3D Heat-Seal Emblem Structure for Flexible Soft Goods
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Solution Overview
Problem
Existing methods for creating 3D emblems on soft goods result in rigid, stiff products that lack flexibility and high dimensional detail, and often use environmentally harmful chemicals, failing to meet the demand for lightweight, flexible, and durable emblems with high aesthetic impact.
Innovation Solution
A method involving laser or inkjet printing on a flexible film, combining it with a high-stretch moldable substrate, embossing, and laser cutting to create a composite that is then molded and applied to soft goods, using environmentally friendly materials and processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If heat deformable synthetic resin is used to form 3D profile in mold, then profile height can be achieved, but the emblem becomes stiff and loses flexibility
Solution Approach 1:
The patent uses a composite structure consisting of a flexible substrate layer combined with a thermoplastic layer. The flexible substrate provides the necessary flexibility and stretchability, while the thermoplastic layer forms the 3D profile when heated and molded. This composite approach allows the emblem to maintain both high profile height and flexibility simultaneously.
Solution Approach 2:
The patent employs a flexible substrate as the base layer that provides the emblem with stretchability and flexibility. This flexible foundation allows the emblem to conform to garment contours and move with the fabric, solving the stiffness problem inherent in traditional resin-only approaches.
2Manufacturing precision
If thick resin layers are used to achieve large profile height differences, then dimensional detail is improved, but the emblem becomes stiff and reduces garment drape
Solution Approach 1:
The patent combines a thin flexible substrate with a thermoplastic layer that is heated and molded to the desired profile. This approach achieves high dimensional detail and large profile height differences without requiring thick material layers, thereby maintaining garment drape and comfort.
Solution Approach 2:
The patent utilizes temperature as a critical parameter, heating the thermoplastic layer to its melting point to enable it to flow and conform to the mold's detailed profile. This thermal parameter change allows precise dimensional detail to be achieved during molding, while the cooled emblem retains flexibility due to the composite structure.
3Shape
If traditional molding methods are used to create 3D emblems, then profile shape is achieved, but environmental harm from chemicals is increased
Solution Approach 1:
The patent employs induction heating to precisely control the temperature of the thermoplastic layer, melting it to conform to the mold profile. This controlled thermal parameter change enables profile shaping without requiring environmentally harmful chemicals, using only heat and pressure to achieve the desired shape.
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 method produces flexible, stretchable, and durable emblems with high resolution detail and deep profiles, maintaining aesthetic impact through multiple wash cycles, while reducing environmental impact.
Implementation Method 1
The layers are heated until they reach the required compression temperature
Implementation Method 2
pressure is applied to impart a 3D profile
Implementation Method 3
The now profiled composite is removed from the mold before or after cooling
Data Source
AI summary
A multidimensional heat-seal emblem having a digitally-printed image on one side in registration to a three-dimensional relief profile. The emblem has enhanced aesthetic impact, flex, stretch, durability and is suitable for soft goods. A method of production is also disclosed that provides 0.05 mm level relief detail with high profile features up to 6 mm in height.