Polyurethane Laminate Structure for Wash-Durable Athletic Decals
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Solution Overview
Problem
Existing methods for applying lettering on athletic wear, such as screen printing and heat transfer printing, result in materials that are either too thick and inflexible or not durable enough to withstand repeated washes without delamination or cracking.
Innovation Solution
A laminate comprising a first layer of polyether or polyester-based polyurethane and a second layer of polyether or polyester-based polyurethane combined with a blocked or encapsulated isocyanate, which can be applied as decals to athletic wear, providing flexibility and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screen printing or hot melt vinyl decals are used for lettering, then the lettering is durable, but the material becomes thick and inflexible
Solution Approach 1:
The lettering material is divided into multiple thin layers (substrate layer, adhesive layer, release liner) rather than using a single thick material. This segmentation allows each layer to be optimized for its specific function while maintaining overall flexibility and durability.
Solution Approach 2:
The invention uses a composite structure combining a polyurethane substrate with a polyurethane adhesive layer containing blocked isocyanate. This composite material provides both the durability of traditional vinyl and the flexibility needed for athletic wear applications.
2Weight of moving object
If heat transfer printing is used for thin lettering, then the material is thin and flexible, but the product is not durable and cracks or delaminates after repeated washes
Solution Approach 1:
The adhesive layer contains blocked isocyanate that undergoes chemical transformation when exposed to moisture and heat during washing. This parameter change activates the adhesive, creating strong chemical bonds that prevent cracking and delamination while maintaining thin profile.
Solution Approach 2:
The adhesive layer is pre-formulated with blocked isocyanate in a dormant state that activates during the washing process. This preliminary preparation ensures that the adhesive bonds strengthen during repeated washes rather than degrading, solving the durability problem of thin heat transfer materials.
3Reliability
If traditional vinyl materials are used, then the lettering is durable, but the material is not flexible enough for modern athletic wear
Solution Approach 1:
The invention uses a thin film structure with a polyurethane substrate and adhesive layer that inherently provides flexibility. The blocked isocyanate system further enhances flexibility by creating a softer, more elastic bond that moves with the fabric rather than cracking.
Solution Approach 2:
The composite of polyurethane substrate with blocked isocyanate adhesive creates a material that combines the durability of traditional vinyl with the flexibility required for athletic wear. The chemical bonding mechanism provides strength while the thin-layer structure maintains 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
The laminate maintains its integrity and flexibility during repeated washes, preventing delamination and cracking, offering superior performance compared to traditional methods.
Implementation Method 1
a second layer deposited on the first layer, wherein the second layer comprises a polyester or polyether based polyurethane in combination with a blocked or encapsulated isocyanate
Data Source
AI summary
Disclosed herein are improved multi-layer laminates for decals or embellishments for clothing, e.g., lettering for athletic wear, and methods of producing the same.