Texturized Mottled Clothing Label Laminate
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Solution Overview
Problem
Conventional polymer-reinforced papers lack the aesthetic appeal and durability required for clothing labels, particularly failing to withstand multiple wash cycles without delamination or significant damage, and do not mimic the natural color variations of leather labels.
Innovation Solution
A laminate is created by texturizing a paper web with cellulosic fibers and saturating it with a binder composition containing a curable latex polymer and crosslinker, which is then laminated to a base web with a similar composition, forming a durable and aesthetically pleasing clothing tag that can withstand wash cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If paper is saturated with polymer binder to improve strength, then dimensional stability and tear resistance improve, but the surface becomes flat and uniform in color, lacking aesthetic appeal
Solution Approach 1:
The patent applies local quality by texturizing only the outer surface layer of the laminate while maintaining polymer saturation for strength. The surface is embossed or creped to create leather-like texture, while the bulk material remains saturated with binder composition for durability and wash resistance.
2Shape
If multiple papers are laminated together to thicken and improve aesthetics, then color variation and thickness improve, but the laminate cannot withstand multiple wash cycles without delamination
Solution Approach 1:
The patent creates a composite material structure where a paper web is saturated with polymer binder composition and then laminated to a knit or woven fabric substrate. This composite structure combines the aesthetic and printability benefits of paper with the durability and wash resistance of fabric, preventing delamination during wash cycles.
3Ease of manufacture
If paper is made thinner to reduce cost, then manufacturing cost decreases, but the paper lacks sufficient strength to survive wear and tear
Solution Approach 1:
The patent uses a composite laminate structure where a thin paper web saturated with polymer binder is laminated to a stronger knit or woven fabric substrate. This allows the use of thinner, less expensive paper while the fabric substrate provides the necessary strength and wear resistance to survive normal use and washing.
4Ease of manufacture
If uniform color is applied to the paper, then manufacturing simplicity is maintained, but the label lacks natural color variations expected in leather labels
Solution Approach 1:
The patent applies local quality in coloration by using pigmented binder composition that creates natural color variations during the saturation process. Different areas of the paper web receive varying amounts of pigmented binder, creating a mottled, non-uniform appearance that mimics natural leather while maintaining relatively simple manufacturing through the saturation process.
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 provides exceptional strength, printability, and durability while maintaining a leather-like appearance, capable of surviving multiple wash cycles without significant damage and retaining its appearance, thus offering a cost-effective and environmentally friendly alternative to leather or polyurethane labels.
Implementation Method 1
The paper web can be saturated with a binder composition
Implementation Method 2
The first binder composition can include a first curable latex polymer, a first crosslinker
Data Source
AI summary
Laminates and methods of making them are generally provided. The methods of making a laminate for use as a clothing tag can include laminating a first fibrous web to a second fibrous web. Both the first and second fibrous webs can include cellulosic fibers and a binder composition present in the respective fibrous web from about 10% by weight to about 100% by weight of the dry weight of the fibrous web. Both the first and second binder composition can include a curable latex polymer and a crosslinker. The second fibrous web can be creped and can have a thickness less than 10 mils. The laminate can be aged for at least about 1 hour at an aging temperature of greater than about 150° F. The resulting laminated and their use in clothing are also provided.