Heat Transfer Label Structure to Prevent Ghost Marks on Performance Fabrics
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Solution Overview
Problem
Existing heat transfer methods for performance fabrics, such as synthetic textiles, often result in damage and unwanted 'ghost' markings due to high heat, pressure, and long dwell times, which are not effectively addressed by current technologies.
Innovation Solution
A heat transfer label design with a support portion and transfer portion, utilizing a hot melt adhesive layer and ink design layer with recoverable stretch properties, is applied at reduced temperatures, pressures, and dwell times, and incorporates a shaped release layer to minimize ghost image formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high heat, high pressure and long dwell time are used for heat transfer labeling, then secure heat transfer is achieved, but burn marks, pressure marks, bonder marks, die marks, release marks, transfer marks and other unwanted markings are generated on the fabric surface
Solution Approach 1:
The patent changes the thermal and mechanical parameters of the heat transfer process by using a hot melt adhesive with lower melting point and reduced viscosity, enabling transfer at below 140°C, below 1 Bar pressure, and less than 15 seconds dwell time, thereby avoiding fabric damage and unwanted markings while maintaining secure heat transfer
Solution Approach 2:
The patent introduces a shaped release layer as an intermediary between the hot melt adhesive and the fabric. This release layer is sized and shaped to conform to the ink design layer, acting as a mediator that prevents direct contact between the adhesive and fabric, thereby eliminating ghost image generation and transfer marks while ensuring secure adhesive transfer
2Manufacturing precision
If conventional heat transfer methods are used, then ink design transfer is achieved, but ghost images are generated due to release layer markings
Solution Approach 1:
The patent applies local quality by creating a shaped release layer that is specifically sized and shaped to conform to the ink design layer geometry. This localized approach ensures that the release layer markings precisely match the intended design area, preventing ghost images in unintended regions while maintaining design integrity
Solution Approach 2:
The patent converts the potentially harmful effect of the release layer into a beneficial feature by shaping it to match the ink design layer. The release layer's markings, which would normally cause ghost images, are instead used to define the precise boundaries of the transferred design, eliminating unwanted markings while maintaining design accuracy
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 achieves secure and high-quality heat transfer with minimal visible marking, maintaining fabric integrity, wash resistance, and stretchability while using less rigorous conditions.
Implementation Method 1
a hot melt adhesive layer having a first surface and a second surface, the first surface being exposed to permit its direct contact with a performance fabric to be labeled
Implementation Method 2
transfer of the transfer portion from the support portion to a performance fabric under conditions of heat and pressure for a given dwell time
Implementation Method 3
an ink design layer, said ink design layer is in contact and positioned in conformance with the second surface of the hot melt adhesive layer, said ink design layer exhibits recoverable stretch properties
Implementation Method 4
the release layer is sized and shaped in substantial conformance with the size and shape of an image delineated by said ink design layer, thereby substantially eliminating ghost image generation by the release layer upon heat transfer application
Data Source
Figure 1~3
AI summary
A heat transfer label suitable for labeling performance fabrics with minimal transfer marking, comprising: a. a support portion (41) having a label carrier layer (43) and a release layer (45); and b. a transfer portion (47), said transfer portion being positioned over said support portion release layer for transfer of the transfer portion from the support portion to a performance fabric under conditions of heat and pressure for a given dwell time, said transfer portion comprising: i. a hot melt adhesive layer (49) having a first surface and a second surface, the first surface being exposed to permit its direct contact with a performance fabric to be labeled, and ii. an ink design layer (48), said ink design layer is in contact and positioned in conformance with the second surface of the hot melt adhesive layer, said ink design layer exhibits recoverable stretch properties; c. the release layer (45) of the label carrier is sized and shaped in substantial conformance with the size and shape of an image delineated by said ink design layer (48), thereby substantially eliminating ghost image generation by the release coating upon heat transfer application, wherein each shaped release section (52a-d) is transferrable with the ink design layer; and d. said hot melt adhesive layer (49) securely transfers the heat transfer label to performance fabrics at transfer temperature of below about 140°C, a pressure of below about 1 Bar, and dwell time of less than 15 seconds, while substantially eliminating transfer marks on the performance fabrics.