Microfiber Mark-Fabric Adhesive Layer to Prevent Sublimation Seepage
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Solution Overview
Problem
Conventional mark-fabric materials using composite fabrics with sublimation transfer suffer from adhesive layer seepage and defects like peeling and poor wash fastness due to differences in sublimation temperature and pressure, leading to distorted designs and unsellable products.
Innovation Solution
A mark-fabric material comprising microfibers, a thermoplastic adhesive layer with a melt flow rate of 100 g/10 min or less, and a release sheet, where the microfibers are 100% polyester and the adhesive layer is formed directly on the fabric to prevent seepage during sublimation transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an adhesive layer is formed on a composite fabric with non-woven fabric for sublimation transfer, then adhesion strength is improved, but adhesive layer seepage occurs during thermal pressing causing defects
Solution Approach 1:
A release sheet is introduced as an intermediary layer between the adhesive layer and the pressing surface. This release sheet prevents direct contact between the adhesive layer and the heating press, thereby preventing adhesive seepage during thermal pressing while maintaining adhesion strength. The release sheet acts as a mediator that allows heat transfer but blocks adhesive material flow.
Solution Approach 2:
A thin film release sheet is used to cover the adhesive layer during pressing. This thin film structure allows thermal energy to penetrate through to the adhesive layer for proper bonding while physically containing the adhesive material to prevent seepage onto the fabric surface.
2Manufacturing precision
If thermal pressing is performed at high temperature for sublimation transfer, then dye transfer quality is improved, but adhesive layer melts and seeps through causing peeling defects
Solution Approach 1:
The release sheet serves as a protective intermediary that stabilizes the adhesive layer during high-temperature pressing. It prevents the adhesive from melting and seeping through by providing a containment barrier, while still allowing the necessary heat transfer for sublimation dye transfer to occur at high quality.
Solution Approach 2:
The release sheet is placed on the adhesive layer before thermal pressing begins, providing preemptive protection against adhesive seepage. This prior cushioning prevents the harmful effect of adhesive melting and peeling before it can occur during the high-temperature sublimation process.
3Strength
If pressure is increased during thermal pressing to improve adhesion, then bonding strength is improved, but adhesive layer seepage increases causing design distortion
Solution Approach 1:
The release sheet acts as a mediator that allows high pressing force to be applied for strong bonding while preventing the adhesive from seeping out under pressure. It transmits the mechanical pressure needed for adhesion but blocks the adhesive material flow that would cause design distortion.
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 adhesive layer seepage and maintains design integrity, ensuring strong adhesion and resistance to washing and rubbing, thus producing high-quality marks without the need for an intermediate layer.
Implementation Method 1
a thermoplastic adhesive layer with a melt flow rate of 100 g/10 min or less
Implementation Method 2
the sublimation dye of the color, motif, design etc. printed onto the transfer paper using sublimating dye is caused to sublimate
Data Source
AI summary
A mark-fabric material includes a mark-fabric including, in the following sequence, microfibers, an adhesive layer including a thermoplastic resin having a melt flow rate of 100 g/10 min or less, and a release sheet.