Systems and methods for the printing of pre-constructed clothing articles and clothing article so printed
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Solution Overview
Problem
Existing methods for customizing pre-constructed clothing are limited by their inability to print cohesive, high-quality images across multiple components of an article, resulting in a 'homemade' appearance due to the need for image centering and the stiffness caused by surface printing techniques, which restricts the ability to create true full-color designs and flexible, detailed images on large areas.
Innovation Solution
The method involves all-over printing, where a digital image is proportioned and printed across multiple components of clothing using dye sublimation or similar processes, ensuring coherency and flexibility by maintaining the image's integrity across seams and folds, and using a jig to align the clothing for even printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If embroidery is used for customization, then rugged and attractive clothing is produced, but the process is labor intensive and limited in reproducing actual images
Solution Approach 1:
The patent replaces mechanical embroidery systems with inkjet printing technology. Instead of using needles and threads to physically stitch designs into fabric, the system uses digital inkjet printers to deposit dye directly onto the clothing surface, dramatically reducing production time while maintaining design flexibility and image reproduction capability.
Solution Approach 2:
The invention changes the fundamental parameters of the customization process by transitioning from additive embroidery (building up thread layers) to subtractive/direct printing (depositing dye molecules). This parameter change enables full-color photorealistic images to be produced quickly without the labor-intensive constraints of thread-by-thread embroidery.
2Ease of manufacture
If screen printing is used for customization, then full-color images can be printed, but the ink makes the fabric stiff and thick
Solution Approach 1:
The patent changes the physical and chemical parameters of the printing medium by using reactive dyes that bond chemically with natural fibers at the molecular level. Unlike screen printing inks that sit on the fabric surface and require thick layers, these dyes penetrate and bond with the fiber structure, producing flexible, breathable fabric that maintains its original handfeel while displaying vibrant full-color images.
Solution Approach 2:
The invention replaces the mechanical screen printing process with digital inkjet printing technology. This substitution eliminates the need for mesh screens, emulsion coatings, and multiple printing passes, allowing for direct digital deposition of dye in a single pass that does not stiffen the fabric.
3Adaptability or versatility
If traditional printing methods are used on pre-constructed clothing, then customization is achieved, but the image appears 'homemade' due to centering requirements
Solution Approach 1:
The patent introduces dynamic positioning capability where the digital image can be precisely placed on any component of the pre-constructed clothing using computer-controlled inkjet printers. The system can accommodate various clothing sizes, styles, and component arrangements, dynamically adjusting the print position and scaling to achieve professional, cohesive results rather than fixed centering requirements.
Solution Approach 2:
The invention creates a universal printing system that can handle multiple clothing types (shirts, pants, jackets, hats) and component configurations. The digital printing platform can print on any surface area and position, making it adaptable to various garment constructions without requiring manual centering or creating a homemade appearance.
4Ease of manufacture
If embroidery threads are used for color reproduction, then a wide variety of colors can be used, but the human eye can distinguish more than 15 million colors which would make the system impossibly complex
Solution Approach 1:
The patent replaces the mechanical thread-based color system with a digital color printing system. Instead of physically storing and managing thousands of different colored threads, the inkjet printer uses a small set of dye cartridges (typically 4-8 colors) that can mix and reproduce over 15 million colors through digital control of deposition quantity and position, dramatically simplifying the system while expanding color capability.
Solution Approach 2:
The invention changes from a discrete color system (individual thread colors) to a continuous color mixing system (digital dye deposition). By controlling the amount, position, and layering of base dye colors, the system can generate any color in the visible spectrum, reducing complexity from managing thousands of thread spools to managing a few dye cartridges with digital precision.
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 allows for cohesive, high-quality images that cover entire surfaces of clothing, maintaining coherency when worn, and enhances the appearance by integrating unprinted areas into the design, providing a more natural and uniform look without the stiffness associated with traditional methods.
Implementation Method 1
using dye sublimation or similar processes
Data Source
AI summary
A system and method which allows for a pre-constructed article of clothing to having printing on substantially all of its external surface area. Specifically, an image may be simultaneously printed across multiple components of a clothing article. The method generally provides for transfer of a digital image, such as a digital photograph, to be applied to an article of clothing in a manner that prints an entire two-dimensional surface of the clothing with a coherent image that maintains coherency when the article of clothing is worn. There is also provided an article of clothing produced using the systems and methods.