System and method for colored woven label fabrication

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Solution Overview

Problem

Conventional methods for creating colored two-dimensional code fabrics are not wear-resistant, lead to poor softness, and result in high production costs due to the use of multiple colored yarns, while also being environmentally unfriendly due to water and chemical usage in dyeing processes.

Innovation Solution

A system comprising an image processing device, yarn coloring mechanism, and weaving machine that generates and applies color to yarns using thermal sublimation with inner and outer colored papers, eliminating the need for multiple colored yarns and reducing material usage, thereby improving softness and reducing environmental impact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple colored yarns are knitted into basic-colored yarns to create colored two-dimensional code fabric, then anti-counterfeiting effect is enhanced, but fabric thickness increases resulting in poor softness

Engineering Contradiction:

Improveanti-counterfeiting effectVSAvoidfabric thickness and softness

Core Design Contradiction:

ReliabilityVSShape

Solution Approach 1:

The patent uses printed color patterns on paper that are transferred to the fabric surface, creating a visual copy of the colored yarn effect without actually using multiple colored yarns. The print pattern replicates the appearance of colored threads while maintaining uniform basic-colored yarn structure throughout the fabric.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces the mechanical approach of physically knitting multiple colored yarns into the fabric structure with a surface printing and color transfer method. This substitution allows the color information to be applied as a surface layer rather than being embedded in the fabric's structural layers.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If multiple colored yarns are used to weave colored two-dimensional code fabric, then anti-counterfeiting effect is enhanced, but production cost increases due to larger amount of raw materials needed

Engineering Contradiction:

Improveanti-counterfeiting effectVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent creates a visual copy of the colored yarn effect through printed patterns on paper, eliminating the need to purchase and manage multiple types of colored yarn raw materials. This copying approach reduces material costs while maintaining the anti-counterfeiting functionality.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The basic-colored yarn serves multiple functions: it provides the fabric structure and simultaneously serves as the base layer for color transfer. The single type of yarn performs both structural and color-receiving functions, reducing material variety and cost.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If traditional dyeing process is used to color yarns, then colored yarns are produced, but large amount of water vapor and fuel are used causing air pollution

Engineering Contradiction:

Improveyarn coloring capabilityVSAvoidair pollution from water vapor and fuel

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The patent replaces the thermal-dyeing process with a mechanical color transfer process using printed paper. Instead of using heat and chemicals to dye yarns, the system uses physical contact and pressure to transfer printed colors from paper to fabric surface, eliminating combustion-related air pollution.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Ease of manufacture

If traditional dyeing process with chemicals such as dye accelerating agent is used, then yarns are colored, but large amount of waste water is generated requiring waste water treatment

Engineering Contradiction:

Improveyarn coloring capabilityVSAvoidwaste water pollution

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The patent substitutes the chemical dyeing process with a mechanical color transfer method using printed paper. This replacement eliminates the use of dye chemicals and accelerating agents, thereby preventing the generation of contaminated waste water that would require treatment facilities.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 system produces a thinner, more comfortable, and cost-effective colored woven label with enhanced anti-counterfeiting properties, while minimizing water and chemical consumption, thus reducing environmental harm.

Implementation Method 1

A system and method for colored woven label fabrication that generates and applies color to yarns using thermal sublimation

Methodology Applied

Scientific EffectThermal sublimation: Sublimation

Data Source

PatentUS11879187B2System and method for colored woven label fabrication

Publication Date: 2024.01.23 FU HUA PAI

AI summary

A system for colored woven label fabrication includes an image processing device, a yarn coloring mechanism and a weaving machine. The yarn coloring mechanism colors a yarn to be woven into a colored woven label by the weaving machine according to a weaving electronic file generated by the image processing device.