcome with reduced complexity and improved energy efficiency
2Device complexity
If fiber solid-state laser is used on pure indigo dyed fabric, then the equipment is more compact and energy efficient, but the laser cannot effectively mark or fade the fabric
Solution Approach 1:
The patent applies a preliminary action by depositing a zinc oxide layer onto the pure indigo dyed fabric before laser treatment. This pre-treatment enables the fiber laser to effectively mark and fade the denim fabric by creating an intermediate layer that absorbs laser energy and facilitates the desired visual effect
Solution Approach 2:
The patent introduces zinc oxide as an intermediary substance between the laser and the pure indigo fabric. This intermediary layer absorbs the laser energy and transfers it to the fabric, enabling effective marking without requiring the fabric to directly absorb the laser wavelength
3Reliability
If traditional water-based denim finishing is used, then the desired worn and faded look is achieved, but significant amounts of water and natural resources are consumed
Solution Approach 1:
The patent substitutes traditional water-based mechanical finishing processes with a laser-based optical system, eliminating the need for large volumes of water and chemical resources while achieving the same worn and faded denim appearance through controlled fabric ablation and melting
4Reliability
If CO2 laser finishing process is used, then denim wear patterns are produced, but processing time and production costs increase
Solution Approach 1:
The patent changes the laser operating parameters, specifically using a fiber laser with wavelength 1.07 μm and adjusting power, speed, and pulse duration to optimize processing efficiency. This enables faster processing speeds while maintaining the quality of denim wear patterns, thereby reducing production time and costs
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 solution provides cost-effective, efficient, and environmentally friendly denim finishing with high precision and repeatability, reducing processing time and costs while maintaining the look and feel of traditional techniques.
Implementation Method 1
A solid-state laser marker of the fiber optic laser type irradiates with at least one laser beam to at least one marking point or pixel of a predetermined zone of the dyed textile impregnated with an over-pigmentation composition superficially deposited on the base pigment of the textile material, totally or partially removing selected portions of both the over-pigmentation composition and a dyeing base pigment
Implementation Method 2
The NIR near infrared fiber optic laser marker radiates wavelengths within the range of 1,060 to 1,090 nm, preferably wavelengths of 1,070 nm... the over-pigmentation composition and the base pigment are totally or partially removed without the textile material supporting great thermal impact
Data Source
Figure 1~2
Figure 3A~4
Figure 5A~5B
AI summary
A solid-state laser marker modifies the finish of a textile material (B) dyed with a base pigment (C) and an over-pigmentation composition (D) superficially deposited on the base pigment (C) of the dyed textile material (B), the solid-state laser marker irradiates a laser beam (A) toward a pixel of a predetermined impregnated zone of the dyed textile material (B), the over-pigmentation composition (D) forms a spot, stained zone, on the surface of the predetermined zone of the dyed textile material (B), the laser beam (A) wholly or partially removing both the over-pigmentation composition (D) and the base pigment (C) fabric (B) located in the stained zone.