Patent Description:
Decals are often applied to garments for decorative and identification purposes. For example, an athletic jersey may have a player's name and number applied to it along with a team logo. These graphics are applied by heat transfer and are composed of non-air-permeable material. As a result, the areas of the garment on which the graphics are applied have reduced breathability and may cling to the wearer's body when the garment becomes damp.

<CIT> discloses three-dimensional resilient appliqué articles which are produced by superimposing a layer of compressible resilient padding material on a support material, superimposing upon the padding material a layer of sheet material, at least one of the materials being latently adhesive, severing at least the layers along the contour line of the desired appliqué, and simultaneously pressing the layer of sheet material against the support material at the selected zones inwardly of the contour line whilst activating the latently adhesive material in said zones and thereby adhering the layer of sheet material to the support material in these zones and across the facing means. The padding material may comprise a thermoplastic foam, a natural or synthetic fibrous layer or a layer of material consisting of discrete particles which entrap air pockets so that when the sheet material comprises gas-impervious thermoplastic material the latter is distended away from the support material owing to the expansion of the gas in said pockets and the thermoplastic becoming deformable in response to application of the heat during the bonding. The sheet material and the support layer may consist of synthetic thermoplastic material, e.g. vinyl material, or one or both may consist of a textile material. The layer of sheet material may be at least in part light-transmissive either by being partially opaque and partially transparent and translucent or by providing cut-outs. The surface of the layer of padding material visible through the light-transmissive portions may be smooth, or sculptured, and it may be coloured, printed or otherwise decorated so as to complement a design provided on the remaining portions of the sheet material and/or on the light-transmissive portions. A layer of synthetic plastics foam material is superimposed upon a support and a layer of synthetic plastics material is adhered to the support across portions of the layer along zones due to the latently adhesive layer melting along the zones when subjected to pressure and heat in these zones. The layer may be metallized and an additional layer of transparent synthetic plastics material superimposed thereon. The layer may have one or both of its surfaces embossed to impart a frosted appearance. The support may be reinforced with a backing layer adhered to the support along portions corresponding to the zones. Portions of the backing layer intermediate the adhered portions may be removed. The support may also be provided with an adhesive backing in the form of an activatable or active adhesive protected by a release paper. The appliqué article may be provided with lettering, symbols, entire pictorial representations of flowers, animals, and any selected portions of such designs may be provided either raised or depressed. They may be provided in the form of "stick-on" patches for garments, adhesive signs or adhesive advertising stickers, decorative panels for furniture, wallpaper. An apparatus for making the appliqué articles comprises a work-table, a mould platen connected to a heating platen, the underface of the mould platen being provided with a projection having cutting edges in correspondence with the contour line of the appliqué to be produced, and projections having flat edge faces located within the projections and projecting from the face by a smaller distance than the cutting edges. The platen is mounted for movement towards and away from the work-table.

<CIT> discloses a system including at least one elastomeric, vulcanisable ink that defines a decorative decal image. The decal image has perimeter edges and a display area extending between the perimeter edges. The vulcanisable ink is vulcanized upon a carrier sheet. A heat-activated adhesive layer is applied to overlie the display area of the decal image, and the heat-activated adhesive layer is also partially activated upon the display area of the decal image. The decorative decal image having the partially activated adhesive layer is then thermally transferable to a vulcanized rubber product such as a side wall of an automotive tyre, after which the carrier sheet is removed.

<CIT> discloses an ornamental relief plaque incorporating appliqué material.

<CIT> discloses a fabric decoration structure that is provided with: an embossing part, which is set on the back surface of the fabric and presses a region of the fabric outward towards the front surface; and a decorative section placed on the region of the fabric that is pressed outward towards the front surface by the embossing part. The region of the fabric that is pressed outward by the embossing part has a flat surface. In the decorative section, the region in contact with the region of the fabric fits within the limits of the flat surface. The decorative section comprises a decorative layer and an adhesive layer for gluing the decorative layer to the region of the fabric that is pressed outward by the embossing part. In cross-section, the edge of the front surface of the decorative layer is formed with an angle of less than <NUM> degrees.

<CIT> discloses a method for transferring an image to a fabric which includes providing a transfer image that is affixed to a first side of a transfer sheet. The transfer image composition is expandable upon an application of heat, and the transfer sheet composition is adherable to fabric upon an application of heat. The outside surface of the fabric is positioned adjacent a compressible surface, and the transfer sheet's first side is positioned adjacent an inside surface of the fabric. A generally rigid heat-conducting platen is heated to a temperature sufficient to expand the transfer image and also to adhere the transfer sheet to the fabric's inside surface. Pressure is applied to the platen against a second side of the transfer sheet for a predetermined time, the second side being opposite the first side. The pressure, heat, and time together are sufficient to effect a raised image on the fabric's outside surface.

At a high level, aspects described herein relate to a decal kit for applying a decal to an article of clothing, the kit comprising: a first carrier sheet; a first overlay having a first surface and a second surface, wherein the first surface is temporarily bonded to the first carrier sheet and wherein the first overlay is comprised of a plurality of discontinuous portions of decal material; and a plurality of dimensional spacers bonded to the second surface of the first overlay. Another aspect of the invention provides an article of clothing having a three-dimensional decal applied thereon, the article and decal comprising: a substrate layer having a first side and a second side; a first overlay comprised of a plurality of discontinuous portions and having a first side and a second side, and wherein an adhesive is applied to at least a portion of the second side of the first overlay to form a perimeter bond with the first side of the substrate layer; and one or more offsets, wherein the offsets comprise: a plurality of dimensional spacers positioned between the second side of the first overlay and the first side of the substrate layer, wherein the dimensional spacers are aligned such that a perimeter margin of the first overlay extends beyond a perimeter of each of the dimensional spacers, wherein the perimeter margin of the first overlay is coupled with the substrate layer and is effective to maintain each of the plurality of dimensional spacers in a location relative to the substrate layer.

This and other aspects of the present invention will be discussed in further detail in the Detailed Description.

The present invention is described in detail herein with reference to the attached drawing figures, wherein:.

Athletic uniforms have long included an indication of one or more of an athlete's name, an athlete's number, and a team's logo or identification. Over time, athletic apparel has evolved to include various technologies to enable the fabric of athletic garments to be more breathable and lightweight. This has resulted in uniforms being made of fabric that wicks moisture away from the athlete, has ventilation to allow more airflow to the athlete's skin, and has fast-drying capabilities to keep the athlete cool and dry. However, the advantages of these fabrics are hampered when a traditional solid decal or embellishment for the athlete's name, number, or team logo is applied to the uniform. Placing solid numerals on a soccer jersey, for example, may result in the soccer player experiencing greater heat retention and cling at the location where the numeral sits on the jersey. This results in discomfort for the player.

Traditional decals may be made of a variety of materials, but these materials may be continuous, such that the surface of the decal is uninterrupted and solid, and have limited air-permeability. Decals or embellishments are often applied to athletic garments using a standard heat press. The decals may originally be mounted onto carrier sheets or heat transfer paper that aids in the alignment, positioning, and orientation of portions of the decal. The decal is then placed over a uniform and the heat press is used to compress the decal onto the uniform, applying heat and pressure. A decal or embellishment may include one or more features to alleviate the problems mentioned above while still being compatible with existing application mechanisms and techniques.

First, the decal or embellishment, such as a decal having the player's number, name, or team logo, may be broken up into discontinuous and discrete portions that combine to make up a greater whole graphic. The individual portions may be interrupted by gaps allowing for air flow through the uniform fabric at the gap(s) between the individual portions of decal that would otherwise exist in a continuous decal (i.e., a decal not having discontinuous portions forming a traditional whole decal portion). The gaps allowing for air flow may also enhance the vapor permeability and/or breathability of a garment having such a decal. In addition, the spacing between the portions of decal may allow for the fabric of the garment to flex more easily, making the garment more comfortable for the athlete to wear.

Second, the decal may include offsets or three-dimensional spacers so that the fabric of the jersey or uniform that contacts the athlete's skin protrudes out (e.g., protrudes towards the user's skin) at various points where the decal is applied to the jersey or uniform. These protrusions or offsets reduce the surface area of the jersey that comes in contact with the athlete's skin, reducing the perception of cling. The effect of these offsets may be most noticeable by a user when the jersey has become damp due to sweat or other moisture. In addition, the offsets provide greater airflow by breaking up the inner surface of the garment relative to a traditional decal omitting the dimensional spacers.

Disclosed herein is a decal, decal kit, and article having a decal applied thereon. The decal includes a number of dimensional spacers paired to an overlay. When applied to an article, the decal creates offsets in the article. These offsets are created on an interior surface of an article to reduce the amount of contact that the article has with a user's skin. The decal overlay may consist of discontinuous portions of overlay material such that the decal has increased flex and breathability. It is contemplated that a decal may utilize the dimensional spacers independently on a continuous decal or in combination with a decal composed of individual, discontinuous portions of decal material. Further, while aspects provide for an offset that extends in a direction toward a user's skin (e.g., inner surface extension); it is contemplated that an exterior offset (e.g., a depression or embossment) that pulls a portion of the inner surface away from the user's skin may also be implemented.

The invention provides a decal kit according to claim <NUM> of the accompanying claims.

A further aspect of the invention provides an article according to claim <NUM> of the accompanying claims.

As will be provided in greater detail hereinafter, it is contemplated that a decal providing a substrate (e.g., an article of apparel) dimensional offsets may be structured in a variety of manners. For example, it is contemplated that the decal may be comprised of a dimensional spacer positioned between the first overlay and the substrate. In alternative arrangements not embodying the invention, the dimensional spacers may be positioned on the side of the substrate layer opposite the first overlay. In another example not embodying the invention, offsets may be created by molding a substrate and/or the first overlay that is applied thereon to form a dimensional offset. In this example of molding one or more of the materials (e.g., substrate, first overlay), it is contemplated that a dimensional spacer is not included, but instead the molded material(s) form the dimensional offset. In yet another example not embodying the invention, the first overlay and the dimensional spacers may be a unitary piece of material. Any of the contemplated arrangements may be combined or used in part. For example, it is contemplated that a dimensional spacer is provided on both surfaces of a substrate and at least one of the surface also includes an overlay. Further, it is contemplated that on a common substrate one or more of the arrangements may be used to form dimensional offsets. For example, in a first portion of the substrate an integral overlay and spacer may be implemented while in a second portion of the substrate a discrete overlay and a discrete spacer combination may be implemented. The selection of various arrangements may be determined by wearability, washability, effectiveness, aesthetics, and the like as contemplated herein.

Referring now to <FIG>, an exploded, perspective view of a decal <NUM> not embodying the invention is illustrated. The decal includes a first overlay <NUM>, a plurality of dimensional spacers <NUM>, a second overlay <NUM>, and a perimeter overlay <NUM>.

The first overlay <NUM> may be made of textile, fabric, plastic, vinyl, polyurethane (PU), heat transfer film, heat transfer ink, and the like. The first overlay <NUM> may be made of heat reactive material that bonds to other materials upon activation by energy (e.g., thermal, ultrasonic, pressure). Additionally or alternatively, adhesive may be applied to one or more surfaces of the first overlay <NUM>. For example, the first overlay <NUM> may be made of PU film and PU adhesive may be applied to one or both surfaces of the PU film and/or a to-be adjoining material (e.g., substrate, spacer, additional overlay). The PU film may bond to a substrate with the PU adhesive upon activation with heat and pressure. The first overlay <NUM> may comprise a discontinuous pattern of individual overlay portions arranged to form an overall graphic. For example, in <FIG>, the first overlay <NUM> forms a circle that is made of individual diamonds spaced evenly apart. As will be provided in greater detail hereinafter, a combination of discrete overlay portions may form an overall impression of an intended graphic. For example, as will be discussed with <FIG>, a plurality of discrete overlay portions form an overall graphical appearance of the number "<NUM>. " This is in contrast to traditionally discrete overlay elements, such as a separate "<NUM>" and a separate "<NUM>" forming a traditional marking of "<NUM>. " In the example of a "<NUM>" and a "<NUM>" while there are discrete overlay elements forming an overall graphical impression of "<NUM>," the traditionally individual elements (i.e., the "<NUM>" and the "<NUM>") forming the overall graphical impression are not individually discontinuous and discrete. Instead, to have discontinuous and discrete overlay elements, the example of "<NUM>" would have the "<NUM>" formed from a plurality of discrete overall elements and the "<NUM>" also formed from discontinuous and discrete overlay elements. Further, it is contemplated that one or more connecting elements may join the discrete overlay elements to aid in alignment, positioning, and orientation to form the overall graphical impression of the discrete and substantially discontinuous overlay elements.

The density of the arrangement of individual overlay portions that combine to form a graphic may be selected based upon a readability threshold. The readability threshold may be determined based upon a readability standard so that there is a maximum space that may exist between the overlay portions such that the overall graphic maintains a given level of clarity to a viewer. For example, a readability standard may be set by an athletic organization so that a referee may easily identify a player's number based upon the decal applied to the player's jersey. In other examples, the individual overlay portions may be spaced based upon body maps which reflect how a region of the human body deforms during movement. For example, if a decal is applied on a garment at a location covering a user's joint, the decal may be broken into individual overlay portions based on how that joint moves such that movement of the user's body is not impeded. Therefore, the density, arrangement, size, and/or shape of discrete overlay portions may be changed to achieve flexibility, readability, permeability, and/or general aesthetic results.

The dimensional spacers <NUM> comprise three-dimensional pieces of material that exhibit the property of resilience where resilience may be defined as the ability of a material to return to its original size/shape after being deformed due to, for example, a compressive force or other types of forces. In examples, the dimensional spacers may comprise puff ink (e.g., a plastisol expanding material), reactive foam, foam sheet, textile, laminate, thermoplastic polyurethane, and/or <NUM>-D printed foam. Puff ink or reactive foam may be applied flat (e.g., in a non-expanded state relative to a final state of the material) and then expand upon exposure to a stimulus such as pressure, heat, chemical compositions, and the like. In alternative examples, the dimensional spacers <NUM> may be comprised of material having dynamic dimensionality. For example, a dynamic dimensional material may be a gel or foam that dimensionally changes (e.g., expand) upon absorption or contact with a liquid such as sweat. An example of such a dynamic dimensional material is a superabsorbent polymer, which may also be referred to as a slush powder. In some examples, the dynamic dimensional material may return to a dimensional state when the liquid is removed (e.g., evaporated). Thus the moisture-responsive gel or foam would create dimensional spacers <NUM> only when wet, in this example. 3D screen printing, 2D printing, or digital printing may be used to build layers of material to form the dimensional spacers <NUM> directly onto another layer of the material or another material (e.g., an overlay material). Each layer may be cured before applying additional layers. The material forming the three-dimensional pieces may be individually formed (e.g., discrete elements) or formed from a larger material (e.g., cut, stamped). Cut and placed materials may include foam sheet, textile, laminate, thermoplastic polyurethane (TPU), and the like. The dimensional spacers <NUM> may also be formed through a casting process by either casting a three-dimensional piece of material and then applying it to the overlay material or by casting the material directly onto the overlay. Exemplary materials used for this casting process may be silicone, polyurethane, and the like. Alternatively, the dimensional spacers <NUM> may be formed by pouring polyurethane into a mold, flash curing, and then transferring the material onto the overlay material or substrate material and heat curing to form a bond between the overlay material and the polyurethane. The casting process may be done in layers to build the dimensional spacers <NUM>. For example, each casting may produce a layer between <NUM> and <NUM> millimeters in height. Specifically, it is contemplated that each casting of material may generate a layer of material having a <NUM> millimeter height.

The dimensional spacers <NUM> may have a range of dimensions. The dimensions of the dimensional spacers <NUM> may be in the range of <NUM>-<NUM> millimeters high, <NUM>-<NUM> millimeters long, and <NUM>-<NUM> millimeters wide. Stated differently, the dimensional spacers are at least <NUM> millimeter in height, at least <NUM> millimeters in width, and at least <NUM> millimeters in length. The dimensions of the dimensional spacers <NUM> may be in the range of <NUM>-<NUM> millimeters high, <NUM>-<NUM> millimeters long, and <NUM>-<NUM> millimeters wide. The dimensions of the dimensional spacers <NUM> may be <NUM> millimeters high, <NUM> millimeters long, and <NUM> millimeters wide. The height may be the offset from the overlay surface and the length and width are measured in a plane defined by the overlay.

One discrete dimensional spacer 104A of the dimensional spacers <NUM> may be paired with each portion of the first overlay <NUM>. Stated differently, it is contemplated that a single discrete dimensional spacer 104A may be paired with a single first overlay <NUM>. Alternatively, some portions of the first overlay <NUM> (e.g., a discrete first overlay <NUM> portion) may not include any dimensional spacers <NUM> or may include multiple dimensional spacers <NUM>. Alternatively, each portion of the first overlay <NUM> may include multiple dimensional spacers <NUM> of different sizes and shapes.

Additional overlays, such as the second overlay <NUM> and the perimeter overlay <NUM>, may also be incorporated into the decal to provide variable properties. For example, the second overlay <NUM> may provide alternative abrasion properties from the first overlay <NUM>. Alternatively, the second overlay <NUM> and first overlay <NUM> may vary in level of tackiness or grip to increase or decrease a coefficient of friction. For example, decals may be placed on portions of a garment which have an overlay having a lower coefficient of friction in order to reduce friction during player-on-player interactions. The second overlay <NUM> may also provide different structural effects to a decal such as stiffness. The layering of the second overlay <NUM> over the first overlay <NUM> may provide visual effects to a garment. For example, the second overlay <NUM> may be of a different color than the first overlay <NUM>. The second overlay <NUM> may include perforations or apertures created by laser cutting, such that portions of the first overlay <NUM> are visible through the second overlay <NUM>. Additionally, as will be discussed hereinafter, the perimeter overlay <NUM> may be effective to securely bond a perimeter of the decal <NUM> to an underlying substrate, such as an article of clothing to resist peeling by providing a more robust transition or a continuous edge for the transition.

<FIG> is merely exemplary in nature and intended to illustrate a contemplated construction of a decal having one or more overlays and one or more dimensional spacers. Alternative configurations are provided herein to illustrate a broader scope of contemplated implementations.

<FIG> shows an exploded, perspective view of the exemplary decal of <FIG> as part of a decal kit <NUM>, embodying the invention. Here, the first overlay <NUM> and plurality of dimensional spacers <NUM> are temporarily bonded to a first carrier sheet <NUM>. The second overlay <NUM> is temporarily bonded to a second carrier sheet <NUM>, and the perimeter overlay <NUM> is temporarily bonded to a third carrier sheet <NUM>. These temporary bonds may be created in various ways such as a static adhesion (e.g., an imbalance of electrical charge between materials), screen printing overlay material directly onto the carrier sheets, or use of reversible adhesives such as pressure-sensitive adhesives. For example, the overlay material may be printed onto a carrier sheet one (or more) layer(s) at a time and a layer of heat-activated adhesive may also be printed, such as a final layer. Alternative temporary bonding techniques and mechanisms may be implemented.

The first carrier sheet <NUM>, second carrier sheet <NUM>, and third carrier sheet <NUM> may be made of heat transfer paper, plastic sheets, or other material suitable for temporarily maintaining one or more elements (e.g., overlay material, dimensional spacers) in a desired orientation, position, and spacing for eventual application to an article. The temporary bond may be made with an adhesive that degrades under heat. Alternatively, the adhesive may be a weak adhesive, a removable adhesive, a pressure sensitive adhesive, and the like. For example, it is contemplated that the bond between a carrier sheet and an element maintained thereon has a bonding strength that is less than a bond formed between the element temporarily maintained thereon and an article to which the element is applied. Therefore, the element separates from the carrier material instead of the article onto which the element is applied.

Alternatively, multiple overlay material may be layered and included on a single carrier sheet so that a decal may be applied to a substrate in a single step. In the example provided in <FIG>, the perimeter overlay <NUM>, second overlay <NUM>, and first overlay <NUM> are all aligned and stacked on top of each other on a single carrier sheet, such as the carrier sheet <NUM>.

The optional second overlay <NUM> may be made of the same material as the first overlay <NUM> or a different material. The second overlay <NUM> is configured to overlap at least a portion of the first overlay <NUM>, in the depicted arrangement. The second overlay <NUM> may be bonded to the first overlay <NUM> with an adhesive. For example, in <FIG>, the second overlay <NUM> includes a plurality of triangles and the first overlay <NUM> includes a plurality of diamonds. When the layers are overlapped, the triangles cover a portion of the diamonds, as shown in <FIG>. However, it is also contemplated that a first overlay and a second overlay do not overlap, but instead form different portions of an overall decal. For example, the first overlay in this non-overlapping example may have the dimensional spacers associated therewith while a second overlay is affixed to the underlying article without associated dimensional spacers. The second overlay <NUM> may include multiple layers of material built upon each other.

The optional perimeter overlay <NUM> may be made of the same material as the first overlay <NUM> and/or second overlay <NUM>, or a different material. The perimeter overlay <NUM> is configured to overlap the edges of the first overlay <NUM> and second overlay <NUM>, to secure the overlays to a substrate. The perimeter overlay <NUM> may have adhesive applied to a surface to bond the perimeter overlay <NUM> to one or more of the first overlay <NUM>, second overlay <NUM>, and substrate <NUM>. However, it is also contemplated that the perimeter overlay <NUM> does not overlap both the first overlay <NUM> and the second overlay <NUM>. Instead, the perimeter overlay <NUM> may overlap only a select additional overlay or not overlap any overlays.

In some examples, a kit could include a jig to aid in registering multiple layers of overlay. In examples where offsets are formed by molding, as are discussed below with reference to <FIG>, the jig may also be used to register molds included in the kit.

An article <NUM> having a decal applied thereon is depicted in <FIG>. In this example, the decal <NUM> of <FIG> is applied to a substrate layer <NUM>. The substrate layer <NUM> may be an article, such as an article of clothing (e.g., shirt, shorts, pants, jacket, jersey, singlet, socks, shoes, hat, gloves, and the like). The substrate layer <NUM> comprises a fabric formed from organic and/or synthetic materials. The substrate layer <NUM> may have a greater elasticity than the material the decal <NUM> is comprised of. For example, the substrate layer <NUM> may be knit, woven, extruded, layered, mesh, and/or sheet-like, and the like. The substrate layer <NUM> may be made of nylon, cotton, polyester, or any other material suitable for affixing a decal thereon. The substrate layer <NUM> may be breathable and permeable to moisture vapor. The substrate layer <NUM> may also have wicking properties and may be constructed of a multi-density differential fabric that supports a wicking-like response to moisture.

<FIG> is a top plan view <NUM> of the article <NUM> of <FIG>. The layers shown in <FIG> and <FIG> are shown assembled into one decal. The different layers of overlay may be utilized to create different visual effects. For example, in <FIG> the first overlay <NUM> and second overlay <NUM> combine to form diamonds that are a first appearance (e.g., color, texture, contrast, luminance) on one half and a second appearance on the second half. In addition to differences in color providing alternative appearances, the material of the overlays may provide structural or textural qualities. Each overlay may differ in reflectiveness, fluorescence, texture, thickness, air permeability, resistance to abrasion, and the like. Additionally or alternatively, the multiple layers of overlay may be combined to provide reinforcement, stiffness, or raised textures.

Turning to <FIG>, a perspective view of an article <NUM> is shown. This view shows the underside (e.g., a skin-facing side of an article) of the substrate layer <NUM>. Raised offsets <NUM> are shown extending outward from the surface of the substrate layer <NUM>. Here, the offsets <NUM> are shaped like diamonds. Other shapes and spacing of offsets <NUM> are possible. For example, the offsets <NUM> may be shaped as hemispheres, squares, triangles, ovals, rectangles, pyramids, stars, and the like. The offsets <NUM> may be grouped together, linearly arranged, staggered, randomly oriented, and/or continuously linked. The placement of the offsets <NUM> may be determined by a body heat map to achieve a determined concentration and placement of offsets relative to a human body to reduce cling of an article, air circulation, and/or moisture movement. The offsets <NUM> may be placed on an article in places where the article commonly clings to the body of a wearer, where body heat is greatest, and/or areas of perspiration, for example.

The offsets <NUM> may serve to raise the article off of the skin of a wearer. For example, the article <NUM> may be an athletic jersey with a decal is applied to the exterior surface. Offsets <NUM> are created on an interior surface of the jersey to raise the jerseys off of the skin of the jersey's wearer. This serves to create more air flow around the decal and to reduce the perception of cling at the location of the decal. As a result, the wearer of the jersey is more comfortable, even when the jersey becomes wet with sweat or other liquid. The offsets <NUM> combined with a decal having discontinuous overlay portions may also serve to reduce the weight of a garment worn during physical activity by decreasing sweat absorption into the garment and by increasing the rate of evaporation of sweat off of the wearer. Additionally or alternatively, the offsets <NUM> may be provided on an exterior surface of a garment to provide texture effects or to modify aerodynamic properties of a garment (i.e. increasing or decreasing drag).

<FIG> is a cross-sectional view of an exemplary article <NUM> having a decal applied thereon. The article <NUM> includes a substrate layer <NUM> having a first side <NUM> and a second side <NUM>. The substrate layer <NUM> has a first elastic modulus. The substrate layer <NUM> is located adjacent a first overlay <NUM> having a first side <NUM> and a second side <NUM>. The first overlay has a second elastic modulus which is higher than the first elastic modulus of the substrate (e.g., the substrate layer <NUM> is more elastic than the first overlay <NUM>). The first overlay <NUM> has a first thickness from <NUM> to <NUM> millimeter. Specifically, it is contemplated that the first thickness may be <NUM> millimeters. The first overlay may be comprised of a plurality of discontinuous portions. The discontinuous portions may be arranged into one of a number, a letter, and/or a logo.

As depicted in <FIG>, two (i.e., a pair of) dimensional spacers <NUM> are shown located between the first side <NUM> of the substrate layer <NUM> and the second side <NUM> of the first overlay <NUM>. The dimensional spacers <NUM> have a first surface <NUM> and a second surface <NUM>. The dimensional spacers <NUM> have a second thickness, which is greater than the first thickness of the first overlay <NUM>. The dimensional spacers <NUM> are at least <NUM> millimeters; however, it is contemplated that the dimensional spacers are <NUM> millimeter to <NUM> millimeters in thickness. A thickness greater or smaller is also contemplated. The dimensional spacers <NUM> are aligned such that a perimeter margin <NUM> of the first overlay <NUM> extends beyond a perimeter of each of the dimensional spacers <NUM>. The perimeter margin <NUM> of the first overlay <NUM> is coupled with the substrate layer <NUM> and is effective to maintain each of the dimensional spacers <NUM> in a location relative to the substrate layer <NUM>. Because the substrate layer <NUM> has a lower elastic modulus than the first overlay <NUM>, in this example, the dimensional spacers <NUM> protrude outward through the substrate layer <NUM> creating a greater offset on the second side <NUM> of the substrate layer <NUM> than on the first side <NUM>. As mentioned above, the dimensional spacers <NUM> may be made of material having dynamic dimensionality. The dynamic dimensionality may be caused by a number of stimuli such as heat, light, moisture, and the like. For example, sweat or other liquid may transfer through the substrate layer <NUM> and transfer the liquid to the second surface <NUM> of the dimensional spacer <NUM> from the first side <NUM> of the substrate layer <NUM>. Alternatively, precipitation or other liquid may transfer through the first overlay <NUM> and be transferred from the second side <NUM> of the first overlay <NUM> to the first surface <NUM> of the dimensional spacer <NUM>. Upon contact with the liquid, the dimensional spacer <NUM> may expand. However, it is contemplated that alternative relative modulus of elasticity, forming techniques, molding techniques, bonding techniques and the like may be implemented to affect the direction and degree of protrusion from the dimensional spacers.

The first surface <NUM> of the dimensional spacers <NUM> is bonded to the second side <NUM> of the first overlay <NUM>. This may be accomplished by applying adhesive to one or more of the first surface <NUM> of the dimensional spacers <NUM> and the second side <NUM> of the first overlay <NUM>. The adhesive may be activated by time, light, chemicals, heat, and/or pressure. In alternative examples not embodying the invention, the second surface <NUM> of the dimensional spacers <NUM> may be bonded to the first side <NUM> of the substrate layer <NUM>. Adhesive may be applied to either the second surface <NUM> of the dimensional spacer <NUM> or the first side <NUM> of the substrate layer <NUM> or both. In yet another example, the first surface <NUM> of the dimensional spacers <NUM> is bonded to the second side <NUM> of the first overlay <NUM> and the second surface <NUM> of the dimensional spacers <NUM> is bonded to the first side <NUM> of the substrate layer <NUM>, so that the dimensional spacers <NUM> are bonded to both the substrate layer <NUM> and the first overlay <NUM> to secure the position of the dimensional spacers <NUM>. Alternatively, the dimensional spacers <NUM> may not be bonded on either surface. The bonding of various surfaces may be achieved by an adhesive or a bond formed between two materials (e.g., chemical and/or mechanical without a separate adhesive).

An optional second overlay <NUM> having a first side <NUM> and a second side <NUM> is located proximate the first overlay <NUM>. The second overlay <NUM> is configured to overlap at least a portion of the first overlay <NUM>. The second side <NUM> of the second overlay <NUM> is bonded to the first side <NUM> of the first overlay <NUM> at the portions where the second overlay <NUM> overlaps the first overlay <NUM>. Adhesive may be applied to one or more of the second side <NUM> of the second overlay <NUM> and the first side <NUM> of the first overlay <NUM> to create the bond. The bonding in this example may be achieved by application of thermal energy and pressure. However, as provided herein, the bonding may be accomplished by a variety of techniques.

An optional perimeter layer <NUM> (also referred to as a perimeter overlay herein) is located proximate an outer edge of the second overlay <NUM>. The perimeter layer <NUM> includes a first side <NUM> and a second side <NUM>. The second side <NUM> of the perimeter layer <NUM> is partially bonded to the first side <NUM> of the second overlay <NUM> and is partially bonded to the first side <NUM> of the substrate layer <NUM>. This may be accomplished by applying an adhesive to the second side <NUM> of the perimeter layer. Alternatively, adhesive may be applied to the first side <NUM> of the second overlay <NUM> and the first side <NUM> of the substrate layer <NUM>. The perimeter layer <NUM> functions to secure the edges of the first overlay <NUM> and second overlay <NUM> to the substrate layer <NUM> and create a smooth border.

<FIG> depicts an alternative article <NUM>, not embodying the invention. Here, the dimensional spacers <NUM> are located proximate to the second side <NUM> of the substrate layer <NUM>. The first surface <NUM> of the dimensional spacers <NUM> is bonded to the second side <NUM> of the substrate layer <NUM>. In this configuration, the dimensional spacers <NUM> would contact a user's skin when the article <NUM> is worn. The dimensional spacers <NUM> function to create offsets on the second side <NUM> of the substrate layer <NUM>, which is closest to a wearer's skin when the article <NUM> is worn. The dimensional spacers <NUM> reduce the amount of contact that occurs between the article <NUM> and the wearer's skin, reducing the perception of cling.

<FIG> depicts yet another example of an article <NUM>, not embodying the invention. Here, the article does not include dimensional spacers <NUM>. Instead, offsets <NUM> are created by molding the substrate layer <NUM> after the first overlay <NUM>, second overlay <NUM>, and perimeter layer <NUM> have been applied. For example, the first overlay <NUM>, second overlay <NUM>, and perimeter layer <NUM> may be made of a heat reactive material. The first overlay <NUM>, second overlay <NUM>, and perimeter layer <NUM> are applied to the substrate layer <NUM> with a heat press. Then the article <NUM> having a decal applied thereon is placed in a heat mold to deform the substrate layer <NUM>, first overlay <NUM>, second overlay <NUM>, and perimeter overlay <NUM> into a shape such that offsets <NUM> are created. An exemplary mold may have a top portion with protrusions and a bottom portion with corresponding indentations that mate with the protrusions (e.g., a tongue and groove mechanical engagement). An exemplary decal kit may include a disposable or reusable mold for use with a heat press to deboss and/or emboss an article in addition to applying a decal. These offsets <NUM> function the same as if dimensional spacers were placed in the article. The offsets <NUM> reduce the amount of contact that the article <NUM> has with a wearer's skin and allow for increased air flow where the decal is applied.

<FIG> depicts a cross-section view of a decal not embodying the invention applied to an article. Instead of having a separate first overlay <NUM> and dimensional spacer <NUM> as in <FIG>, a unitary structure <NUM> creates both the overlay and the spacer. The unitary structure <NUM> may be formed by an additive process, such as three-dimensional printing and may be made of, for example, silicone printed in layers. Additional layers are built to form protrusions that form offsets when applied to a substrate layer <NUM>. Alternatively, the unitary structure <NUM> may be molded from a single type of material. The unitary structure <NUM> may also be co-molded from different materials that are integrally formed into one piece. It is also contemplated that the unitary structure <NUM> may be formed from a reductive technique, such as milling. The portions of the unitary structure <NUM> that correspond with the first overlay <NUM> of <FIG> are bonded to the substrate layer <NUM>. In addition, the portions of the unitary structure <NUM> that correspond with the dimensional spacers <NUM> may also be bonded to the substrate layer <NUM>.

<FIG> shows a side cutaway view of an exemplary decal kit <NUM>, embodying the invention. A first carrier material <NUM> has a first surface <NUM> and a second surface <NUM>. The second surface <NUM> of the first carrier material <NUM> is temporarily bonded to a first surface <NUM> of a first overlay <NUM>. The temporary bond is made with a first adhesive or other interaction between the materials effective to maintain the materials, temporarily, in a set relative position. For example, a first adhesive may be applied to the second surface <NUM> of the first carrier material <NUM>. Alternatively, the first adhesive may be applied to the first surface <NUM> of the first overlay <NUM>. Dimensional spacers <NUM> are bonded to a second surface <NUM> of the first overlay <NUM>. The bond between the dimensional spacers <NUM> and the first overlay <NUM> is made with a second adhesive and is permanent, in this example. However, it is contemplated that the bond between the dimensional spacers <NUM> and the first overlay <NUM> may be temporary or temporary until later converted to a permanent bond by way of an activator (e.g., thermal energy, light, pressure, and/or chemical interaction). The first overlay <NUM> may be made of heat activated material that bonds to an article (e.g., fabric forming an article of clothing) when heat and pressure are applied. The first overlay <NUM> may be made of PU film and PU adhesive may be applied to the first surface <NUM> of the first overlay <NUM>. Upon activation, such as with heat, the first surface <NUM> of the first overlay <NUM> is bonded to an article to which it is applied. For example, the first carrier material <NUM> can be placed over an article to which a decal is to be applied. The dimensional spacers <NUM> are positioned proximate the outer surface of the article. Heat and pressure are applied to the first carrier material <NUM> with a heat press. The heat press activates the first overlay <NUM> and a perimeter margin of the first overlay <NUM> bonds to the article, forming a permanent bond. The permanent bond formed between the first overlay <NUM> and the article is stronger than the temporary bond holding the first surface <NUM> of the first overlay <NUM> to the first carrier material <NUM>, in this example. Therefore, once the decal is bonded to the article, the first carrier material <NUM> can be removed.

A second carrier material <NUM> has a first surface <NUM> and a second surface <NUM>. The second surface <NUM> of the second carrier material <NUM> is temporarily bonded to a first surface <NUM> of a second overlay <NUM>. The second surface <NUM> of the second overlay <NUM> is located proximate the first surface <NUM> of the first carrier material <NUM>. The second surface <NUM> of the second overlay <NUM> may be configured to extend over at least a portion of the first surface <NUM> of the first overlay <NUM>.

Similar to the first carrier material <NUM> and first overlay <NUM>, the temporary bond may be made with an adhesive that is less strong than the bond made between the second overlay <NUM> and the first overlay <NUM>. This allows the second overlay <NUM> to be applied to an article already having a first overlay <NUM> applied, activating an adhesive of the second overlay <NUM> with heat, and then removing the second carrier material <NUM>.

The decal kit <NUM> may be designed to be compatible with existing heat press machines in use with traditional decals not having dimensional spacers. Alternatively, modifications to existing equipment may be required. First, the first carrier material <NUM> is applied to a substrate with the dimensional spacers <NUM> facing the substrate. Heat and pressure are applied to bond the first overlay <NUM> and dimensional spacers <NUM> to the substrate. Then, the second carrier material <NUM> is applied over the first overlay <NUM> and substrate so that the second overlay <NUM> contacts the first overlay <NUM>. Heat and pressure are applied to bond the second overlay <NUM> to the first overlay <NUM>. Alternatively, the first overlay <NUM>, dimensional spacers <NUM>, and second overlay <NUM> may all be temporarily bonded onto a single carrier sheet. Such a carrier sheet would allow for application of the decal to an article in a single step. While a heat press is described, it is contemplated that alternative mechanisms may be implemented to achieve a securing of one or more materials to one or more additional materials. For example, decal materials may be applied with physical pressure, application of steam, passing the materials through a curing oven, and the like.

<FIG> illustrate various illustrative, but non-limiting, embodiments of portions of overlay material covering dimensional spacers. <FIG> shows a top plan view <NUM> of a square overlay portion <NUM>. This square overlay portion <NUM> is placed over a square dimensional spacer <NUM>, indicated by long dashed lines. The square overlay portion <NUM> has a perimeter margin which extends beyond a perimeter of the dimensional spacer <NUM>. The perimeter margin is large enough to allow the overlay portion to securely bond to a substrate layer. In examples, the perimeter margin extends beyond the perimeter of the dimensional spacer <NUM> at least <NUM> millimeter, or at least <NUM> millimeters. In alternative examples, the overlay portion is at least equal to the thickness of the dimensional spacer.

The example of <FIG> illustrates an overlay portion <NUM> being paired with a dimensional spacer <NUM> of a corresponding shape. The short dashed lines indicate a perimeter bond <NUM> that is formed when the square overlay portion <NUM> is bonded to a substrate layer (not shown). The perimeter bond <NUM> may be a continuous bond completely encapsulating the dimensional spacer <NUM>. Alternatively, the perimeter bond <NUM> may discontinuous such that the dimensional spacer <NUM> is not completely encapsulated between the substrate layer and the overlay portion <NUM>, but there are sufficient contacts between the substrate layer and the overlay portion <NUM> to retain the dimensional spacer <NUM> at a particular location on an article. For example, the perimeter bond <NUM> could consist of separate bonds made at each of the four corners of the perimeter. In another example, the perimeter bond <NUM> could consist of separate bonds made in the center of each of the four sides of the square perimeter.

<FIG> illustrates an example of a circle overlay portion <NUM>. The circle overlay portion <NUM> covers a round dimensional spacer <NUM>, creating a perimeter bond <NUM>. The perimeter bond <NUM> may be a continuous bond completely encapsulating the round dimensional spacer <NUM> or the perimeter bond <NUM> may consist of multiple individual bonds located around the circular perimeter of the circle overlay portion <NUM>.

<FIG> illustrates a triangle overlay portion <NUM> securing a round dimensional spacer <NUM> at a perimeter bond <NUM>. This example illustrates the triangle overlay portion <NUM> being paired with a round dimensional spacer <NUM> having a non-corresponding shape.

As can be seen from the examples of overlay portions and dimensional spacers depicted in <FIG>, the overlay portions which make up the overlay of a decal may be of various shapes. The shape of the dimensional spacers may correspond with the shape of the overlay portion or the dimensional spacers may be of a different shape than the overlay portion. A perimeter margin <NUM> of each overlay portion may extend beyond each dimensional spacer so that the overlay portion can be bonded to a substrate at a perimeter bond. The perimeter margin <NUM> extends at least <NUM> millimeter beyond the dimensional spacer in all directions in some examples. Alternatively, the perimeter margin <NUM> extends at least <NUM> millimeter beyond the dimensional spacer in at least one direction. The perimeter margin <NUM> may extend <NUM> millimeter to <NUM> millimeters beyond the dimensional spacer. In other examples the perimeter margin <NUM> may extend less than <NUM> millimeter or more than <NUM> millimeters beyond the dimensional spacer. This extension of the margin may ensure that the overlay portion is securely bonded to the substrate and that the dimensional spacers are secured in a fixed location.

Turning to <FIG>, an alternative example of circular overlay portions <NUM> is shown in an exploded view <NUM>. Each circular overlay portion <NUM> is configured to pair with each spherical dimensional spacer <NUM>. The spherical dimensional spacer <NUM> may be comprised of <NUM>-D printed foam, puff ink, reactive foam, or other suitable dimensional material. The puff ink or reactive foam may be activated by heat, microwave radiation, ultraviolet radiation, infrared light, radio waves, steam, and the like. The puff ink or reactive foam may have dynamic dimensionality such that the ink or foam expands upon contact with liquid and/or dimensionally retracts when dry. The spherical dimensional spacer <NUM> may be formed separate from the circular overlay portion <NUM> or may be applied directly to the circular overlay portion <NUM>, for example, by digital printing. The spherical dimensional spacer <NUM> may be effective to provide a variable compression resistance while minimizing a contact area of the offset on the formed article. This may be effective to maintain a minimal contact area that adjusts based on a level of compression applied to the article about a user's body. Other shapes may be implemented to achieve a similar result, such as a conical structure, a pyramid structure, or other graduated volume shape.

<FIG> shows a top plan view of the circular overlay portions <NUM> and spherical dimensional spacers <NUM> of <FIG> applied to a substrate layer <NUM> to form an article <NUM>. A cutline 6C is depicted to illustrate a cross section of <FIG> hereinafter. Each circular overlay portion <NUM> is bonded to the substrate layer <NUM>, creating a perimeter bond around each spherical dimensional spacer <NUM>.

<FIG> shows a cross sectional view <NUM> of the article <NUM> of <FIG>. <FIG> shows a cross sectional view <NUM> of the article <NUM> of <FIG> shown in relation to a user's skin <NUM>. The substrate layer <NUM> rests adjacent to the user's skin <NUM>. The spherical dimensional spacers <NUM> are positioned between the substrate layer <NUM> and the circular overlay portions <NUM>. Therefore, the circular overlay portions <NUM> are positioned on the exterior side of the substrate layer <NUM>, facing away from the user's skin <NUM>, in this depicted example.

A bottom perspective view <NUM> of the article <NUM> of <FIG> is shown in <FIG>. This is a view of the surface of the substrate layer <NUM> which would contact a user's skin. The dimensional spacers (not visible) displace the substrate layer <NUM> at positions where overlay portions are bonded to the substrate layer <NUM>. This creates offsets <NUM>, reducing the amount of contact that is made between the article and the user's skin <NUM>. Alternatively, as mentioned above, the dimensional spacers may be positioned on an interior surface of a garment such that the substrate layer <NUM> protrudes out and away from a user's skin creating offsets <NUM> on the exterior of a garment.

<FIG> illustrate various embodiments of overlay portions paired with dimensional spacers. As with <FIG>, these examples illustrate that the overlay portions and dimensional spacers may be of any shape, size, and relative orientation. The overlay portion and the dimensional spacer may be of corresponding or non-corresponding shapes. As long as the overlay portion extends at least <NUM> millimeter, for example, beyond the dimensional spacer, the overlay portion may be bonded to a substrate, securing the dimensional spacer to a location on the substrate. A perimeter margin of a minimum width may ensure that an overlay portion will remain bonded to a substrate through wear and tear from normal use and repeated washing. As previously provided, alternative minimum overlay distances are contemplated, such as a distance equal to a thickness of the dimensional spacer, for example.

A top plan view <NUM> of a circular overlay portion <NUM> is illustrated in <FIG>. This circular overlay portion <NUM> is paired with a cylindrical dimensional spacer <NUM>, indicated by a dotted line. <FIG> illustrates the circular overlay portion <NUM> paired with the cylindrical dimensional spacer <NUM> in a perspective view <NUM>. <FIG> is an exploded view of the circular overlay portion <NUM> and the cylindrical dimensional spacer <NUM>. This is an example of an overlay portion corresponding in shape to a dimensional spacer.

<FIG> illustrate a square overlay portion <NUM> paired with a rectangular cuboid dimensional spacer <NUM>. The overlay portion <NUM> and rectangular cuboid dimensional spacer <NUM> are shown in a top plan view <NUM> in <FIG> depicts a perspective view <NUM> of the overlay portion <NUM> and rectangular cuboid dimensional spacer <NUM>. Finally, an exploded view <NUM> is shown in <FIG>.

<FIG> depict an example of a triangular overlay portion <NUM> paired with a spherical dimensional spacer <NUM>. A top plan view <NUM> of the triangular overlay portion <NUM> and spherical dimensional spacer <NUM> (indicated by dotted line) are shown in <FIG> shows a perspective view <NUM> and <FIG> shows an exploded view <NUM> of the triangular overlay portion <NUM> and spherical dimensional spacer <NUM>. This is an example of an overlay portion which does not correspond in shape to a dimensional spacer.

<FIG> illustrate an oval overlay portion <NUM> paired with an elliptic cylinder dimensional spacer <NUM>. A top plan view <NUM> is shown in <FIG>, a perspective view <NUM> is shown in <FIG>, and an exploded view <NUM> is shown in <FIG>.

<FIG> illustrate a star-shaped overlay portion <NUM> paired with a rectangular cuboid dimensional spacer <NUM>. A top plan view <NUM> is shown in <FIG>, a perspective view <NUM> is shown in <FIG>, and an exploded view <NUM> is shown in <FIG>.

Referring now to <FIG>, another example of a decal <NUM> is shown in a top plan view. An overlay is comprised of multiple square overlay portions <NUM>. These overlay portions <NUM> are spaced evenly to form an overall circle shape. The discontinuous arrangement of the overlay portions <NUM> allows for an underlying substrate to flex more easily and allows for greater airflow through the substrate. The spacing of the overlay portions <NUM> may be adjusted for aesthetic or functional purposes. For example, the overlay portions <NUM> may be arranged to create a visual pattern. Alternatively, the overlay portions <NUM> may be arranged so that the spaces between the portions align with areas on a garment that typically flex as a wearer moves. The overlay portions <NUM> may be arranged according to body maps (e.g. heat maps, temperature maps, sweat maps, deformation maps) or based upon readability.

Square dimensional spacers <NUM>, indicated by dotted lines, are positioned under the square overlay portions <NUM>. The dimensional spacers <NUM> may be positioned under every overlay portion <NUM> or may be positioned under only a subset of the overlay portions <NUM>. The subset of overlay portions <NUM> may be selected based on forming a visual pattern or by functional concerns based on locations of a garment which experience more cling on a wearer's body.

The overlay portions <NUM> are bounded by an optional perimeter layer <NUM>. The perimeter layer <NUM> may be made of the same material as the overlay portions <NUM> or different material. The perimeter layer <NUM> functions to secure the edges of the overlay portions <NUM> at a border to an article. The perimeter layer <NUM> may help to smooth the texture of the decal around its border and may prevent edges of the overlay portions <NUM> at the border of the decal from peeling from an article.

<FIG> illustrates another example of a decal applied to an article <NUM> in a top plan view. Multiple discrete triangular overlay portions <NUM> are arranged together in one cohesive overlay applied to a substrate layer <NUM>. The larger triangular overlay portions <NUM> are paired with smaller, similarly shaped dimensional offsets <NUM>, indicated by dotted lines. As mentioned before, a perimeter margin of at least <NUM> millimeter of the triangular overlay portions <NUM> extends beyond each of the dimensional offsets <NUM>. Here, some of the triangular overlay portions <NUM> are too small to allow a perimeter margin of a determined minimum. Therefore, these triangular overlay portions <NUM> are not paired with the dimensional offsets <NUM>.

There may be a perimeter margin of greater than <NUM> millimeter. For example, a dimensional offset may be significantly smaller than an overlay portion that it is paired with such that there is over <NUM> millimeters of overlay material extending beyond the dimensional offset. This will result in greater contact area between the overlay portion and an underlying article to which the decal is applied. In another embodiment, one overlay portion may be paired with multiple dimensional spacers. For instance, one large overlay portion may be paired with five small circular dimensional spacers. The circular dimensional spacers may be spaced so that one spacer is positioned in the center of the overlay portion and each of the remaining four spacers are positioned in each of the four corners of the square overlay portion so that at least <NUM> millimeter of an overlay margin extends beyond the spacers.

<FIG> illustrates a plan view <NUM> of a pair of athletic shorts <NUM> with a decal <NUM> applied thereon. The decal <NUM> is a logo featuring discontinuous portions of overlay in the shape of circles which are bordered by a perimeter overlay shaped like a star within a circle. Dimensional spacers (not visible) provide offsets that reduce cling of the shorts to a wearer's thigh.

Claim 1:
A decal kit (<NUM>, <NUM>), for applying a decal (<NUM>, <NUM>, <NUM>) to an article of clothing (<NUM>, <NUM>), the kit (<NUM>, <NUM>) comprising: a first carrier sheet (<NUM>, <NUM>); a first overlay (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) having a first surface (<NUM>) and a second surface (<NUM>), wherein the first surface (<NUM>) is temporarily bonded to the first carrier sheet (<NUM>, <NUM>) and wherein the first overlay (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) is comprised of a plurality of discontinuous portions of decal material; and a plurality of dimensional spacers (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) bonded to the second surface (<NUM>) of the first overlay (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>), wherein the dimensional spacers (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) have a greater resilience than the first overlay (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>), and each dimensional spacer (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) is aligned such that a perimeter margin of the first overlay (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) extends beyond a perimeter of each dimensional spacer (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>).