Dye Migration Preventing Layer for Thermoplastic Decorations
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Solution Overview
Problem
Conventional decoration pieces made of thermoplastic synthetic resin on polyester fabric dyed with dispersing dye or sublimation printing suffer from dye migration over time, leading to discoloration, and there is a need to prevent separation of constituent members during attachment.
Innovation Solution
A decoration piece is manufactured with a dye migration preventing layer made of ethylene-vinyl alcohol copolymer or polyamide MXD6, fusion-bonded between the design piece and the lower layer using high-frequency dielectric heating, ensuring the dye remains on the fabric and the components are securely integrated.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a decoration piece is made of thermoplastic synthetic resin and attached to polyester fabric dyed with dispersing dye or sublimation printing, then the decoration piece can be manufactured using high-frequency dielectric heating, but dye migrates from the fabric to the decoration piece over time causing discoloration
Solution Approach 1:
A dye migration preventing layer is introduced as an intermediary barrier between the polyester fabric and the thermoplastic synthetic resin decoration piece. This layer prevents direct contact and dye transfer while allowing the decoration piece to be attached to the fabric. The intermediary layer solves the contradiction by maintaining the ease of manufacture with high-frequency dielectric heating while blocking the harmful dye migration effect.
Solution Approach 2:
The decoration piece structure is segmented into multiple layers: the thermoplastic synthetic resin layer and the dye migration preventing layer. This segmentation allows each layer to perform its specific function - the thermoplastic layer provides structural integrity and allows for high-frequency manufacturing, while the preventing layer specifically addresses dye migration. The segmentation resolves the contradiction by separating the manufacturing function from the protection function.
2Strength
If the lower layer is melted and cut by high-frequency dielectric heating to form the decoration piece, then the design piece can be integrated to the lower layer, but the lower layer material may be unnecessarily damaged if it is cloth or knitting
Solution Approach 1:
The dye migration preventing layer is applied locally between the design piece and the lower layer, specifically where dye migration occurs. This local application provides protection without requiring the entire lower layer to be melted and cut, thus maintaining layer integration where needed while preventing unnecessary damage to the lower layer material such as cloth or knitting.
3Object-affected harmful factors
If a dye migration preventing layer is added between the design piece and the lower layer, then dye migration is prevented, but the device complexity increases
Solution Approach 1:
The dye migration preventing layer is constructed as a composite material system that can be integrated into the existing decoration piece manufacturing process. By using composite materials that are compatible with high-frequency dielectric heating, the layer addition prevents dye migration while maintaining process simplicity. The composite structure allows the new layer to work harmoniously with the existing thermoplastic synthetic resin layer.
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 solution effectively prevents dye migration, maintains the color integrity of the fabric, and ensures the decoration piece remains securely attached without environmental harm, as the materials used are non-toxic and can be melted and cut using high-frequency dielectric heating.
Implementation Method 1
there is also provided a dye migration preventing layer (5) arranged between the design piece (3) and the lower layer (7)... said dye migration preventing layer (5) being capable of preventing any migrating of dye
Implementation Method 2
forming a design piece (3) made of soft polyurethane with a design by high-frequency dielectric heating... said dye migration preventing layer is fusion-bonded to both said design piece (3) and the lower layer (7) by high-frequency dielectric heating
Implementation Method 3
The fusion cutter 105p includes a sharp blade edge positioned along an outer profile line of a design to be formed, and melts and cuts the thermoplastic synthetic resin film 131q that is material of the design piece
Data Source
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AI summary
There is provided a decoration piece in which the dye in the clothing or object is prevented from being migrated to the piece, in which the constituent members are not separated, and in which it can be prepared by high-frequency induction heating. A decoration piece comprises: a design piece (3) made of thermoplastic synthetic resin formed with a design and having an outer profile line; a lower layer (7); and a dye migration preventing layer (5) arranged between the design piece (3) and the lower layer (7), said dye migration preventing layer (5) having an outer profile same as that of said design piece (3), said dye migration preventing layer (5) capable of being adhered to both said design piece (3) and the lower layer (7), said dye migration preventing layer (5) capable of preventing any migrating of dye. The dye migration preventing layer (5) comprises a dye migration preventing film (51) made of ethylene-vinyl alcohol copolymer or polyamide MXD6, or a dye migration preventing film (151) made of polyvinylidene chloride.