Self-Adhesive Patch with Thick Adhesive Layer for Outdoor Gear Repair
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Solution Overview
Problem
Existing self-adhesive patches for outdoor gear are prone to degradation due to exposure to heat, cold, UV light, and mechanical stress, and struggle to adhere well to lightweight or ultralight materials and irregular surfaces, often requiring additional adhesive and heat for application, which can be inconvenient and damaging.
Innovation Solution
A self-adhesive patch with a thick adhesive layer and a scored, crack-and-peel backing, manufactured by laminating fabric with adhesive and allowing it to cure before cutting, which forms a seal around the edges and allows for precise application without separate adhesive bottles or heat sources, suitable for thin and quilted surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If self-adhesive patches are made with waterproof material, then waterproof performance is improved, but adhesion to fabric is worsened due to slick surface interfering with adhesive bond
Solution Approach 1:
The patch is segmented into distinct functional layers: a waterproof outer layer and an adhesive layer. The adhesive layer is positioned between the waterproof material and the fabric, creating separate zones for waterproofing and adhesion functions, resolving the conflict between these two properties.
Solution Approach 2:
An adhesive layer acts as an intermediary substance between the waterproof material and the fabric. This intermediate layer facilitates bonding without requiring the waterproof material itself to be adhesive, allowing both waterproof performance and strong adhesion to coexist.
2Reliability
If additional coatings are applied to protect from UV-degradation, then durability is improved, but adhesion is worsened by interfering with adhesive-fabric bond
Solution Approach 1:
UV protection is segmented into a separate functional layer within the patch structure. The adhesive layer remains distinct and free of UV-coating interference, allowing it to maintain optimal bonding properties while the waterproof outer layer provides UV protection.
Solution Approach 2:
The adhesive layer serves as an intermediary that is shielded from UV exposure by the outer waterproof layer. This protects the adhesive's bonding capability while still providing UV resistance to the overall patch assembly.
3Weight of moving object
If patches are applied to lightweight or ultralight materials, then weight is reduced, but adhesion is worsened due to thinness, stretch characteristics, and heat response
Solution Approach 1:
The adhesive layer's thickness and composition are optimized to accommodate the unique properties of lightweight materials. The increased adhesive layer thickness compensates for the thinness and stretch characteristics of ultralight fabrics, maintaining strong adhesion while preserving weight savings.
Solution Approach 2:
The patch is constructed as a composite material system combining a waterproof layer, adhesive layer, and release liner. This composite structure allows the adhesive to bond effectively to lightweight materials while the overall patch maintains durability and waterproof properties.
4Adaptability or versatility
If patches are stored in high heat and pressure conditions, then portability is improved, but usability is worsened when backing adheres firmly and cannot be peeled away
Solution Approach 1:
The release liner is designed with preliminary separation characteristics that allow it to be peeled away from the adhesive layer even after exposure to heat and pressure during storage. The liner's structure maintains its release properties, enabling easy backing removal when needed.
Solution Approach 2:
The adhesive layer's bonding characteristics are made dynamic, allowing it to adhere strongly to the release liner during storage but release easily when the liner is pulled away. This dynamic behavior enables the patch to withstand storage conditions while remaining usable.
5Adaptability or versatility
If patches are stored in cold conditions, then portability is improved, but usability is worsened when backing separates from adhesive and becomes dusty
Solution Approach 1:
The release liner is designed to maintain its protective function even in cold storage conditions. The liner's structure prevents the adhesive from becoming dusty or contaminated during cold storage, ensuring the adhesive remains clean and effective when the patch is ready for use.
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 patch maintains strong adhesion through challenging conditions and multiple wash cycles, with increased T-Peel and static shear strength, and can be applied in the field without electricity, maintaining aesthetic shapes without compromising adhesive properties.
Implementation Method 1
Some patches have been stitched or sewn onto an item of apparel... self-adhesive patches to repair fabrics... Such patches include an adhesive on one side of the patch, protected by a backing layer
Implementation Method 2
a scored, crack-and-peel backing... manufactured by laminating fabric with adhesive and allowing it to cure before cutting
Data Source
AI summary
Applique, self-adhesive patches for repairing clothing, inflatable sleeping pads, tents, and other fabric articles, and methods for manufacturing and applying the patches. The patch includes a layer of fabric laminated to a layer of adhesive, the layer of adhesive being thicker than the layer of fabric. The patch is cut by a laser or heat punch, forming an edge portion wherein the backing protecting the adhesive, the adhesive, and the fabric are more closely bonded than the rest of the patch.