New Processes for Photo Real Embroidery Technology for Garments in Sustainable and Eco-Friendly Ways

Abstract

PRET (Photo Real Embroidery Technology) (200) systems and processes for producing vibrant graphical images, including with recycled fibers (600) replaces traditional sublimation with numerous industrial efficiencies. Processes, products and an entirely new approach infuse fibers (232), through heat activation with colors to make finished goods (800).

Description

The present disclosures relate to the way that images are printed onto garments. Specifically, the instant disclosures teach an improved process which replaces the sublimation processes currently used to produce more vibrant colors consistently.

The present disclosure also improves processes whereby images printed on paper then used for conventional sublimation transferring with rollers of heat are managed more efficiently and in ways that are more friendly to and less harmful of nature.

BACKGROUND OF THE DISCLOSURES

Complex graphics are notoriously hard to print onto active surfaces. Those working with garments have endeavored for years to use aspects of woven fibers to enhance graphical outcomes and production. Prior art is not comfortable or user friendly to date.

Tradition sublimation is not a viable process in the sustainable world and the costs to create factories and the amount of waste has created the needs for better processes. Along with superior optics, the instant processes address these longstanding needs.

OBJECTS AND SUMMARY OF THE INVENTION

Briefly stated, recycled fibers have generated an improved version of sublimation that make colors more vibrant and garments better viewed by consumers, along with numerous industrial efficiencies. Processes, products and an entirely new approach are offered for consideration.

According to embodiments, there is provided an improved green and eco-friendly process to produce images on garments, comprising in combination, providing a desired image from any medium needed, transferring or scanning to a computer via scan or transfer of an art file image, creating the file, by converting into a digitize-able file, to convert the art file into a readable file for embroidery, employing recycled yarns and inks, which enables transfer of the images to the yarn via the printer heads and directly to embroider needles with colors infused into hollows of the fibers, such as with recycled polyester.

BRIEF DESCRIPTION OF THE DRAWINGS

Various preferred embodiments are described herein with references to the drawings in which merely illustrative views are offered for consideration, whereby:

FIG.1 is a view of the unique fibers of the present invention, generated sustainably;

FIG. 2 is another view of the fibers of the invention showing their arrays of for example panels, for infusion with inks; and

FIG. 3 is a set of finished goods of the present invention, namely any fabric-friendly material which is chosen;

FIG. 4 is a schematic/flowchart of the PRET processes; and

FIG. 5 shows a schematic rendering of a fiber under the PRET system as filled with color, showing examples of apertures, windows and tunnels, according to the present invention.

DETAILED DESCRIPTIONS

The present inventor has discovered that a holistic approach to making better fabrics for garments to be worn by humans is the best approach. He has partnered with a co-inventor who works with farmers for the best organic cotton growers. They work with companies that have imported plastic wastes, spun them into a fiber of cotton or blended yarns at several gage weights, and produce into fabrics.

The present inventors move curbside waist plastics to reuseable new PET (see FIG. 4). Pellets are recycled and extruded into a long fiber to create 100% recycled polyester. Each T-shirt of the prior art takes about three bottles, our PHOTO REAL EMBROIDERY TECHNOLOGY uses about one or less bottles, based on art file size of course. In PRET goods are made with a nice heavier gauge recycled yard.

The process is known those skilled in the art whom have seen it work—and is claimed below, it starts with a desired image, which our factory got by computer via scan or transfer of an art file image, same way files are set up for screen printing and or sublimation printing, as known to Artisans.

Once the file is created, we create into a digitize-able file, to turn this art file into a readable file for embroidery.

PHOTO REAL EMBROIDERY TECHNOLOGY (PRET) is what defines our processes, as described and claimed below. Our new technologies have been custom made. We have had to create a way for our fibers of yarn to be infused with inks with applications applied direct to the yarn stitch by stitch direct to a garment or fabrics of cut panels and or of full finished goods. We have no limits dictated by maximum loom space. Right now we are using a custom built loom and embroider machines with custom printer heads. We have specialties & creative ways are limited to how we transfer the yarn to the printer heads and how we embroider needles with color.

According to embodiments this process can be on black garments in 100% cotton. With our process, our yarns are recycled and our inks are too. The inks are colored & infused into the hollow fiber of the recycled polyester. This creates (Tunnel) a channel therefore you can trap with heat as it's being applied directly to the fiber of colors CMYK process. Then the thread gage feeds through & into the needle, direct with embroidering to the garment or fabrics.

Once this process is complete the garment has a back side soft hand to all end users. See attached of inside garment stitching paths, as well as the provisional from U.S. Appendix showing testing results with products by the process of the present invention.

As shown in FIG. 4, the flow from 100-800 adaption of an embroidery machine and computers, to add and transfer art files 100 to the PRET. As for printing, this is clearly innovative, the way it's done. Ink jet style heads used from recycled goods and re created direct for our one direction use. Fantastic 3 in one. InkHeads to needles & heater heads with infusion added to our process. And able to read the Pixels per square inch on one continuous line to give accuracy and color saturation as the threads applied to the fabric. Infusion is by way of heat, see FIG. 5, for example. Referring still to FIGS. 4 and 5 (schematic of an exemplary fiber) without wishing to be limited to any particular mechanism for how Coloration works with fibers 232, any of bosses, clients, customers or those storing, sharing, streaming or otherwise harvesting images 400 are functionally and operatively linked to smart device 300, or networked to the same and/or linked to clouds. This PRET Process 100 integrates any image stored, used or acquired as an art file with undated data modified by at least one of the database/Artificial Intelligence of any other homunculus or human needed to convert the same into a PRET file 200. Once the interaction with smart device 300 is completed then—for example recycled yarns or other fabrics 600 are used to make PRET types of fabrics 700, including those from plastic wastes 500. Likewise, recycled or post-processed inks 550 further lower the environmental impact. Finally, finished goods 800 are available (see also FIG. 3) which may in any way shape or form embody the vibrantly colored fabrics having soft hand and not challenging the user or wearer with friction based insults or attacks upon the upper layers of dermis of the user, for example, wearing a T-shirt of FIG. 3. FIG. 5 shows a cartoon/schematic of exemplary fiber 232, and aspects of the process for infusing the same with color. Those skilled in the art readily understand that heat energy opens aperture-like pores allowing programmed Color selections to be implemented—and altered per the PRET database 200 whereby Post coloration cooling closes pores in whole and in part and closes related separated spaces, crevasses and spatial openings to product resultory fabrics 700 having 3D optics and soft hand for incorporating into any known pieces 800.

We can make one sample in minutes and are now able to produce in production 20,000 units per day 6 days a week. The efficiency and outputs gained with Photo Real Embroidery Technology (PRET) are now strongly in demand amongst the market.

To summarize, most sublimation printing is “a so-called” CMYK process and is quite standard. Large press process of aluminum plates set up one per color on Huntingtonburg press, very big, very expensive, for set up and very large, minimum's are required per art file. Most sublimation companies have access to this conventional type of printing. After the plates are complete they transfer to a special paper of eucalyptus finishing which holds most of the ink that then is ready to be transferred by heat and large roller press machines, from paper direct to the garment they place paper on that run it through the press and take the garment direct business or to retail. The result are poorly transferred images, with larger border regions, and not user friendly or they've tended to create friction over time against a user's skin. This is because sublimation uses a backing material that is highly frictious. The PRET process eliminated these issues.

While several embodiments of the present disclosure have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and/or structures for performing the functions and/or obtaining the results and/or one or more of the advantages described herein, and each of such variations and/or modifications is deemed to be within the scope of the present disclosure. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the teachings of the present disclosure is/are used.

Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the disclosure described herein. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, the disclosure may be practiced otherwise than as specifically described and claimed. The present disclosure is directed to each individual feature, system, article, material, kit, and/or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and/or methods, if such features, systems, articles, materials, kits, and/or methods are not mutually inconsistent, is included within the scope of the present disclosure.

All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and/or ordinary meanings of the defined terms.

The indefinite articles “a” and “an,” as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to mean “at least one.”

The phrase “and/or,” as used herein in the specification and in the claims, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Other elements may optionally be present other than the elements specifically identified by the “and/or” clause, whether related or unrelated to those elements specifically identified, unless clearly indicated to the contrary.

Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

The terms and expressions which have been employed herein are used as terms of description and not of limitation, and there is no intention, in the use of such terms and expressions, of excluding any equivalents of the features shown and described (or portions thereof), and it is recognized that various modifications are possible within the scope of the claims. Accordingly, the claims are intended to cover all such equivalents.

Furthermore, the described features, structures, or characteristics of the invention may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided to provide a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention may be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.

The schematic flow chart diagrams such as FIG. 4 included herein are generally set forth as logical flow chart diagrams. As such, the depicted order and labeled steps are indicative of one embodiment of the presented method. Other steps and methods may be conceived that are equivalent in function, logic, or effect to one or more steps, or portions thereof, of the illustrated method. Additionally, the format and symbols employed are provided to explain the logical steps of the method and are understood not to limit the scope of the method. Although various arrow types and line types may be employed in the flow chart diagrams, they are understood not to limit the scope of the corresponding method. Indeed, some arrows or other connectors may be used to indicate only the logical flow of the method. For instance, an arrow may indicate a waiting or monitoring period of unspecified duration between enumerated steps of the depicted method. Additionally, the order in which a particular method occurs may or may not strictly adhere to the order of the corresponding steps shown.

The terms “a,” “an,” “the” and similar referents used in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.

Specific embodiments disclosed herein may be further limited in the claims using consisting of or consisting essentially of language. When used in the claims, whether as filed or added per amendment, the transition term “consisting of” excludes any element, step, or ingredient not specified in the claims. The transition term “consisting essentially of” limits the scope of a claim to the specified materials or steps and those that do not materially affect the basic and novel characteristic(s). Embodiments of the invention so claimed are inherently or expressly described and enabled herein.

As one skilled in the art would recognize as necessary or best-suited for performance of the methods of the invention, a computer system or machines of the invention include one or more processors (e.g., a central processing unit (CPU) a graphics processing unit (GPU) or both), a main memory and a static memory, which communicate with each other via a bus.

A processor may be provided by one or more processors including, for example, one or more of a single core or multi-core processor (e.g., AMD Phenom II X2, Intel Core Duo, AMD Phenom II X4, Intel Core i5, Intel Core I & Extreme Edition 980X, or Intel Xeon E7-2820).

An I/O mechanism may include a video display unit (e.g., a liquid crystal display (LCD) or a cathode ray tube (CRT)), an alphanumeric input device (e.g., a keyboard), a cursor control device (e.g., a mouse), a disk drive unit, a signal generation device (e.g., a speaker), an accelerometer, a microphone, a cellular radio frequency antenna, and a network interface device (e.g., a network interface card (NIC), Wi-Fi card, cellular modem, data jack, Ethernet port, modem jack, HDMI port, mini-HDMI port, USB port), touchscreen (e.g., CRT, LCD, LED, AMOLED, Super AMOLED), pointing device, trackpad, light (e.g., LED), light/image projection device, or a combination thereof.

Memory according to the invention refers to a non-transitory memory which is provided by one or more tangible devices which preferably include one or more machine-readable medium on which is stored one or more sets of instructions (e.g., software) embodying any one or more of the methodologies or functions described herein. The software may also reside, completely or at least partially, within the main memory, processor, or both during execution thereof by a computer within system, the main memory and the processor also constituting machine-readable media. The software may further be transmitted or received over a network via the network interface device.

While the machine-readable medium can in an exemplary embodiment be a single medium, the term “machine-readable medium” should be taken to include a single medium or multiple media (e.g., a centralized or distributed database, and/or associated caches and servers) that store the one or more sets of instructions. The term “machine-readable medium” shall also be taken to include any medium that is capable of storing, encoding or carrying a set of instructions for execution by the machine and that cause the machine to perform any one or more of the methodologies of the present invention. Memory may be, for example, one or more of a hard disk drive, solid state drive (SSD), an optical disc, flash memory, zip disk, tape drive, “cloud” storage location, or a combination thereof. In certain embodiments, a device of the invention includes a tangible, non-transitory computer readable medium for memory. Exemplary devices for use as memory include semiconductor memory devices, (e.g., EPROM, EEPROM, solid state drive (SSD), and flash memory devices e.g., SD, micro SD, SDXC, SDIO, SDHC cards); magnetic disks, (e.g., internal hard disks or removable disks); and optical disks (e.g., CD and DVD disks).

Furthermore, numerous references have been made to patents and printed publications throughout this specification. Each of the above-cited references and printed publications are individually incorporated herein by reference in their entirety.

In closing, it is to be understood that the embodiments of the invention disclosed herein are illustrative of the principles of the present invention. Other modifications that may be employed are within the scope of the invention. Thus, by way of example, but not of limitation, alternative configurations of the present invention may be utilized in accordance with the teachings herein. Accordingly, the present invention is not limited to that precisely as shown and described.

Claims

1. A Photo Real Embroidery Technology (PRET) System which comprises, in combination: Providing machines effective for creating a database of fiber filament data from respective yarns for mapping color transfers;Transferring to an outer layer of fiber a desired color dye;Heat activating during bonding and infusion to expand fiber filaments based on respective data on surface pores and activated tunnels linked operatively thereto;And drawing surface dye through the pores;Whereby optical three dimensionality reside in the resultory fabric swatch;Electronic means for capture and storage of images desired to be used on garments and apparel.

2. The PRET System of claim 1, further comprising: Said heat activation transferring latent fiber energy into resultory colored fibers via heat emitters.

3. The PRET system of claim 2, whereby system software guides programmed PRET-type of needle-shifting on the outer surface layer of each fiber to embed into tunnels color and then heat to seal them, making material swatches and then heat sealing them.

4. The PRET system of claim 3, whereby said material swatches having permanently colored fibers are attached to other garments.

5. The PRET system of claim 4, the attachment being one method selected from the group of client embroidery's cutting to a panel the swatch of resultory fabric and otherwise.

6. Products, by the PRET System of claim 5, wherein the finished garment, being directly embroidered has no appreciable border around it, and is integrated into the garment.

7. Products, according to claim 6, wherein optical three-dimensionality is created for any user viewing the same.

8. Products, according to claim 7, whereby no irritation or uncomfortable hand attacks a user's skin wearing a garment having said PRET garment incorporated therein.

9. Products, according to claim 8, further comprising: Shirts, hats, pants and all other fabric and cotton-based goods which can incorporate PRET-types swatches of any size.

10. The PRET system of claim 9, whereby any image which can be rendered digital can be faithfully reproduced with fibers color-coded to create an optically three-dimensional image from recycled materials.

11. An improved green and eco-friendly process to produce images on garments, comprising in combination: Providing at least an art file image;Transferring or scanning to a computer via scan or transfer of said art file image;Creating the file, by converting into a digitize-able file, to convert the art file into a readable file for embroidery;Employing recycled yarns and inks, which enables transfer of the images to the yarn via salvaged printer heads and directly to embroider needles with color infused into hollows of the fibers, such as with recycled polyester.

12. A process for producing recycled fibers comprising: Providing plastic wastes;Spinning them into a fiber of cotton or blended yarns at several gage weights; and,Producing them into fabrics.

13. Products by the processes of claim 11, whereby PHOTO REAL EMBROIDERY TECHNOLOGY enables the fibers of a yarn to be fed whereby inks are infused directly into them, as programmed into a special purpose processing unit.

14. Processes according to claim 12, further comprising: Feeding fibers of yarn to be infused with inks; andWith applications applied direct to the yarn, stitch by stitch, direct to a garment or fabrics of cut panels and or of full finished goods.

15. Products, by the process of claim 11, whereby capillaries in the fibers have tunnels which open upon heating and are filled with ink.

16. Products, by the process of claim 15, whereby active tunnels are sealed with cold air.

17. Products, by the process of claim 16, making said yarn direct to embroidery of the 3D image created through computer technology to digitize the fabric.

18. Products of claim 17, using a custom built looms and embroider machines with custom printer heads.

19. A process for transferring yarn to the printer heads and directly to embroidery needles with color; whereby the process can be on black garments in 100% cotton; and said yarns are recycled and inks are too; wherein said inks are colored & infused into the hollow fiber of the recycled polyester, cotton or any fibers used.

20. A process according to claim 19, further comprising: Ink jet style heads used from recycled goods and re-created direct for one direction use;Ink heads to needles & heater heads with infusion added to the process;And being able to read the pixels per square inch on one continuous line to give accuracy and color saturation as the threads applied to the fabric.