Release Sheet for Rubber Graphics Transfer
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Solution Overview
Problem
Existing label or graphic transfer systems for rubber articles during vulcanization face challenges in withstanding high temperatures and humidity, and require a non-fluorine containing film that minimizes indentation on the rubber surface while ensuring easy removal of the carrier film without damaging the transferred graphic.
Innovation Solution
A release sheet comprising a flexible, non-fluorinated carrier film with a wax release layer and a thermoplastic or elastomer transfer layer, applied in a non-degradating solvent solution, along with a graphic made of a rubber and pigment composition soluble in a non-polar solvent, which allows for effective transfer and removal during vulcanization, and optionally using a UV curable transfer layer and digitally controlled printing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fluorinated carrier film (e.g., PVF/TEDLAR) is used, then the film can withstand high temperature and humidity during vulcanization, but the film contains fluorine which is undesirable for environmental and health reasons
Solution Approach 1:
The patent replaces durable fluorinated films with a disposable paper-based carrier system that is sacrificed during the process. The paper carrier with wax coating performs the function temporarily during vulcanization and is then discarded after serving its purpose, eliminating fluorine usage while maintaining process reliability
Solution Approach 2:
The patent changes the material parameters from fluorinated polymer to paper with wax coating. This parameter change maintains the essential function of withstanding vulcanization conditions while eliminating the harmful fluorine content through substitution with natural fiber-based material
2Manufacturing precision
If the carrier film is pushed into the rubber surface during curing, then the graphic transfers to the article, but it creates an indentation in the rubber surface which can cause mechanical vibration
Solution Approach 1:
The patent segments the carrier system into multiple functional layers: paper carrier base, wax release layer, and transfer layer with graphic. This segmentation allows the transfer layer to contact and transfer the graphic while the wax layer prevents the carrier from bonding to and indenting the rubber surface
Solution Approach 2:
The patent introduces a wax release layer as an intermediary between the carrier and the rubber surface. This intermediary layer facilitates graphic transfer through heat and pressure while preventing the carrier from directly indenting the rubber, thus eliminating the harmful vibration effect
3Ease of operation
If the carrier film is removed after vulcanization, then the graphic remains on the article, but the film may pick or pull portions of the transferred image or rubber surface
Solution Approach 1:
The wax release layer serves as an intermediary that controls the release mechanism. During removal, the wax layer allows the carrier to detach cleanly from the rubber surface without pulling the transferred graphic, ensuring both ease of removal and graphic integrity
Solution Approach 2:
The patent applies the wax release layer in advance on the carrier before transfer. This preliminary action prepares the carrier surface to facilitate clean release after vulcanization, preventing adhesion issues that would cause graphic damage during removal
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 enables the transfer of graphics to rubber articles at elevated temperatures with minimal indentation and easy removal of the carrier film, maintaining the integrity of the graphic and rubber surface, suitable for applications like automotive power transmission belts.
Implementation Method 1
a wax release layer (14) having a drop point between about 80°C and 120°C
Implementation Method 2
the transfer layer (16) is a thermoplastic or elastomer having a good adhesion to the rubber
Data Source
Figure 1
AI summary
A release sheet (10) for transferring a graphic (18) onto an associated object includes a carrier film (12) formed from a flexible polymeric material having melting point greater than about 15O0C, a release layer (14) disposed on the carrier film (12) that is applied to the film in a solvent solution non-degradating to the carrier film (12), a transfer layer (16) disposed on the release layer (14) that is applied to the release layer (14) in a solution non-degradating to the release layer (14) and a graphic (18) disposed on the transfer layer (16) in a form that is non-degradating to the transfer layer (16). The release sheet (10) containing the graphic (18) is formulated for application to an associated object that is cured or vulcanized at an elevated temperature and humidity, such that the graphic (18) transfers to the object during vulcanization or curing and the carrier film (12) and release layer (14) are removable from the object following vulcanization or curing.