System and method of generating a pattern used to process a surface of a fabric through laser irradiation, and fabric created thereby
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Solution Overview
Problem
Traditional stonewash and enzyme processes for creating a faded, worn look on denim fabrics are time-consuming, water-intensive, and pose environmental concerns, while previous laser processing methods struggle to replicate the unique color contrasts and aesthetic effects of these processes.
Innovation Solution
A system and method for generating a pattern image on fabrics using laser irradiation, which involves inputting parameters such as area, density, discontinuity, and dye removal settings to create a pattern that mimics the effects of stonewash and enzyme washes, allowing for precise control over dye removal and pattern creation through computer-processed laser irradiation units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional stonewash and enzyme processes are used to create faded, worn look on denim, then the aesthetic effect is achieved, but the process becomes time-consuming and water-intensive
Solution Approach 1:
The patent replaces the mechanical and chemical stonewash/enzyme process with a laser-based system. The laser processing system uses optical energy to selectively remove dye from denim fabric, substituting the traditional mechanical agitation and chemical enzyme treatment with a non-contact, light-based processing method that achieves similar aesthetic effects without the associated time and water consumption
Solution Approach 2:
The patent employs parameter changes by controlling laser processing variables such as power, speed, pattern density, and area to achieve different levels of dye removal. By adjusting these parameters, the system can replicate various stonewash and enzyme wash effects (from light to heavy fading) while maintaining consistent, controllable processing times that are significantly shorter than traditional methods
2Ease of manufacture
If traditional stonewash and enzyme processes are used, then the worn look is created, but extensive water usage and enzyme handling are required
Solution Approach 1:
The laser processing system substitutes the water-based enzyme process with a dry, light-based method. Instead of using water and enzymes to chemically break down dye molecules, the system uses concentrated optical energy to directly vaporize and remove dye from the fabric surface, eliminating the need for large volumes of water and chemical enzymes
Solution Approach 2:
The patent extracts only the essential function of the traditional process (dye removal to create worn look) while eliminating the harmful byproducts. The laser system directly removes dye molecules through photothermal decomposition, extracting the desired aesthetic effect without the water consumption and enzyme disposal issues inherent in traditional wet processing methods
3Manufacturing precision
If uniform, repeating laser patterns are used, then consistent processing is achieved, but the unique color contrasts of stonewash look cannot be replicated
Solution Approach 1:
The patent introduces dynamics to the laser processing system by implementing variable parameters that change during processing. The system uses non-uniform pattern densities, varying laser powers, and adjustable speeds to create dynamic processing conditions that replicate the natural variation in stonewash effects. This allows the same base pattern to produce diverse color contrasts and fading intensities across different fabric areas
Solution Approach 2:
The patent applies local quality by allowing different regions of the fabric to receive customized laser processing parameters. The system can vary pattern density, laser power, and processing speed locally across the fabric surface, enabling each area to achieve the specific color contrast and fading intensity appropriate for that region, thereby replicating the unique characteristics of hand-stonewashed denim
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
This approach reduces the need for extensive water usage and enzyme handling, efficiently replicates the aesthetic effects of traditional stonewash and enzyme washes, and can be used to create authentic vintage looks on denim fabrics with improved manufacturing efficiency and reduced environmental impact.
Implementation Method 1
processing of the fabric may be accomplished through the use of either multiple passes of a single laser or multiple lasers each lasing an individual pass or multiple passes
Data Source
AI summary
A method is provided of generating a pattern image used to form a pattern on a surface of a fabric using laser irradiation. A plurality of parameters associated with laser irradiation units are input into a user interface. The parameters include an area parameter, a laser irradiation unit density parameter, optionally a discontinuity parameter, and a dye removal parameter. A plurality of laser irradiation units arranged in a pattern area of a user interface based on computer processing of the inputted plurality of parameters is received for viewing at the user interface. The laser irradiation units collectively establish the pattern image for viewing by the user.