HK1128662B - A flocked transfer and a method producing the same, and articles of manufacture including such transfer - Google Patents

Description

Flocked transfer layer, method of making same, and articles including same

This application is a divisional application of the invention patent application having the title "flocked transfer layer and article comprising the flocked transfer layer" filed under the name of high pressure drawing company, filed on the year 7/23/2001, application No. 01814634.1.

Technical Field

The present invention relates to flocked transfer layers and, more particularly, to an improved method of making flocked transfer layers that can greatly reduce the cost and time required to produce the transfer layers.

Background

Previously, flocked transfer layers were typically made by applying a release agent (release agent) to a release sheet (release sheet). A flocked flock of the desired pattern is applied to the release sheet. The adhesive and permanent hot melt adhesive are applied to the backside of the flock and the transfer layer is dried. The adhesive is used to hold the flocked flock in the desired pattern. Hot melt adhesives applied as powders to the transfer layer are used to bond the transfer layer to a substrate (e.g., cloth, neoprene, etc.). The transfer layer may be applied to the substrate by placing the transfer layer on the substrate and contacting the dried hot melt adhesive with the substrate. Then, heat (e.g., heat generated by an iron) is applied to the release sheet. The heat melts the hot melt adhesive, causing the hot melt adhesive to flow and come into intimate contact with the substrate, forming a mechanical and molecular bond with the substrate. The release agent causes the release sheet to be removed from the transfer layer, leaving the flocked flock exposed on the substrate.

Fig. 1 shows a flocked transfer layer 101 of the prior art. As shown, the transfer layer comprises a dimensionally stable release sheet 103 to which is applied a conventional flock transfer release adhesive 105 in a pattern that is compatible with the overall pattern to be flocked. Flocked flock 107 is electrostatically applied to release adhesive 105. Adhesive 109 is applied to the exposed ends of the flock to bond the flock together as a unit. Finally, hot melt adhesive 111 is applied. The transfer layer is then dried. The transfer layer may be applied to the substrate by placing the transfer layer on the substrate (e.g., a shirt or other garment), contacting the hot melt adhesive with the substrate, and applying heat to the transfer layer. The heat activates the hot melt adhesive to bond the transfer layer to the substrate. This method is described in my prior patent, U.S. patent No. 4810549, and my pending application serial No. 09/548839, filed on 13.4.2000. Both of which are incorporated herein by reference.

This traditional approach has been used well for many years. However, the method can be improved by reducing the cost of manufacturing the transfer layer and the cost of the article comprising the transfer layer.

Disclosure of Invention

Generally, in accordance with the present invention, the flocked transfer is made by applying a release agent to a release sheet and then applying flock to the release agent. Unlike conventional methods, no adhesive or bonding agent is added to the ends of the flocked flock.

To produce an article with a flocked transfer layer, a heat-cured hot-melt film (in sheet form or cut to a prescribed shape) is placed on the substrate to which the transfer layer is to be applied. The heat-cured hot melt film is preferably a polyester or polyurethane film, but may be any heat-cured film. The flocked flock with the release adhesive and release sheet (i.e., transfer layer) is placed on the sheet of hot melt film with the release sheet on top so that the flocked flock can be contacted with the heat cured hot melt film. Heat is then applied to the transfer layer. The heat melts the heat-cured hot melt film and secures the flock to the substrate.

Drawings

Fig. 1 is a cross-sectional view of a flocked transfer layer of the prior art;

fig. 2 is a cross-sectional view of a flocked transfer layer of the present invention;

FIG. 3 is an exploded view of a transfer layer, a thermal fuse and a substrate used to make an article;

FIG. 4 is a cross-sectional view of an article utilizing the transfer layer of the present invention showing a portion of the transfer layer applied to a portion of a substrate and a portion of the transfer layer and hot melt film spaced a distance from the substrate;

FIG. 5 is a schematic diagram of a process for continuously producing an article of manufacture (e.g., a mouse pad, a coaster, etc.).

In the drawings, like parts are designated with corresponding reference numerals.

Detailed Description

The following detailed description is merely illustrative of the invention and is not to be construed as limiting the invention. The following description of the preferred embodiments of the present invention enables one skilled in the art to make and use the invention.

The flocked transfer layer 1 of the invention is shown in fig. 2. The transfer layer 1 of the present invention comprises a release sheet 3 to which a conventional release agent 5 (e.g., wax) is applied. The release agent is coated on the release sheet in the shape of a flocked pattern. Flocked flock 7 is applied to the release agent and thus also to the release sheet to form the transfer layer. Flocking flock 7 can be added as described in my prior patent, U.S. patent No. 4810549. This patent is incorporated herein by reference. Unlike prior art methods, no adhesive or hot melt adhesive is used in the manufacture of the transfer layer 1. The transfer layer is bonded to the substrate using a heat cured film, as described below.

Such as a cloth, a mouse pad, or other article having a flocked surface to which the transfer layer 1 is applied, can be easily manufactured using the transfer layer 1. Hot-melt sheet to be cured thermally13 are placed between a substrate 15 and a flocked release sheet to produce the article 11. The heat-curable hot-melt sheet is, for example, a heat-curable polyester sheet sold by Bostik corporation. The heat-cured hot melt sheet may also be made of heat-cured polyurethane. Any other thermosetting film may also be used. The substrate may be cloth, rubber mat (used to make mouse mat or cup mat), etc. The heat-cured hot-melt sheet may be cut in advance to conform to the shape of the transfer layer 1. Transfer layer 1 is then placed on the heat-cured hot-melt sheet with flocked flock 5 opposite heat-cured hot-melt sheet 13. Heat is applied to the transfer layer through the release sheet to activate the heat-cured hot melt sheet. The heat cured hot melt sheet bonds flocking 5 together and bonds flocking 5 to substrate 15. Preferably, in assembling the article, the flocked release sheet, the heat-cured hot melt film, and the substrate are brought together and passed through a hot lamination press in which the three parts are at a temperature of about 300 ° F (about 150 ℃) and about lb/in²Is laminated for about 30 seconds under pressure. Pressure and heat cause the heat-cured hot melt film to adhere to the flock and the substrate. In addition, the heat-cured hot melt film may crosslink or harden, causing the flock to be firmly secured to the substrate.

As shown in fig. 5, an article such as a mouse pad or a cup pad in which the entire top surface of the article is covered with flocked flock may be continuously manufactured. The flocked release sheet 1, the heat-cured hot melt film 13 and the rollers 21, 23 and 25 of the substrate 15 are provided. The three materials are placed together at a laminating station 33. Rollers may be provided in front of the station 33 to bring the three materials into close proximity with each other as they enter the laminating station. At the lamination station, heat and pressure are applied to the three sheets (flocked release sheet, heat cured hot melt film and backing) to melt the heat cured hot melt film. As described above, the molten heat-cured hot melt film will harden or cross-link, bonding the flock to the substrate. The web 35 is output from the lamination station. The fabric 35 is then cooled. Finally, the web 35 is fed to a cutting station where it is cut into individual articles. Once the fabric 35 has cooled, it can be immediately sent to a cutting station (after the fabric 35 has cooled); alternatively, if the web is wound on a winding roll, it can be cut into individual articles at a later time or at a different location. At the cutting station, the release sheet is removed from the flocked flock and collected on a roll-in roller or removed. After the release sheet is removed from the flocked flock, the substrate to which the flocked flock is adhered is cut to form the product 11.

Preferably, the release sheet is flocked and supplied in a roll as shown in fig. 5. However, flocking of the release sheet may be part of the method.

In order to produce flocked articles such as shirts, jackets or the like which are not easily flocked in succession, a heat-curable hot-melt sheet material may be applied to the transfer layer 1 before the transfer layer is applied to the substrate. To do this, the heat-cured hot melt film may be brought into contact with the flock of the transfer layer, and the transfer layer and release sheet heated to a temperature at which the heat-cured hot melt film becomes tacky but below the temperature at which the heat-cured hot melt film begins to harden and crosslink. The heat-cured hot melt film can be bonded to the transfer layer 1 by placing the transfer layer, placing the heat-cured hot melt film in a position on the article (i.e., a piece of cloth), and applying heat and pressure to the transfer layer, such as with an iron, sufficient to melt the heat-cured hot melt film, causing the heat-cured hot melt film to harden and crosslink, forming a transfer layer that can be subsequently applied to the article.

The method eliminates two steps of the prior art method: (1) applying an adhesive binder; and (2) applying, cleaning, sintering and drying the hot melt adhesive. Moreover, the method does not require adhesive and hot melt adhesive application stations, and drying stations for the finished transfer layer, in a continuous process. The machinery required to produce the article 11 is inexpensive (both in actual cost and in maintenance cost) because there is no need for a station for applying (i.e., printing) adhesive and hot melt adhesive to the flock as part of the transfer layer. In addition, because adhesive and hot melt adhesives are not used, the cost of the product is also greatly reduced.

As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

Claims (18)

1. A transfer layer, comprising:

a flocked transfer layer, the flocked transfer layer comprising:

a release sheet;

a release agent on the release sheet; and

flock on a release agent, the flock in a desired pattern, the release agent securing a first end of the flock to the release sheet; and

a heat-cured hot melt film engaging the flocking flock in the flocked transfer layer,

wherein the second end of the flocking flock is in direct contact with the heat-cured hot melt film without the application of adhesive binder.

2. The transfer layer of claim 1, wherein the heat cured hot melt film is a polyurethane film or a polyester film.

3. An article comprising a flocked transfer layer, the flocked transfer layer comprising: a release sheet; a release agent on the release sheet; and flock on a release agent, the flock in a desired pattern, the release agent securing a first end of the flock to the release sheet,

wherein a heat-cured hot melt film engages the flocking flock and a second end of the flocking flock is in direct contact with the heat-cured hot melt film without an adhesive applied thereto, and

wherein the flocked transfer layer is adhered to the substrate and the heat-cured hot melt film is positioned between the substrate and the flocked flock.

4. The article of claim 3, wherein the heat cured hot melt film is a polyurethane film or a polyester film.

5. The article of claim 3, wherein the heat cured hot melt film hardens and crosslinks.

6. A method of manufacturing an article having a flocked surface, the method comprising:

providing a flocked release sheet, the release sheet being bonded to a first end of the flocked flock;

providing a heat-cured hot melt film;

adhering the heat-cured hot melt film to the flocked flock, wherein the second end of the flocked flock on the flocked release sheet directly contacts the heat-cured hot melt film; and

the heat cured hot melt film is bonded to a substrate.

7. The method of claim 6, wherein the step of adhering the heat-cured hot melt film to the flocked flock comprises:

heating the heat-cured hot melt film to a temperature at which the heat-cured hot melt film becomes tacky but below a temperature at which the heat-cured hot melt film begins to harden and crosslink, with the heat-cured hot melt film in contact with the flocking flock; and

pressure is applied to the heated heat-cured hot melt film to embed the second ends of the flocking flock in the heat-cured hot melt film.

8. The method of claim 6, wherein,

the step of adhering the heat-cured hot melt film to the substrate comprises: heating the heat-cured hot melt film to a temperature at which the heat-cured hot melt film hardens and crosslinks, and

the method does not include the steps of applying an adhesive binder and drying the hot melt adhesive.

9. The method of claim 8, wherein the heat cured hot melt film is heated to about 300 ° F, wherein no station is required for applying adhesive and hot melt adhesive on the flocking flock.

10. The method of claim 6, wherein the steps of adhering the heat-cured hot melt film to the flock and adhering the heat-cured hot melt film to the backing are performed simultaneously in a single process, and wherein no adhesive bonding agent is used.

11. The method of claim 6, wherein the method is continuous.

12. The method of claim 6, wherein the heat cured hot melt film is a polyurethane film or a polyester film and the heat cured hot melt film is applied as a solid film over the second ends of the flocking flock.

13. The method of claim 7, wherein the heat cured hot melt film is activated by applying heat to the hot melt film through a release sheet.

14. The method of claim 6, wherein prior to the bonding step, a heat-cured hot melt film is pre-cut into a shape corresponding to a transfer layer to be formed by the flocked release sheet.

15. The method of claim 6, wherein after the flocking flock is adhered to the heat-cured hot melt film, the heat-cured hot melt film has flat upper and lower surfaces and a uniform thickness.

16. The method of claim 6, wherein the interface between the flock and the heat cured hot melt film is free of adhesive bonding.

17. The method of claim 6, wherein the heat cured hot melt film is applied with heat and pressure sufficient to melt the heat cured hot melt film.

18. An article made by the method of claim 6.