Sportswear Patch Anti-Migration Shielding Layer
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Solution Overview
Problem
Existing patches for sportswear face challenges such as difficulty in application to mesh-form sportswear, migration of pigments, and high production costs, along with environmental pollution concerns.
Innovation Solution
A patch with a substrate layer and a special anti-migration shielding layer, comprising polyurethane coatings and barrier layers, is developed, which includes a double-sided adhesive for easy application and prevents pigment migration, using a hot-melt adhesive sheet and primer coatings to ensure durability and environmental friendliness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a binder is used to fix the patch to sportswear, then the patch can be attached to the garment, but the binding process becomes very difficult on mesh-form sportswear and the patch may be removed during washing
Solution Approach 1:
A transfer paper serves as an intermediary carrier that holds the pattern and transfers it to the sportswear fabric. The pattern is first formed on the transfer paper, then the paper is positioned on the sportswear and pressed to transfer the pattern without requiring direct binding of the patch to the mesh fabric, thus avoiding the difficulty of binding to mesh-form sportswear
Solution Approach 2:
The pattern is pre-formed on the transfer paper before application to the sportswear. This preliminary formation of the pattern on a stable substrate (transfer paper) allows for precise pattern creation that can then be cleanly transferred to the sportswear without the complexity of direct patch binding to mesh fabric
2Strength
If the patch is fixed through embroidery processing, then the patch can be securely attached, but the processing becomes complicated and must be done upon sewing the sportswear
Solution Approach 1:
The transfer paper acts as an intermediary that simplifies the attachment process. Instead of complex embroidery processing, the pattern is transferred through a simple pressing operation using the transfer paper as a mediator, significantly reducing processing complexity while maintaining attachment strength
Solution Approach 2:
The complex mechanical embroidery process is replaced with a simpler thermal or pressure-based transfer process. The pattern transfer is achieved through pressing rather than needle-and-thread mechanical embroidery, reducing device complexity and processing steps
3Illumination intensity
If pigment or dye is applied to sportswear, then the sportswear gains color, but migration onto the patch pattern occurs over time deteriorating product quality
Solution Approach 1:
A barrier layer is introduced as an intermediary between the colored sportswear fabric and the patch pattern. This barrier layer prevents direct contact and migration between the dye/pigment in the fabric and the pattern, maintaining color fastness while allowing the sportswear to retain its color intensity
Solution Approach 2:
The potential harm of dye migration is converted into a benefit by using the barrier layer to selectively block pigment transfer. The barrier layer allows the sportswear to be brightly colored while preventing the very migration that would otherwise deteriorate product quality
4Illumination intensity
If a laminated patch structure is used, then the pattern has a three-dimensional appearance and is visually prominent, but the patch becomes susceptible to migration and difficult to apply
Solution Approach 1:
The patch system is segmented into separate functional components: the pattern layer on transfer paper, the barrier layer, and the sportswear fabric. This segmentation allows each component to perform its specific function independently - the pattern layer provides visual prominence while the barrier layer prevents migration and simplifies application
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 is securely fixed to sportswear without migration, even after frequent washing, and is produced without environmental pollutants, reducing production costs and inventory burdens, while maintaining a three-dimensional appearance.
Implementation Method 1
a hot-melt adhesive sheet layer
Implementation Method 2
the first barrier coating layer for preventing the color of a dye or a pigment from migration from sportswear
Data Source
AI summary
Disclosed are a patch for sportswear, which is fixed on the surface of a T-shirt or team uniform, and a method of producing the same, wherein the patch includes a substrate layer, including a polyester fabric layer having a pattern, a colorless polyurethane base coating layer, and first, second and third polyurethane-mixed coating layers, which are sequentially formed; an anti-migration shielding layer, including a hot-melt adhesive sheet layer, a first primer coating layer, a first barrier coating layer, a second barrier coating layer and a second primer coating layer; and a double-sided adhesive layer for bonding the substrate layer and the shielding layer to each other, whereby the patch can be simply fixed on a finished sportswear product, does not migrate over time, and is not stripped even after washing at least 50 times, thus exhibiting high durability, and whereby environmentally friendly production of the patch is possible.