LASER MODULATED, EXPLORED, TO PROCESS SURFACES OF MATERIALS
Background Denim garments and other materials have often been processed to make them look worn. Consumers have shown a desire to buy battered garments. Processing techniques currently available for these garments include sandblasting or other abrasive treatment; friction by hand, mechanics or robotics and others. Effects can include local abrasion which is a pattern of wear from below the waist to below the knee section. Another effect is the global abrasion that describes a pattern of wear from below the waist to the back of the pants. "Beards" is a term that describes the wear that occurs along the folds and the hem of the article during use. Still another sight of wear is the rectangular area marked on the back pocket of the denim trousers, which simulates the view of the wear and tear caused by carrying a wallet in the back pocket. Yet another view of wear is known as "fraying", where the degree of wear is so severe that the individual threads of the cotton fiber are exposed. This pattern section
You may even have holes in the denim fabric. The sandblasting process for local and global abrasion can use sandblasting equipment to polish the jeans with sand particles or other abrasive media. This process shoots sand particles from a sandblasting device to a pair of jeans. The random spatial distribution of the sand creates a special appearance in the treated area that is known as "feathered". Abrasion in the feathered area varies from slight along the perimeter of the pattern, for example, the edges and the top of the pattern, to dense in the center of the pattern. This exclusive look can simulate the sight of denim jeans that have been worn for a considerable time. However, the sandblasting process has several problems and limitations. For example, the process of sandblasting or other abrasive media presents environmental and health problems. Typically, a worker needs to wear protective clothing and masks to reduce the impact of inhaling the sand that carries the air. Work is considered to be hazardous work, and can cause high turnover of employees. The operator's individual dexterity may also be critical in reducing the waste rate associated with the sandblasting process. This has the effect
additional to increase certain labor costs for the sandblasting operator that are typically higher than the labor rate for other employees in the denim finishing plant, since their skill may be important. The actual treatment process can be presented in a room that is protected from other areas in the manufacturing facilities. Other environmental problems arise with the cleaning and disposal of the sand. The sandblasting process is an abrasive process, which causes wear of the sandblasting equipment. Frequently the equipment needs to be replaced annually or even more frequently. This, of course, can result in added capital, maintenance and installation costs. Also new designs such as shading effects along the top or bottom of the beards are difficult to obtain with conventional sandblasting processes. In total, the sandblasting process can cost more than $ 1.00 per pair of jeans because of the cost of labor, materials, and waste produced, and environmental cleanup required. It is difficult to duplicate the exact placement of the sandblasting pattern from one garment to the next
due to the variability of the process itself and the variability of one worker with another. The sandblasting process can also adversely affect the tear and pull properties of denim jeans due to abrasion of the sand on the denim. It is not uncommon for the sandblasting process to reduce the tear and tensile strength of denim by as much as 50 percent. In addition, the variation of tear and tensile strength after sandblasting is high due to the lack of control of the abrasive process. Some manufacturers need to test the tear and pull properties of denim at specific locations where abrasion is the least until it passes the company's standards for tear and tensile strength. Other approaches to creating wear views present their own problems. In the case of beards or frays, manufacturers can rely on a lot of expensive and slow labor by hand rubbing or sandblasting processes where beard or fraying is applied to the denim by rubbing sand by hand. times with a rotating burr such as a DREMEL® tool. In addition to the labor costs associated with this process, this hand-sanding operation is often associated with defects after washing, where the washing of the individual beards on the jean can
being too little or too much resulting in a low quality product. Some manufacturers have tried to use robotic sanding processes to avoid these problems, although with a considerable capital investment and with limited flexibility. Despite the above disadvantages, sandblasting and rubbing processes are still in use because the market wants a denim that looks worn. The assignee of the present has described the laser processing of denim, for example, in US Patents 5,990,444; 6,002,099 and 5,916,961. These techniques allow using a laser to change the view of a textile product. Compendium Recognizing the above, the inventors propose new devices and techniques of laser tracing to simulate specific views of wear on fabrics and garments. One aspect includes using a laser to trace lines on a garment, where the energy density per unit time of the laser causes the garment to change color to varying degrees from indigo blue or black to white or gray. Both the individual scanned lines and the different sections of the laser pattern can have a varied energy density per unit of time. The variation of energy density per unit of time can be checked by changing the power, speed, distance, or cycle of
Laser work as the lines are drawn on the material. Other aspects are also described. BRIEF DESCRIPTION OF THE DRAWINGS These and other aspects will now be described in detail with respect to the accompanying drawings, wherein: Figure 1 shows a global laser application system; Figure 2 shows a controllable laser system; Figure 3 shows a control screen for a specific wear view; Figures 4-12 show control screens for different specific wear views; Figure 13 shows a material management system with automatic return; Figure 14 shows a material delivery system with a two-sided laser. Detailed Description The system and the methods described show a system for producing worn out views on textiles and / or garments that are made of these textile materials. These worn out views may include abrasion effects that simulate the sight of a worn garment, beard effects, fraying effects, as well as any other effect that occurs on a garment or other product made
of a textile material and which makes the textile material look more similar to used textile material. In addition, completely new views are possible with this invention that can not be reproduced with conventional sandblasting or rubbing processes. This is done using various techniques described in detail herein. A first technique uses a laser. The laser output is caused to move along the textile material. The energy applied from the laser changes the view of the textile material without making undesirable burns or perforations, or otherwise damaging the textile material. The basic operation of applying energy of a laser is described in US Pat. No. 5,990,444. In the system described, the effective applied energy of the laser, for example, the energy density per unit time ("EDPUT") of the laser, is changed when the laser is drawing a line through the material ("on the fly"). ). The line that is being drawn can be a straight line or a waveform of any pattern; however, the laser forms a line that runs through the textile or garment from one edge to the other. The present application introduces the concept of applied effective energy. This includes the amount of energy that is effectively applied to an area of the material. That area can have any size or shape. The "effective energy applied"
it can include the energy density per unit of time, but it also includes changing the line sweep speed, the power level or the speed level or the laser duty cycle level. It includes changing the distance from the laser to the material, which can defocus the laser, and by this change the energy density per unit of time. It also includes that applied effective energy that is being applied in multiple sessions or times, applying multiple steps, for example of a fixed power, and so on. The effect is to apply more energy to some areas than to others. Another element produces a control sequence that simulates a statistically random property of the particle distribution as it would be produced by a sandblasting process. This technique is used with a user interface program, which allows the designer to paint the information on a screen of the interface. The image on the screen is applied to the material with a laser. Another aspect of the technique allows the use of a laser with much higher power than previous systems of this type. As described above, the amount of change that the laser produces on the textile material is based in part on the effective energy applied to the material; previously described in the patent US 5,990,444 as the energy density level per unit time of the laser in relation to the material. The energy density per unit of time depends on the power
of the laser, the size of the application point and the scanning speed of the laser system in relation to the material. A laser output is used to trace multiple lines along the material. The line can be repeated, that is, in a waveform, zigzag or triangle. In accordance with the present invention, the level of energy density per unit of time changes while a line is being scanned through the material. That is, at some point between the ends of at least one sweep line, the energy density per unit of time is different from that at the end of the line. The controller system controls the change of the level of energy density per unit of time by controlling the parameters, which control the energy density per unit of time (power or duty cycle or speed or distance). The energy density per unit of time administered to the material can be changed in different ways. A first way is to change the wattage or power of the laser output in a continuous or discontinuous manner. A laser depends on light that bounces back and forth inside a laser cavity. The level of excitation of the laser itself can be variable in certain lasers. Therefore the excitation unit 200 can actually be variable to vary the power output of the laser. In this way, this first way to change the level of energy density per unit of time of the laser controls
Directly the excitation levels of the laser in an analogical way. The other energy density controls per unit of time do not change the actual laser power output, but instead change the effective amount of energy density per unit of time that reaches the material. Another control of the energy density per unit of time is via the control of the work cycle. The control pulse 198 to the drive unit 200 can be cycled between on, and off, at a relatively fast speed. The speed of turning on and off must be fast in relation to the movement of the laser. This technique changes the duty cycle of laser output 205, effectively controlling the laser to manage a different average energy level. At any short time, that is, in the amount of time it takes for the laser to travel a distance equal to one or two times the width of the laser beam, the duty cycle can be adjusted multiple times. The effective applied energy density per unit of time can therefore be adjusted by this system, since the square root of the mean of the squares of the instantaneous values of the power varies with time just as if the power were changed. The laser also uses an adjustable shutter, as shown as element 210. This shutter can use a fast piezoelectric element to open and close an opening through
from which the laser beam 208 passes. The mechanical shutter can also turn the shutter on and off relatively quickly. Therefore, this mechanical shutter forms an alternative way to change the duty cycle of the laser application. The laser beam is applied to the garment and causes it to move relative to the garment by moving the laser element 215. This laser movement element may include moving mirrors, or some other way of changing the movement of the laser. In this mode, the controller can also produce an output that controls the speed of laser scanning. By changing the speed of the laser, the energy density per unit of time changes along the course of its line, even if the laser output power remains constant. Still another way to change the energy density per unit of time is by changing the output size of the laser beam. Figure 2 shows a remote lens assembly 120 that is electrically controlled. The controller 199 can produce an output signal that changes the relative position of the lenses to each other and thereby electrically changes the size of the illuminated spot. Alternatively, platform 230 that maintains the material can be moved. Placing the garment on a curved surface is still another way to change the levels of energy density per unit of time causing intentional-
If the center of the section is exactly in focus, the laser beam will be out of focus (decreasing the energy density per unit time) in the curved sections. Still another way to change the energy density per unit of time is to make multiple steps or laser sweeps on different segments of the pattern. Sections that have multiple steps will have more effective energy densities per unit of time if all other laser operating parameters remain constant. This system is used to try to imitate the processes that occur naturally. The worn out views obtained from a conventional laser trace process can be seen to be too uniform in some circumstances. This can be referred to as an artificial or pasted view. The goal, however, is to produce a view as natural as possible. US Patent 5,916,461 describes the use of a probability density function to randomly turn the laser on and off to simulate the "feathered" on the material. The inventors recognize, however, that continuously and discontinuously changing the level of energy density per unit of time within each laser scan line can further improve the effect. By doing so, this system alters the amount of change or abrasion to the textile material, as the laser traces individual lines on the textile material. This invention provides complete degree control
of feathered. The degree of featheredness can be continuously controlled then, by changing the levels of energy density per unit of time in any part of the pattern. The control of the feathered in this way can achieve wear views that seem authentic. One aspect of this system, therefore, produces a wear view or other desired view on a textile material by scanning a laser along the textile, and uses the laser to change a color of the material, where the effective energy density per unit of laser time is changed at least once within a sweep line. In accordance with one aspect, sand-polished garments are typically examined. This examination reveals different patterns of shapes and wear. These patterns are basically non-uniform in nature. A high degree of feathered, or material variation (abrasion) is observed, along the edges and top and bottom of a pattern, either directly by a human examiner, or via an automated examination process . Different concentrations of wear are also observed along different areas of the pattern. The present system stores information of this observation in the memory 195 that is associated with the controller. This information incs geometric information about the wear pattern to be drawn. The information also incs the view of the actual scanned portion.
This view is moved to a special type of parameter matrix. The matrix can be a matrix of energy density per unit of time, a power matrix, a work-cycle matrix or a velocity matrix, for example. The inventors have found by experimentation that the amount of energy per unit time that is applied to any specific area of certain textiles can change the view in proportion to the amount of energy applied. This proportion does not need to be a linear proportion. The change of view can also inc the view after washing. Different patterns can therefore be scanned, for example, using a scanner or camera. The scanner can evaluate each of the sections of the garment, shown here as denim jeans. The system can evaluate, using the total resolution of the scanner, the color of that section. A look-up table can be established by relating the color of certain materials with the energy density per unit of time applied or the power or duty cycle or speed or distance. In this way you can set the energy density per unit time for each area on the jeans. This information can be used to form the matrix described above, storing any of the parameters described above. This matrix can then be used as the information in the memory 195 that drives the controller to
drive the laser In this way, different levels of energy density per unit of time can be applied to different sections of the textile based on the information obtained by observing some other material. Alternatively, the user can examine the wear pattern and manually enter changes in energy density per unit of time (power, speed, duty cycle, or distance) that are associated with the change in abrasion throughout of the geometry of the pattern. These techniques can replicate any desired view, and can also produce a completely new view. In another aspect, existing views can be edited. The view is scanned as noted above to form a matrix. The matrix can then be edited to keep the desirable parts, and change other parts. Examples of the distribution of energy density per unit of time along a single scanned line can be seen as shown in Table I.
Table I. Calculations of energy density per unit of time for a scanned line Power Stain Area Speed EDPUT (watts) (mm) (mm2) mm / sec watts-sec / mm3
Scan Number 1: Scan Start 150 0.30 0.0707 25,000 0.08
First Section of 190 0.30 0.0707 25, 000 0.11
First Quarter scan of 225 0.30 0.0707 25, 000 0.13
Second Quarter Scan of 250 0.30 0.0707 25, 000 0.14
Half Scan Scan 250 0.30 0.0707 25, 000 0.14
Third Quarter of 225 0.30 0.0707 25,000 0.13 Fourth Quarter of 190 0.30 0.0707 25,000 0.11
Scanning End Scan 150 0.30 0.0707 25,000 0.14
Scan Number 2: Start Scan 50 0.30 0.0707 50, 000 0.01
First Section of 500 0.30 0.0707 50,000 0.14
Scanning First Quarter of 800 0.30 0.0707 50, 000 0.22 Scanning Second Quarter of 1000 0.30 0.0707 50,000 0.28 Scanning Half of Scanning 1000 0.30 0.0707 50, 000 0.28 Third Quarter of 800 0.30 0.0707 50, 000 0.22 Scanning Fourth Quarter of 500 0.30 0.0707 50 , 000 0.14
Scan End Scan 300 0.30 0.0707 50, 000 0.08
Scan Number 3: Scan Start 50 0.30 0.0707 10, 000 0.07
First Section of 300 0.30 0.0707 10, 000 0.42
First Quarter Scan of 500 0.30 0.0707 10, 000 0.71
Second Quarter Scan of 1000 0.30 0.0707 10, 000 1.41
Scan Half Scan 1000 0.30 0.0707 10, 000 1.41
Third Room of 500 0.30 0.0707 10, 000 0.71
Fourth Quarter scan of 300 0.30 0.0707 10, 000 0.42
Scan End Scan 50 0.30 0.0707 10, 000 0.07
This table shows that the energy density per unit of time varies from approximately 0.08 watts-sec / mm3 to approximately 0.14 watts-sec / mm3 for the first scan line that can produce local abrasion patterns. The energy density per unit time varies from approximately 0.01 watts-sec / mm3 to approximately 0.28 watts-sec / mm3 for the second scan line which can produce somewhat different local abrasion patterns. The energy density per unit time varies from approximately 0.07 watts-sec / mm3 to approximately 1.4 watts-sec / mm3 for the third scan line. In the latter, the higher energy densities per unit of time can be associated with more aggressive abrasion patterns, including fraying. However, it should be seen that within a certain scanned line, the value of the energy density per unit of time can vary 40 percent or so and still within another line, the energy density can vary more than 1000 percent . Of course, energy density values per unit time can vary as little as 25 percent or as much as 2000 percent to create different wear views with different degrees of featheredness. In general, seeing these values, the energy density per unit of time can be increased any desired amount. Moreover, while this system shows that the energy density per unit of time changes sometimes within the
scanning, the energy density per unit of time can change any number of times within a scan line. The control of the energy density per unit of time in this way is infinite and can vary from a low percentage to several thousand percent along each scanned line and from one line to another. The inventors observed that the cycle time for laser tracing of the scorched pattern on the denim legs can be reduced to 8 seconds or less at a scanning speed of 50,000 millimeters / second using a higher power or faster duty cycle. maintain the intensity of the image. Table II shows the variation and intensity of energy per unit of time along a single line scanned for a different pattern.
Table II. Energy density calculations per unit of time for wear pattern number 2 Power Spot Area Speed EDPUT (watts) (mm) (mm2) mm / sec watts - sec / mm:
Wear Pattern Number 2: Start of scan 20 0.30 0.0707 10000 0.03
First Section of 50 0.30 0.0707 10000 0.07
First Quarter Scan of 500 0.30 0.0707 10000 0.71
Second Quarter Scan of 500 0.30 0.0707 10000 0.71
Half Scan Scanning 500 0.30 0.0707 10000 0.71
Third Quarter of 300 0.30 0.0707 10000 0.42
Fourth Quarter scan of 150 0.30 0.0707 10000 0.21
Scan End Scan 20 0.30 0.0707 10000 0.03
Pattern of Wear Number 2: Start of Scanning 20 0.30 0.0707 20000 0.01
First Section of 50 0.30 0.0707 20000 0.04
First Quarter Scan of 500 0.30 0.0707 20000 0.35
Second Quarter Scan of 500 0.30 0.0707 20000 0.35
Half Scan Scanning 500 0.30 0.0707 20000 0.35
Third Quarter of 300 0.30 0.0707 20000 0.21
Fourth Quarter scan of 150 0.30 0.0707 20000 0.11
Scan End Scan 20 0.30 0.0707 20000 0.01
Wear Pattern Number 2: Start of Scanning 20 0.30 0.0707 50000 0.01
First Section of 50 0.30 0.0707 50000 0.01
First Quarter Scan of 500 0.30 0.0707 50000 0.14
Second Quarter Scan of 500 0.30 0.0707 50000 0.14
Half Scan Scan 500 0.30 0.0707 50000 0.14
Third Room of 300 0.30 0.0707 50000 0.08
Scanning
% -3J) - Fourth Quarter of 150 0.30 0.0707 50000 0.04
Scan End Scan 20 0.30 0.0707 50000 0.01
The inventors realized that having the ability to vary the energy density per unit of time or the power or duty cycle along each individual scanned line have superior control advantages of the degree of featheredness, and so Thus, the creation of an almost infinite variety of wear views. In addition, the energy density per unit time or power or duty cycle could change both along each individual scanned line and from one scanned line to another scanned line. The energy density distributions per unit of time such as those shown in Tables III-IV could easily be achieved, along with almost any other energy density distribution per unit of time that is specified. Table III shows a non-uniform pattern with a somewhat symmetric shape along the center, while Table IV shows a non-uniform pattern with more concentrated energy applications in the left lower quadrant of the pattern. In this way, a great variety of patterns of energy density can be created per unit of time and thus with this technique, wear views can be created.
Table III: Energy density per unit of time (watts-sec / mm3) Matrix for Pattern Wear Number 3 Position X (mm) 0 5 10 15 20 25 30 Position Y (mm) 0 0.05 0.1 Q.2 0.3 0.1 0.08 0.02
0.1 0.3 0.5 0.5 0.2 0.1 0.03
0.2 0.4 0.7 0.7 0.3 0.2 0.1
0.4 0.6 0.7 0.7 0.4 0.3 0.1
40 0.4 0.5 0.7 0.7 0.3 0.3 0.1
50 0.3 0.4 0.7 0.6 0.2 0.1 0.05
60 0.2 0.3 0.4 0.5 0.1 0.1 0.03
70 0.1 0.2 0.3 0.4 0.05 0.05 0.02
80 0.05 0.1 0.2 0.3 0.05 0.03 0.01
Table IV: Energy density per unit of time (watts-sec / mm3) Matrix for Pattern wear Number 4 X position (mm) 10 15 20 25 30
Y position (mm) 0 0.01 0.03 0.05 0.1 0.2 0.2 0. .05
0.01 0.03 0.1 0.3 0.3 0.2 0..025
0.05 0.4 0.7 0.6 0.6 0.5 0. .09
0.05 0.5 0.7 0.6 0.4 0.3 0. .1
40 0.1 0.7 0.7 0.5 0.4 0.3 0. .1
50 0.2 0.7 0.7 0.6 0.6 0.3 0. .05
60 0.1 0.6 0.6 0.3 0.5 0.1 0..03
70 0.01 0.05 0.1 0.5 0.4 0.05 0. .02
This revolutionary concept changes the "black and white" characteristic of the laser image to a new "grayscale" feature. In laser marking of materials such as wood, plastic, metals, etc., the image is created at an energy density per unit of time or power or constant duty cycle. In the case of laser marking the denim, as described in the above patents of the inventors cited above, the image can be created using a constant energy density per unit of time
on each line. In this way, a uniform color is formed after the laser application and the wash that was between indigo blue or black (for the trace with energy density per unit of time) and white or gray (for the plot with density of energy per unit of high time). Nevertheless, the ability to continuously or discontinuously change the energy density per unit of time allows the image to assume any hue (after washing) between indigo blue and white, along any section of the pattern. The hue is associated with the degree of abrasion or the degree of wear. Therefore, the ability to control the hue also allows the control of the degree of abrasion and featheredness. In addition, this new flexibility can thus allow the creation of completely new views impossible by any other economic means. You can create worn-out views, images, or completely new views with sections of nuances continuously or discontinuously different between white and indigo blue. The techniques of continuously or discontinuously changing the energy density per unit time during laser mapping as described herein may have other applications in other material industries where lasers are used to mark materials such as wood, glass, plastic, Rubber, cloth, steel and others. As mentioned earlier, this system has the ability to more accurately assess the spent views. This
it is done by producing a control sequence that replicates the desired properties; in an on / off manner, continuously, discontinuously or in an analogical manner. Any desired amount of control can be provided, limited only by the number of energy density graduations per unit of time produced by the system. The general profile of the energy density per unit of time can still be specified graphically, but you can also control the precise point during the tracing of a line at which the energy density per unit of time will change. The profile of the energy density per unit of time may include a percentage of the highest duty cycle power required. As an example, 50 percent values can be chosen for areas that require slight abrasion and 100 percent values can be chosen for areas that require concentrated abrasion. A new technique that helps the design of garments is described. This allows the operator to paint the desired shape or the desired geometry of the desired pattern to be blurred over the denim to obtain the view used on the computer screen. In addition, the designer specifies the degree of featheredness or energy density per unit of time or power or profile of work cycle. Again, this specification can simply be a percentage of the energy density per unit of time, the power or the cycle of
maximum work. Each effective power level applied is associated with a color. Different sections of the pattern are painted with different color contents, where the color content may be in full power, for example, levels of red, green, blue or gray scale levels. In one modality, colors are associated with different levels of laser work cycle control. The user draws on the computer screen, with the mouse, the desired shape of the pattern. Then the user can select different colors from different areas. This can use a point-and-shoot technique or menu selection or by right-clicking on an area and selecting it from the context menu. This click associates different sections of the pattern with different levels of energy density per unit of time / power / work cycle. The actual power level or duty cycle associated with a given color can be set by a user, and can be modified for different materials. A local abrasion effect can be produced using the user interface screen shown in Figure 3. Figure 3 shows a graphical user interface that allows the formation of a pattern, or a portion of a pattern which will form the basic design that is going to draw on the garment. The actual pattern 300 is formed of a plurality of different sections. The external section 305 defines the perimeter
external global of the form. Also within the sections are other perimeters shown as 310, 315, 320 and the like. The most internal forms, such as 325, are also shown. For shapes of this type, where patterns define an oval pattern, many of the sections are concentric or semi-concentric. The sections can be defined by perimeters. The spaces between each two perimeters define a section. Alternatively, each section can define a separate layer. Figure 3 also shows a plurality of operating parameters that can be set. This includes 330, which sets the speed in centimeters per second and 332 which sets the laser scale factor in units per centimeters. The scale factor of pattern 334 can also be set. The dimension of the pattern in the laser can be set. 338 indicates the drawing section of the laser. 340 represents the color change. A limit length is set at 342. For some random or pseudo-random process, a random seed may be necessary. This random seed can be fixed. Typical edit controls are also displayed, such as edit, save, preview, and so on. 350 represents the profile of the power. The colors 352 are on the left side, and the power profile on row 354 is associated with that color. The system starts with the user selecting a section, either the outermost section or any of the
lower sections that are shown. Each of these sections can be set by having a specific power profile associated with a color from the color palette 352 with a section. The power profiles represent different laser intensities (energy density levels per unit time) and thus different degrees of wear. For example, lighter external sections such as 310 and 305 may be associated with a power duty cycle level plus b ja. This creates a lighter wear view. Darker sections of the pattern, such as section 325, can be associated with higher power duty cycles and represent a more concentrated wear view. The 325 could represent the part of the pattern that is drawn in the knee section. Different shades of gray (after washing the garment) are shown in the areas between the two ends. These areas represent colors of the pattern section that is between indigo blue and full white after processing by the laser and washing the garment. Each of these changes are displayed in color. The values can be saved either in gray scale or in full color and are stored as part of the pattern file, shown here as left.ppx. The pattern file represents the power profile information for the specific pattern that is displayed and editable via the user interface.
Other additional processing features are also used to give the pattern a more realistic view. A set of tools, shown as 360, can be selected to carry out these functions. A first tool that is described here is the mixing function. The mixing can be carried out either pixel by pixel, or area by area. The specific area that is mixed can be selectable. A mixture calculates the average color of each pixel or area by forming a weighted average of the pixel color or area and the color of the neighboring pixels or areas, for example, eight pixels or neighboring areas. The number of pixels that form the weights can be varied to achieve several results. Another tool, shown here as the beard tool, can help the generation of beards. Users can set the length and angle of the beard, and then automatically produce a pattern of beards that can be edited later by the user. A "grain" tool is shown as part of 360 which produces a "grainy" view. The process for the grainy view gives each pixel, and its neighboring pixels, a color vote. The weight of each vote depends on how long the pixel has kept the specific color. The terminology of "long" may refer to the number of image units in an area, for example. Again, although this system refers to colors, it should be understood that gray scales can also be
use to see the separate sections. Sections can also be marked with other area delimiters, such as shading, dotting or the like. Another tool developed as part of this invention is a "jet treatment" tool. In a manner similar to that used by the "spray can" tool supplied with many computer drawing programs to "spray" a specific color, the jet treatment tool sprinkles "increasing intensity" on the pattern. To continue with the analogy, each time a "drop" of the spray can reach the surface of the drawing, the pixel or area that is reached adopts the color that is being sprayed. With the jet treatment tool, a pixel reached by a drop of increased intensity has its color level increased to the next higher level. The effect of the tool produces an effect whose impact depends on the amount of time occupied by "treating with jet" a given region. A longer period of jet treatment causes more pixels to be colored with the effect and therefore causes a greater impact. The jet treatment tool can also be used in an intensity removal mode. In this mode, the pixels that are reached have their color level changed to the next lower intensity level. Any pattern that is formed by natural wear can be accurately simulated through the use of
jet treatment tool. In addition, this tool can be automated to draw several common features automatically, for example, a curved line that simulates a beard, a pattern of pocket wear and the stepped pattern that appears along the seams of the used jeans. An "undo" function allows one or many functions to be reversed if the user does not want the effect. This can, for example, allow treating different sprays or other effects to test them if a good result is obtained. If not, the operation is reversed. This system can produce several different effects. The communication of pattern parameters from the design computer to the laser control computer can be used to develop an efficient system. Many formats have been developed for computer view, generation and transmission of graphic images. The format of these files may allow a greater degree of image complexity (eg, color) than that required for the present purpose and therefore tends to provide more information and details than is necessary for the present purposes. A new file format called TBF (TechnoBlast Format) has been developed which precisely communicates those parameters required to convert the desired image into laser control commands. The file in eX format "TBF" can be a format
mapped into bits of a matrix. Each value represents the power level / work cycle / energy density per unit time for each pixel in the image as well as other control values. This file format therefore includes a value of energy density per unit of time, or at least one indicator value of the effective amount of energy to be applied to a pixel associated with each pixel or group of pixels that are handled as a unit. Since information can be stored at a pixel-in-pixel level, laser writing can write either horizontally or vertically, or in any other direction for that case, based on the same information. The writing direction can be selected by the drawing direction 38. Assuming that the writing is in the horizontal direction, the image is sliced into fragments one pixel wide. Slice 370 shows, in exaggerated form, one of these fragments with pixel width. It should be understood, however, that these pixels are not drawn to scale, and that in fact a real pixel could be of any desired size. Note that each pixel such as 372, 374 may have a different level of energy density per unit of time associated with it. The level of energy density per unit of time is changed as the laser is scanned from pixel to pixel. Many different kinds of views can be produced using this system. The following describes only examples of
these views. It should be understood that other effects will easily occur. Any of these views can be obtained in any of the ways described herein, that is, by authorizing a special image intended for use to change the color of a textile fabric, or by scanning an actual garment and using the results of scanning to form information to use to change the color. Figure 4 shows a localized wear view extending from a little below the waistband to a little below the knee of each leg of the denim trousers. The color of the weathered view (after washing) varies from white or gray in the intense areas of the knee shown in 402 to black or indigo blue (less intense areas) along the upper, lower and portions side of the knee shown as 404. Figure 5 shows an alternative view that is intended for use in the back portion of the denim trousers, for example in the seat area. Again, this portion is substantially oval in shape, but has some worn portions in the center 502 and less weathered portions toward the edge 504. Figure 6 shows an overall wear view from the waistband to the end of the belt. section of the leg where the color of the wear view (after washing) varies from white or gray in the intense areas to the
length of the center and length of the pattern to indigo blue or black along the top, bottom and edges of the pattern. Figure 6 also shows the overall wear view from the rear waistband to the end of the leg section, where the color of the wear view changes from white or gray in the intense areas of the pattern to indigo blue or black along the top, the bottom and the edges of the pattern. Figures 7 and 8 show a wear view of barbs with multiple lines from about 0.32 centimeters to about 5.08 centimeters wide by 2.54 to 35.56 centimeters in length. The color of the pattern changes from white or gray in the center of the pattern to indigo blue or black along the edges of the pattern. The wear of beards can be along any area in the front and back of denim jeans and can contain one or several rectangular sections. A frayed view on the knee, in the rear sitting area, along the bottom of the front and back leg section or any other area of denim jeans is shown in Figures 9-10. The energy density per unit time is of sufficient magnitude to fray the denim so that individual yarns are exposed or real holes are provided in the
denim This goes against the teaching of the earlier patent "444, which teaches that drilling through the material is not desired.The specific" fraying "effect provides sufficient energy density per unit of time to intentionally cause damage to the material However, in a controllable and desired manner, a rectangular wear pattern of approximately 5.08 centimeters by 10 centimeters along the back pocket of the denim trousers is used to similarly wear a wallet in the back pocket, where the color of the pattern is white or gray along the periphery of the rectangle and indigo, blue or black at the center Figure 11 shows the image of the TechnoBlast pattern created for this type of view, any of these views can be combined into a single image The composite image can then be used to apply lasers to denim jeans, which may represent an additional benefit of this system. In previous systems, different processes were used to obtain different effects. For example, conventional sandblasting is used to produce local abrasion on the leg sections of the front and rear denim jeans. Beards are made using a hand-treatment operation where individual workers produce the
different beard patterns. The frayed views use hand-treatment tools and the like. In this system, however, multiple effects can be included within the same file. For example, Figure 12 shows a composite file that includes a plurality of the effects shown above. An additional effect, in which the barbs are shaded, is shown as 1202 in Figure 12. Just above or below the beard, a section is colored white. This indicates that there is no laser application in that section so that after washing the area is blue denim. The same beard can be of different colors to produce different feathered effects. This technique produces a shading effect for beards that is considered quite desirable. Previous systems of this type have used relatively low power lasers, for example, from 25 to 100 watts, of a preferred type to make materials. Laser markers have been used to form graphic images and text in plastic, wood, steel and glass. Another class of laser called the laser cutter, typically produces much higher powers, for example from 250 to 2500 watts. One problem noted by the inventors is the cycle time to apply the worn pattern. When low power lasers have been used, the cycle time may be in the order of minutes for each application. The present application describes the use of a laser of much higher power, for example a laser having a level
of power of 250 watts or more, still more preferably 500 watts or more, and still more preferably 1000 watts or more. For example, a cycle time to burn denim jeans may be minutes with a 50-watt laser that is typically used for marking. A 500-watt laser can produce a pattern in a few seconds. This 500 watt laser has typically only been used for cutting operations. The expectation is that these high-powered lasers would intentionally damage the material. However, by adjusting the energy density per unit of time, the highest power areas can be safely used. As a specific example, the inventors were able to use the 500-watt lasers to make abrasion patterns on the front and back sections in 15 seconds compared to 2 minutes for the sandblasting process. Using 2500 watts laser for the application area is also contemplated, which will decrease the cycle time even more. Additional discoveries were made during the initial tests with high-power lasers. A noted problem is that the desired level of energy or duty cycles at the beginning of a line's tracing may be higher than required, here called an overdraft. The physical nature of the laser process requires that when changing from a lower level of power or work to a higher power level or cycle of
In work, the "inertia" of the energy can cause the power of the work cycle to initially have an overshot of the highest desired power or duty cycle. That can cause a visible initial surplus impact on the denim goal. This effect can be stronger when the laser is actually switched from off (zero energy) to on. The effect on denim becomes much more evident when using higher power lasers, for example, 500 watts or higher. To overcome this problem, a boundary solution is used. The desired pattern is given a "boundary" area. The laser power is set at a level x that is as high as possible without causing any visible effect on the denim or other garment material. The laser output is brought to a position outside the boundary. In this way the laser is at the energy level x, this does not cause visible change. When the laser beam enters the desired visible impact region, the effective energy level increases. The effective energy level increases less at that time, since the increase is from x to the desired level, instead of zero to the desired level. Overtightening of the initial ignition can be reduced in this way. Another important aspect noted by the present application is based on the interference based on patterns / lines that are drawn by the laser, and the direction of the lines of the seams of the materials. Certain "interference patterns"
Undesirable can be produced by the interaction between the laser writing properties, the frequency of the laser and the directional properties of the material. These directional properties can include any aspect of the material that is asymmetrical - and can specifically include the cut, warp and weft of the denim fabric. A rotation of the fabric or the direction of writing can change this effect. Orient the material so that the sweep line makes a 90 degree angle with the cut, warp or weft minimizes the effect, when you want to minimize that effect. However, some of the interference patterns themselves produce quite interesting views for denim jeans and may be desirable. Therefore, one aspect of this system includes taking into account the effects of the interaction between laser scanning and the directional properties of the material. Therefore, another parameter of this system requires the directional pattern of the material that is placed in a specific orientation. This can also be controlled by changing the direction of the drawing using the control 338. Another aspect uses a camera vision system pointing to the surface of the material and automatically detects the directional properties of the material. These properties are entered into the computer, and are used as a parameter of operation. As mentioned previously, it is very desirable to edit an artificial or false view when you try to simulate the
natural wear Therefore it is useful to minimize the opportunity for the human eye to perceive any irregularity in the pattern produced by the laser. One approach to achieve this is to allow the user to specify the energy levels in the design, but to make the precise point at which he switches to the power between two adjacent levels is determined randomly. This feature may not always be desirable. Therefore, making the change of energy level random is a user selectable option. Higher energy lasers can operate faster, and therefore benefit from more automated processes. The conveyor system shown in Figure 1 provides denim jeans 100 on a 102 shape. Denim jeans are introduced to the laser in a horizontal direction. The laser then traces the worn view, after which a second pair of jeans shown as 110 remain behind it and are introduced for further processing. After processing a batch of jeans in this way, they can be removed from the shape and inverted either the same or different laser to write the worn out views on the back. Figure 1 also shows an online material processing system; which includes an online laundry device 120, for example, a system that applies shampoo with a brush, and a removal system, such as a wet vacuum
130. This can use components of commercially available carpet cleaning systems, for example, a RUG DOCTOR® or similar combination of shampoo / vacuum and can produce a desired effect with an in-line system. Figure 1 shows a conveyor system with a straight path. However, a carousel type conveyor is contemplated. An alternative system is shown in Figure 3. The jeans 1300 are located in a shape shown as 1302. The shape keeps the jeans in some way pro example using bras on the inside shown as 1304, 1306. These bras They keep denim jeans in place over the shape. Each of the shapes also includes a rotation rod 1308 connected to a rotator 1310. The denim trousers are transported along the conveyor 1312, which includes at least two of these rotators, the second being shown as 1315. Instead, the jeans are placed in contact with a first laser 1320. This laser produces the wear view on the front of the jeans shown as side 1. After doing so, the rotator 1308 rises and makes the jeans turn to the side 2. Subsequently, the side 2 comes into contact with the second laser 1330 which traces the rear wear view. The jeans are removed from the form after processing, and a new pair of
Unprocessed jeans are applied to the shape. Although this system describes using two lasers, it should be understood that a single laser could be used, that is, by tracing the front side of one or multiple pairs of pants, and then turning all the pants over and tracing the other side. An automated system can detect if the front or back is presenting, for example, by forming an image of the garment so that it looks for the label or the bar code on the jeans. A camera vision system can modulate a specific area of the jeans such as the waist at a time and simply adjust the laser to ensure proper placement of the image on the denim each time. Figure 14 shows still another system. Denim pants are kept from their sides by holding them over a restraining area at a specific location, for example the inside of the pocket where minimal processing will be performed on the denim. Other areas of restraint are also possible. The material processing system leads to denim by areas of fasteners, for example, by a wire that is continuously moving. Alternatively, a shape of the type shown in Figure 13 can be used as a free independent conveyor system. In this mode, dual lasers are used, with one at the top tracing the wear view on the top surface 1400 of the pants and the other 1420 laser
at the bottom, tracing the wear view on the bottom surface of the jeans 1405. For this you can use any free independent conveyor system. For example, this can be done with the garment suspended in a hanging system in the vertical direction. Different forms are also possible. Different types of wear views can be obtained depending on the type of shape used. For example, typical metal forms such as those used in the dry cleaning industry produce a wear view that is similar to that obtained from sandblasting, since the garment is relatively flat as the laser traces the View of wear on the garment. However, using an inflatable balloon type shape, such as was used in some denim finishing plants, a somewhat different wear view occurs. The balloon inflates into the leg of the denim trousers, causing the fibers to extend, the trouser wraps around the shape in a concave manner during the tracing. The inventors noted that this invention produced benefits in the production of denim jeans with beard patterns to simulate wrinkles along the thigh and the knee section. Denim manufacturers have tried numerous methods to create the desired beard patterns. Many have noticed that only the process
Sandblasting by hand was really acceptable to create the authentic wear view for the beards. This process can be very delayed and the quality of the beard pattern is a function of the skill of the worker who sands the beards on the denim. There is considerable variability from one worker to another, as would be expected. Some workers apply too much pressure and some too little pressure so that the quality of the final product is quite variable. However, the inventors noted that using the new technique of changing the energy density per unit of time along the individual drawn lines, any beard pattern could replicate exactly. In addition, a typical beard pattern could be applied to denim trousers with this invention in a few seconds, compared to several minutes with the hand-jet treatment operation. The quality of the beard pattern produced from this system is consistent from one denim trousers to the other due to the consistency of the laser tracing process. Therefore, the performance would be expected to be significantly greater with this invention compared to the hand-jet treatment operation. Although only some embodiments are described, other modifications are possible and are intended to be encompassed within the following claims. For example, other marking elements are contemplated in addition to a laser.