Stippling Pattern Stitching via Interlocking Convex-Concave Boundaries
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Solution Overview
Problem
Existing sewing machines struggle to stitch large stippling patterns accurately, as they require manual skill to maintain constant stitch pitch and often result in discrepancies or overlaps when dividing patterns across a large area.
Innovation Solution
A sewing machine system that stitches stippling patterns within a square embroidery area by using convex and concave portions defined by specific point groups on opposite sides, allowing for the combination of unit patterns without overlap or discrepancy, utilizing a central processing unit to control the stitching mechanism and motor operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If the stippling pattern is stitched mechanically by use of a sewing machine in a large stitching area, then the stitching can be automated without requiring manual skill, but it becomes impossible to stitch the stippling pattern at a time and the cloth must be displaced relative to the holder requiring stitching in a plurality of steps
Solution Approach 1:
The patent divides the large stippling pattern into multiple unit patterns that can be stitched separately within the limited embroidery stitching area. Each unit pattern is designed with convex and concave portions that align with corresponding features of adjacent unit patterns, enabling automated multi-step stitching while maintaining overall pattern accuracy through systematic segmentation of the design.
2Area of stationary object
If the stippling pattern is divided into unit patterns for repeated stitching, then the stitching can be completed within the limited embroidery area, but the unit patterns are often overlapped or inappropriately spaced showing gaps between them
Solution Approach 1:
The patent applies local quality by designing specific convex and concave portions at the boundaries of unit patterns. These localized features ensure that when unit patterns are arranged adjacently, their convex and concave portions interlock perfectly, eliminating gaps and overlaps. This local structural modification at pattern boundaries ensures continuous, seamless stitching across the entire large pattern area.
3Manufacturing precision
If manual operation with free motion technique is used to stitch the stippling pattern, then the stitch pitch can be maintained constant by skilled operators, but it requires special skill and is almost impossible for general machine users to stitch at a large kilt cloth
Solution Approach 1:
The patent replaces the manual mechanical free motion technique with an automated computer-controlled system. The central processing unit automatically calculates and controls the stitching path, needle position, and fabric movement based on the stitch data. This substitution eliminates the need for operators to manually coordinate multiple parameters, making precise large-area stippling stitching accessible to general users without special skills.
4Area of moving object
If the cloth is displaced relative to the holder to stitch in a plurality of steps, then large patterns can be stitched beyond the single embroidery area limit, but the divided parts may be displaced from the original position making it very difficult to restore the pattern
Solution Approach 1:
The patent incorporates feedback mechanisms where the central processing unit tracks the position of the holder and cloth throughout the multi-step stitching process. The system uses the predefined convex and concave portion alignment requirements as reference points to continuously verify and adjust positioning. This feedback control ensures that each unit pattern is stitched at the correct position relative to the overall design, preventing displacement errors even when the cloth is repositioned between steps.
Data Source
AI summary
The convex portions 25 are formed as arranged in contact or substantially in contact with the points A1˜A7 of first group respectively that are provided on the upper side limit line 76 and the concave portions 26 are formed as arranged with a predetermined space provided away from the points a1˜a7 of first group respectively that are provided on the lower side limit line 77. On the other hand, the concave portions 26 are formed as arranged with a predetermined space provided away from the points of second group respectively that are provided on the upper side limit line 76 and the convex portions 25 are formed as arranged in contact or substantially in contact with the points b1˜b4 of second group respectively that are provided on the lower side limit line 77. Thus the upper and lower side limit lines 76, 77 that are arranged opposite to each other have the points A and a of first group and the points B and b of second group provided thereon respectively while the convex portions 25 and the concave portions 26 are formed as arranged in reversed relation in connection with the upper and lower side limit lines 76 and 77.