Stretchable Textile Appliqué With Elastomeric Adhesive Bonding
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Solution Overview
Problem
Existing methods fail to create textile appliqués with elastic properties that match those of stretchable and elastic materials, leading to adhesive layer failure, cracking, and detachment when stressed, which affects both the aesthetic and functional qualities of the design.
Innovation Solution
A method involving a sublimation dye heat transfer process followed by the application of an elastomeric adhesive layer with specific properties, including a first and second thermoplastic adhesive film and an elastomeric film, to create a self-supporting adhesive layer that maintains elasticity and adhesion even under deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a traditional adhesive layer is used to bind the textile appliqué to the elastic article, then the appliqué can be attached to the article, but the adhesive layer splits and cracks when stretched, causing detachment and distortion
Solution Approach 1:
The patent changes the physical and chemical parameters of the adhesive layer by incorporating elastomeric materials that can undergo reversible deformation. The adhesive layer is formulated with elastic modulus and tensile strength parameters that match the underlying elastic fabric, allowing it to stretch and recover without cracking or splitting, thereby maintaining integrity under dynamic stress conditions
Solution Approach 2:
The adhesive layer is constructed as a composite material system combining traditional adhesive components with elastomeric additives and plasticizers. This composite structure provides both the bonding strength needed for attachment and the elastic properties required to match the stretchable fabric, preventing the splitting and cracking that occurs with conventional rigid adhesives
2Reliability
If the adhesive layer is made more elastic to match the stretchable article, then the adhesive layer can recover its shape, but the bond strength between the appliqué and article decreases
Solution Approach 1:
The patent optimizes the adhesive layer's mechanical parameters by adjusting the elastomeric content, crosslinking density, and plasticizer concentration. These parameter changes enable the adhesive to achieve a balance where the elastic recovery ratio matches that of the underlying fabric while maintaining sufficient bond strength through controlled adhesion to both the appliqué and substrate
Solution Approach 2:
The adhesive layer exhibits spatially varying properties with different regions optimized for different functions. The formulation creates local zones with enhanced bonding characteristics at the interfaces while maintaining elastic recovery properties in the bulk, allowing the adhesive to simultaneously achieve strong attachment and shape recovery
3Shape
If a rigid adhesive layer is used to maintain the shape of the appliqué, then the appliqué retains its form, but the adhesive layer cannot stretch with the elastic article, causing cracks and splits
Solution Approach 1:
The patent modifies the adhesive layer's mechanical parameters by incorporating elastomeric materials and plasticizers that reduce the glass transition temperature and increase chain mobility. These parameter changes enable the adhesive to undergo large elastic deformations while recovering its original shape, providing both shape retention and stretchability to match the dynamic behavior of elastic apparel
Solution Approach 2:
The adhesive layer transitions from a static, rigid structure to a dynamic, elastic system that can adapt its shape in real-time. The elastomeric formulation allows the adhesive to dynamically follow the deformation of the underlying fabric during stretching and recovery cycles, maintaining shape fidelity without cracking
4Shape
If the adhesive layer is made thinner to reduce distortion, then the appliqué lies flatter, but the adhesive layer becomes more prone to cracking under stress
Solution Approach 1:
The patent formulates the adhesive layer as a composite material system that incorporates elastomeric polymers, traditional adhesive components, and plasticizers in specific ratios. This composite structure provides enhanced toughness and crack resistance even at thin cross-sections, allowing the adhesive to maintain both flatness and structural integrity under dynamic stress conditions
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 allows for the creation of appliqués that maintain their elasticity and adhesion to the article, preventing detachment and distortion, while ensuring the appliqué and article move together without curling or losing their shape, thus enhancing the aesthetic and functional qualities.
Implementation Method 1
applying, at a sublimation temperature, a sublimation dye heat transfer image to appliqué media
Implementation Method 2
adhering a self-supporting elastomeric adhesive layer to the sublimation printed appliqué media
Data Source
AI summary
A stretchable knit appliqué is described. The appliqué is configured by a woven textile material adhered to an elastomeric film by a first adhesive continuously distributed over elastomeric film. Moreover, the appliqué is configured to stretch with the elastomeric film. The appliqué can have a first and second woven materials, with a printed design in registration with the first and second textile materials. The printed design can be a sublimation printed design.