Dye Sublimation Polyester Laminate for Tagless Garment Labels
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Solution Overview
Problem
Existing tagless labels and dye sublimation technologies face challenges in achieving durable, visually appealing, and bulk-free applications on garments, particularly in maintaining color strength and image quality without the bulk of separate tags.
Innovation Solution
A digitally printed dye sublimation ink laminate with a polyester substrate, adhesive layer, and optional release layer, applied using heat and pressure to create a durable, visually appealing tagless label that captures color strengths and reduces bulk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional separate tags are used for garment labeling, then product identification is achieved, but the garment experiences additional bulk and discomfort
Solution Approach 1:
The patent merges the label function with the garment fabric itself by applying dye sublimation printing directly onto the fabric surface. The printed indicia becomes an integral part of the fabric structure, eliminating the need for separate physical tags while maintaining product identification functionality. This integration removes the bulk and discomfort associated with traditional separate tags.
Solution Approach 2:
The patent creates a visual copy of traditional tag information by printing indicia directly on the fabric. Instead of using a physical tag that attaches to the garment, the information is copied onto the fabric surface through dye sublimation, providing the same identification function without the physical presence of a separate tag element.
2Manufacturing precision
If dye sublimation printing is applied to cotton fabrics, then color strength and image quality are improved, but the fabric must be inherently capable of supporting dye sublimation inks
Solution Approach 1:
The patent modifies the fabric parameters by applying a polyester coating or laminate layer to cotton or other non-polyester fabrics. This parameter change enables the fabric to accept dye sublimation inks, as the polyester layer provides the necessary chemical affinity for the dyes while the underlying fabric maintains its original properties. This allows cotton fabrics to achieve the color strength and image quality of dye sublimation printing.
Solution Approach 2:
The patent creates a composite material structure by combining cotton fabric with a polyester coating or laminate layer. The composite structure leverages the advantages of both materials: the cotton provides comfort and breathability while the polyester layer enables dye sublimation printing with superior color strength and image quality. This composite approach expands fabric compatibility while maintaining high print quality.
3Ease of operation
If heat transfer methods are used to apply labels, then tagless application is achieved, but the label may not capture the full color strength of digitally printed images
Solution Approach 1:
The patent utilizes the phase transition of dye sublimation inks from solid to gas state under heat and pressure. The solid ink particles sublime directly into gas phase and penetrate into the polyester fibers, creating a permanent bond. This phase transition mechanism ensures superior color strength and image quality compared to traditional heat transfer methods, while still achieving tagless application through direct printing on the fabric.
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 provides increased durability and improved image quality on garments, eliminating the feel of separate tags while maintaining the aesthetic appeal of dye sublimation images, suitable for various fabric items.
Implementation Method 1
The dye from the ink layer sublimates into a material layer such as a polyester interacting with the molecules of the polyester layer
Implementation Method 2
applied using heat and pressure to create a durable, visually appealing tagless label
Data Source
AI summary
A laminate that possesses dye sublimation properties, particularly for use as tagless labels and embellishments for garments, apparel, fabric items and so forth such as sportswear fabrics, clothing and accessories is provided. The laminate includes a dye sublimation ink layer that overlies a substrate in which the dye sublimation ink interacts with the substrate's chemical make-up.