Applying a design on a textile
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Solution Overview
Problem
Existing methods for applying designs to textiles face issues with color coverage, durability, and dye migration, particularly requiring multiple processing steps and being unsuitable for various fabric types and materials.
Innovation Solution
An applique system using a flock adhesive and a hot-melt adhesive applied to a substrate, such as a polyurethane film or fabric, with a multi-coloured flock fibre layer, allowing for easy application with heat and pressure, eliminating the need for additional material deposition and curing, and utilizing a migration-resistant barrier when necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple drying and screen printing operations are used to apply design to textile, then the design can be applied to fabric, but the process becomes complex with multiple processing steps
Solution Approach 1:
The patent combines multiple separate operations (screen printing, flocking, adhesive application, drying) into a single integrated applique unit. The applique pre-assembles the design pattern with flock fibres and adhesives in a factory setting, eliminating the need for multiple sequential processing steps during garment manufacturing.
Solution Approach 2:
The design pattern, flock fibres, and adhesives are prepared and assembled into the applique form in advance during manufacturing. This preliminary preparation allows the applique to be applied directly to the garment in a single step without requiring intermediate drying or printing operations at the point of use.
2Reliability
If granules are melted and made to seep into fabric to fix design, then the design adheres to textile, but there are issues with coverage over certain colours and durability on certain fabric types
Solution Approach 1:
The applique uses different adhesive types in specific locations: permanent adhesive (flock adhesive) where flock fibres need to be retained, and application adhesive (hot-melt) for bonding the applique to the garment. This localized adhesive placement ensures durability on the design while adapting to various fabric colours and types without requiring uniform treatment across the entire applique.
Solution Approach 2:
The applique combines multiple materials with different properties: flock fibres for the design pattern, permanent adhesive for fibre retention, hot-melt adhesive for garment bonding, and optionally a migration-resistant barrier layer. This composite structure provides both durability and versatility across different fabric types and colours.
3Ease of manufacture
If a disposable peel-off sheet is used to apply design, then the design can be transferred to textile, but additional manufacturing operations are required
Solution Approach 1:
The patent removes the disposable peel-off sheet from the final application process. Instead, the applique is designed with permanent and application adhesives that allow direct bonding to the garment without requiring a release sheet, thereby eliminating an additional manufacturing operation while maintaining ease of application.
4Reliability
If traditional flocking methods are used, then design can be applied to fabric, but resistance to dye migration into textile is insufficient
Solution Approach 1:
The applique introduces a migration-resistant barrier layer as an intermediary between the flock adhesive/flock fibres and the garment fabric. This barrier layer prevents dye from migrating into the textile while allowing the applique to be used with various fabric types, maintaining both reliability and adaptability.
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 approach enhances color versatility, ease of application, durability, and resistance to dye migration, reducing manufacturing steps and enabling use with diverse materials like woven textiles and hot-melt films, while maintaining design clarity and flexibility.
Implementation Method 1
the application adhesive can be a hot-melt. A garment or piece of fabric can be provided with the applique as described above
Implementation Method 2
The substrate can include a migration-resistant barrier
Data Source
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Figure 5~7
AI summary
An appliqué for applying a design to a fabric includes a flock in a predetermined multi-colour pattern retained by a flock adhesive and an application adhesive suitable for adhering the appliqué to a fabric. A garment or piece of fabric having an appliqué and a method of decorating a fabric by applying an appliqué using an application adhesive are disclosed.