Decorative Transfer Coating for Abrasion-Resistant Textiles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for decorating coated textiles, such as screen printing, are cumbersome, costly, and produce patterns with questionable quality, especially on irregular surfaces, leading to poor mechanical resistance and visual degradation over time.
Innovation Solution
A process involving a multilayer transfer complex with a support layer, colored layer, and fusible layer is applied to the textile under heat and pressure, allowing for the creation of durable, varied patterns without cutting the support layer, followed by varnishing and embossing to achieve a structured surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If screen printing is used to decorate coated textiles, then decorative patterns can be applied, but the manufacturing process becomes cumbersome, complex and costly
Solution Approach 1:
The decorative patterns are pre-applied to a transfer film before being transferred to the coated textile. This preliminary action allows the patterns to be created in advance under controlled conditions, then transferred as a complete unit to the textile surface, eliminating the need for complex in-situ screen printing operations
Solution Approach 2:
A transfer film serves as an intermediary carrier between the pattern design and the final textile product. The pattern is first applied to this intermediate film, then the entire film is transferred to the coated textile surface, simplifying the manufacturing process while maintaining pattern quality
2Adaptability or versatility
If screen printing is used on irregular surfaces, then decorative patterns can be applied, but the process requires fixed frames and cutting operations
Solution Approach 1:
The decorative patterns are pre-applied to a flexible transfer film that can be easily handled and positioned. This preliminary action eliminates the need for complex fixed frames and cutting operations, as the entire patterned film can be transferred to irregular surfaces in a single operation
Solution Approach 2:
A flexible transfer film is used as the carrier for the decorative patterns. This thin film can be easily conform ed to irregular textile surfaces and manipulated during the transfer process, eliminating the need for rigid fixed frames and complex cutting equipment
3Manufacturing precision
If multiple printing passes are used to achieve sufficient ink coverage, then pattern visibility is improved, but the cost and complexity of the process increases
Solution Approach 1:
The decorative patterns are pre-applied to the transfer film with sufficient ink coverage in advance. This preliminary action ensures that the pattern is fully formed before transfer, eliminating the need for multiple printing passes on the textile itself and reducing process complexity
Solution Approach 2:
Multiple printing operations that would normally be required to achieve sufficient ink coverage are merged into a single preliminary printing operation on the transfer film. The entire patterned film is then transferred in one operation, combining multiple steps into a simplified process
4Strength
If heat and pressure are applied to transfer patterns, then adhesion to the coating layer is improved, but color modification and bubble formation occur
Solution Approach 1:
The thermal and pressure parameters are carefully controlled and optimized to achieve sufficient adhesion without causing color modification or bubble formation. By precisely adjusting these parameters, the transfer process achieves strong bonding while avoiding the harmful effects of excessive heat and pressure
Solution Approach 2:
The decorative pattern is transferred as a complete copy from the transfer film to the coated textile. This copying process allows the pattern to be reproduced with faithful color and detail, avoiding the color modification and bubble formation that occur with direct screen printing under heat and pressure
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 method results in patterns with improved resistance to abrasion and better visual quality, simplifying the manufacturing process and reducing costs by eliminating the need for complex cutting operations and multiple printing passes.
Implementation Method 1
pressure and heat conditions are then applied so as to cause adhesion of the fusible layer to the upper coating layer
Implementation Method 2
passing the textile complex under an imprint having the inverted graining pattern, which is applied under temperature and pressure conditions in order to be able to conform the upper coating layer
Data Source
Figure 1~3
Figure 4~6
Figure 7
AI summary
The invention relates to a method for making a textile complex (10) including a textile web (11) and an upper coating layer (12) having an irregular surface condition, and comprising decorative patterns (8, 9, 58) applied onto the upper coating layer (12), characterized in that the method comprises the following steps: preparing a decorative multilayer complex (1) comprising at least three basic layers, i.e. a substrate layer (5), a colored layer (4), a heat-fusible layer (2), by cutting the colored layer (4) and the heat-fusible layer (2) along the outlines (6) of the decorative patterns (8, 9) without cutting the substrate layer (5) and then removing the fractions of said colored (4) and heat-fusible (2) layers outside the pattern areas (8, 9); arranging said prepared multilayer complex (1) on the upper coating area (12) of the textile complex (10) by means of the surface thereof with the heat-fusible layer (2); applying temperature and pressure conditions that trigger the adhesion of the heat-fusible layer (2) to the upper coating layer (12) of the textile complex; subjecting the assembly to a processing (27) resulting in a structured and regular surface condition of the upper coating layer.