WO1991000177A1

WO1991000177A1 - Laminated product

Info

Publication number: WO1991000177A1
Application number: PCT/AU1990/000285
Authority: WO
Inventors: Ian Alexander Cran
Original assignee: Individual
Current assignee: Individual
Priority date: 1989-07-03
Filing date: 1990-07-03
Publication date: 1991-01-10
Anticipated expiration: 1992-01-03
Also published as: EP0480948A4; KR920703328A; JPH04506488A; EP0480948A1; CA2063267A1

Abstract

Promotional headgear (1) comprises a brim portion for seating on the head of a user, and a display portion (3) which is pushed into an upstanding position with respect to the brim portion when in use, by the user's head. The headgear (1) comprises an open cell foam material (6) having a printed film (5) adhered to a surface thereof, and can be manufactured by cutting or stamping an outline from a sheet of laminated foam material (38).

Description

LAMINATED PRODUCT The present invention relates to laminated products, particularly for use as promotional or entertainment devices, and finds particular application in low cost headgear.

It is known to produce advertising and publicity products out of card, including promotional headgear. The card is printed with relevant publicity or advertising material on a surface which will be exposed in use. An example of such products is a simple hat constructed from flat piece of card having a central aperture through which the top of a user's head projects. The hat sits on the user's head in the manner of a hat brim, without a crown. This form of headgear may also be provided with a logo carrier which projects into the central aperture when the hat is out of use but which is bent to stand upright when the hat is in use, by the user's head as it projects through the central aperture, so as to attract attention.

This type of product suffers from the disadvantage that it is relatively delicate and easily destroyed. The logo carrier does not therefore perform its function for a substantial length of time.

It has been recognised in making the present invention that by substituting a foam of polymeric type for card in the manufacture of articles of the type described, a significantly longer lasting article can be produced. However, a problem arises in that it is not a simple matter to decorate the surface of a suitable foam product with promotional material such as advertising logos, or other decoration. The type of foam product suitable for use in applications such as the manufacture of fun hats as described above relies on the use of an open celled foam. It is not possible to print directly on to an open celled foam in a manner that is sufficiently clear, detailed or long-lasting to be acceptable.

It is an object of the present invention to provide a laminated product, embodiments of which can be used as a low cost promotional or entertainment device, particularly for instance promotional or entertainment headgear, and a method for producing such a laminated product, wherein the product remains attractive and/or suitable for use over a significant period of time.

Embodiments of the present invention have the advantage that they can be manufactured in large numbers, without excessive cost, and can present a pleasing appearance while being sufficiently robust to withstand considerably rougher and/or longer lasting treatment by a user than has hitherto been possible with a comparable cost product.

According to the present invention, there is provided a laminated object, such as a promotional or entertainment device, comprising a foam product having a body of foam and a printed film which is adhered to a surface thereof.

The foam may comprise a known polymeric foam. Preferably, it comprises an open cell foam.

The printed film may comprise a plastics material such as polyethylene or polypropylene.

There are substantial difficulties involved in making a low budget, shaped and decorated item out of foam, and in particular out of open cell foam, including the fact that it tends to move during printing or cutting. However, it has now been found possible to apply a printed film to the foam, even to open cell foam, and in doing so to overcome a number of problems. Inmore detail, relevant problems andpossible solutions are as follows.

As mentioned above, foam and particularly open cell foam has a mobile structure which makes direct printing very difficult, as well as cutting out of exact predetermined shapes.

A feature of the present invention is that the use of an adhered film not only provides a carried for the printing but also stabilises the foam for cutting out.

It is not however a simple matter to adhere a suitable film to the surface of an open cell foam. Glues tend not to stick to the film, which can present a very flat surface, and ithas not therefore been found satisfactory to simply apply a glue treated film to the foam.

To improve the adherence of glue to the film, the surface of the film can bemodified, for instanceby flame or coronadischarge treatment.

Another problem lies in achieving satisfactory lamination of a film onto the surface of an open cell foam. There is a tendency for the film to wrinkle, or for the relative tensions of film and foam to vary so that the laminated product is warped.

A significant factor in achieving satisfactory lamination has been found to be the thickness of the film being adhered. This is further discussed below.

A further problem has been encountered in that printing inks used inproducing printed film were found to react with the film so asto make it brittle. This leads to the problem that with continued use, the film and/or the pattern printed thereoncan become damagedand unsightly. Further,a lot of inksand printing processes are too costly for use in a low price item, or the inks themselves are inflexibleor will not adhere to the film surface.

These problems have been overcome primarily by the useof flexographic inks, and flexographic or gravure printing, in combination with a polyethylene film which has beensurface treated for instance by a flame or corona discharge treatment, as mentioned above, to avoid ink being pulled off the film during the production process.

The open cell foam to which the printed film is laminated may comprise one of several materials including polyethylene, polyurethane, and polyester, polyethylene foams having been found preferable in terms of cost.

The production process comprises in general the surface treatment of polymeric film, particularly polyethylene film, by for instance flame or corona discharge treatment, the application of printing to the film, followed by laminating of the printed film on to a roll of open cell foam in laminating equipment, according generally to a known laminating process. In the laminating process, adhesive is applied either to the foam or to the film, any solvent-based adhesive being found suitable, and the film is then applied to the surface of the foam.

Where the printed, laminated foam is to be used to make fun hats it has been found that a thickness of about 7 mm is suitable. This produces a hat which is sufficiently stiff that a portion will stand up so as to be clearly visible when the hat is worn, while the amount of materials used is kept relatively low, thus avoiding extra cost and volume. A foam thickness in the range 5 to 10 mm is preferable, 7 mm having been found to be optimal.

As mentioned above, the thickness of the film has been found to have a significant effect on the success or otherwise of the laminating process. Although a thin film, of a thickness in the range from 25 to 45 microns has been found satisfactory, it may be found mechanically easier to deal with film a little thicker, for instance up to 100 microns, or more particularly 60 to 70 microns, in the laminating process. This makes it easier to achieve correct alignment between film and foam, and relative tension of the two.

Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 shows a plan view of a fun hat made according to an embodiment of the present invention;

Figure 2 shows a fun hat as shown in Figure 1, in use; Figure 3 shows schematically a laminating process for laminating a printed film onto a strip of open cell foam;

Figure 4 shows a cross section on the line A-A of Figure 1, viewed in the direction indicated by the arrows; and

Figure 5 shows part of a laminated sheet prior to cutting into fun hats.

Referring to Figures 1, 2 and 4, a fun hat made according to an embodiment of the present invention comprises a flat panel 1 of open celled foam 6 having a printed film 5 on its upper surface. The composite panel 1 has an aperture 2 therein with a scalloped edge. The aperture 2 has a "cut-out" 3 which extends from an edge thereof into the centre of the aperture. When the hat is placed on a user's head, the cut-out 3 is pushed upwards to stand upright in a clearly visible position.

The scalloped edge of the aperture 2 is merely to provide grip on the wearer's head, and could be replaced by a smooth-edged aperture or by some other shape such as a toothed profile.

Referring to Figure 2, it can clearly be seen that the panel 1 of foam must have a certain thickness such that the cut-out 3 will be self-supporting, in use. In embodiments shown, the open cell foam panel 1 has a thickness of 7 mm.

Referring to Figure 3, the fun hat is produced using a laminating machine. A roll 4 of open cell foam is fed to a pair 31, 32 of laminating rollers where it meets, and is laminated to, the printed film 33. The printed film 33 is supplied from a roll 30, being fed to the laminating rollers 31, 32 via a tensioning roller 34 and an adhesive applying roller 35. At the laminating rollers 31, 32, the adhesive covered surface of the printed film is applied to the open cell foam, whereafter the adhesive is cured and the laminated product 38 stamped or cut into multiple fun hats. Laminating processes of this general type are known and elements of the equipment are therefore known. For instance, the adhesive applying roller 35 is of known type, having a bath 36 applying adhesive to the surface of the roller 35 and thence to a face of the printed film 33. Conveniently, the adhesive applying roller 35 can be moved away from the printed film 33, for instance, for maintenance, loading and starting up operations.

The relative tension between the film 33 and the foam 37 is important. If it is incorrect, the film can tend to wrinkle when applied, or to warp the finished product if it is significantly tighter than the foam in the laminating process. The tension can be adjusted to correct such defects by means of the tensioning roller 34 which is adjustable in the tension it applies. Preferably a "banana" roller is used, such rollers having a slightly convex outer surface in cross section, this having the effect of spreading the film 33 outwards towards the edges of the surface of the roller 34 and therefore keeping it flat.

The application of adhesive for attaching a film to a foam product is a known technique, for instance in the manufacture of carpet underlay and any solvent based adhesive is suitable for use in embodiments of the present invention. However, the use of a printed film which can subsequently be laminated onto- an open cell foam material presents certain problems. In addition to the type of ink being used, which should not destroy the flexible and lasting properties of the film to be laminated, it is necessary to treat the film so that it accepts both the ink and the adhesive. Unless the film is treated, films such as polyethylene film tend not to accept adhesive or printing ink well, these either not adhering to the film or being too easily removed. The film is therefore subjected to a surface treatment to improve adherence, such as corona discharge treatment.

Corona discharge treatment has the effect of slightly oxidising the surface of the film, so as to increase the plurality of the surface molecules by forming for instance methyl groups. Such surface modification permits the ink or adhesive to spread more evenly on the surface during a subsequent printing or adhesive application step and also promotes the formation of strong chemical bonds. Both factors give increased adhesion. In one form of the technique, the film is passed through a high energy electrical corona discharge formed between an electrode and an earthed roller which may or may not be provided with a dielectric cover. Suitable equipment is commercially available and operates from normal mains voltage to generate sufficient power at high frequency to produce a corona discharge. The film surface is subjected to a high energy electrical and ionic bombardment, the intensity of which is usually controlled by adjustment of the electrical flux applied at the electrode. Corona discharge treatment is described and discussed in the following publications:

"Electrode Developments for Treating Advancing" by F Echkart Prinz and Karl-Heinz Meyer, published in PAPER, FILM AND FOIL CONVERTER, September 1988;

"Alkathene Polyethylene", Technical Service Note A105 2nd Edition, by the Polyolefines Group of ICI Plastics Division in a Series entitled "Printing of Polyethylene Film".

After corona discharge treatment, the polyetlylene film is printed for instance by a known technique such as flexography or gravure to produce an image of a selected decoration on one side of the film, and can then be stored in a roll. Subsequently, glue is spread on the non-printed side of the film, which is then adhered to the open cell foam in the laminating process described above.

After laminating, the composite sheet 38 produced must be cut in register with the printed fun hats 50. In order to achieve accurate cutting, sets of four fun hats 50 are printed in respective panels 52, each panel 52 being provided with a marker 51. The cutting machine (not shown) detects the marker 51 for each panel 52, each marker 51 being accurately and consistently located with respect to the printed hats 50 of that panel 52. The cutting machine is thus able to align itself in order to cut the fun hat outlines in register with the printing thereof.

Although different types of film could be used, and different thicknesses, polyethylene film at a thickness in the range 25 to 45 microns has been found suitable, giving the open cell foam sufficient strength for the decorative cut-out to stand up. However, as mentioned above, in order to make the tension adjustment between film and foam easier, film having a thickness in the range 60 to 70 microns is preferable.

By using the combination of flexographic ink and the polyethylene film, about six different colours can be printed and photographic images can be reproduced thereby. Either high or low density polyethylene films can be used but low density films are preferred. These films can be either clear and transparent, or coloured.

An advantageous alternative material for use as the printed film is polypropylene. Although more expensive than polyethylene, it tends to stretch less and is therefore more easy physically to manipulate, for instance during the laminating process.

The film used can be printed on either side with respect to the surface to be adhered to the foam. Either it can be reverse printed on the surface to be glued, or it can be positively printed on the surface which will be exposed in the finished product. If it is reverse printed, only one side of the film must be corona discharge treated since one side of the film only receives both ink and adhesive. This makes the printed but unglued film slightly easier to store on a roll since the untreated side of the film does not significantly lift the ink from the printed side. However, if positive printing is used, the number of colour print runs can be reduced for instance where a background colour is to be applied. In reverse printing, the background must be printed on but in positive printing, the film can itself be coloured .

A suitable type of ink which does not interfere significantly with the printed film, or the adhesive, and which does not tend to lift off significantly when the printed film is stored in a roll, comprises a solventresistant, wax-free laminating ink. Such an ink is obtainable under the trade mark "POLARIS" from the Company COLLIE COOK CONSOLIDATED.

Products according to embodiments of the present invention are relatively cheap to manufacture, convenient to produce in large quantities, for instance in the order of 10,000 a batch, and are long-lasting while remaining brightly coloured and therefore good promotional material.

The above-described arrangements and methods have been advanced merely by way of explanation and many modifications may be made thereto without departing from the spirit and scope of the invention which includes every novel feature and combination of novel features herein disclosed.

Claims

CLAIMS : 1. A laminated article, for use as a promotional or entertainment device, comprising a foam material product having a body of foam material (1) and a printed film (5) dhered to a surface thereof.

2. An article according to claim 1 wherein said body of foam material (1) comprises a polymeric foam material.

3. An article according to either preceding claim wherein said body of foam material (1) comprises an open cell foam material.

4. An article according to any one of the preceding claims wherein said body of foam material (1) comprises a layer of foam material (6) having a thickness in the range 5 to 10mm inclusive.

5. An article according to any one of the preceding claims wherein said printed film (5) comprises a polymeric film having a thickness in the range 25 to 100 microns inclusive.

6. An article according to claim 5 wherein said printed film (5) comprises a polymeric film having a thickness in the range 60 to 70 microns inclusive.

7. An article according to any one of the preceding claims wherein said printed film (5) comprises a polymeric film printed with a flexographic ink.

8. Headgear comprising an article according to any one of the preceding claims.

9. Headgear according to claim 8 comprising a brim portion (1) to seat around the head of a user, and a display portion (3) attached to an inner margin of said brim portion (1), which display portion (3) projects inwardly of the brim portion (1) when the headgear is not in use and projects from the brim portion (1) in an upstanding manner when the headgear is in use, being supported in said upstanding manner by the head of said user.

10. Headgear according to claim 9 wherein said brim and display portions (1,3) are integral.

11. Headgear according to either one of claims 9 or 10 wherein said brim portion (1) has a scalloped or otherwise undulating or jagged inner margin to provide some resistance to removal of the headgear from a user's head, in use.

12. A method of making a laminated article according to any one of claims 1 to 7, the method comprising the following steps:

i) surface treating a polymeric film (5) so as to increase the adherence of ink thereto;

ii) applying ink printing to the polymeric film (5); and

iii) laminating the printed film (5) onto open cell foam material (6), including applying adhesive to one o both of the printed film (5) and the open cell foam material (6).

13. A method according to claim 12 wherein said surfac treating step comprises the application of flame or coron discharge treatment to a surface of the polymeric film (5).

14. A method according to either one of claims 12 or 1 wherein said open cell foam material (6) comprises a lamina material, the method further comprising the step of cuttin the laminated article from an area of the open cell foa material (6) to which the printed film (5) has bee laminated.

15. A method according to claim 14 wherein the printed film (5) carries printed registration marks in addition to printed material for display on said laminated article, the registration marks being for use during said cutting step to align cutting equipment with the position of the laminated articles prior to cutting thereof.