Process for high and medium energy dye printing a flocked article

Inactive Publication Date: 2005-12-08
ABRAMS LOUIS BROWN
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0011] The flock of the present invention, when combined with the various flocking techniques set forth herein, can provide a wide format design inexpensively and in high volumes, particularly using sublimation ink transfer printing. Unlike certain other polyesters, the flock of the present invention can withstand the high temperatures and pressures used during sublimation transfer printing while maintaining the loft, flexibility, resilience, and plush appearance of the fibers. Typically, the shrinkage experienced by the flock fibers during sublimation ink printing, including heat lamination or sublimation transfer printing, is no more than about 5% and even more typically is no more than about 2.5% in length. Such designs are particularly attractive when combined with highly resilient flock such as thermally modified PCT. When compared to PET flock fibers, PCT flock fibers

Problems solved by technology

The use of sublimation ink printing of flock has generally not been widely practiced because it has produced a very low quality product.
Some polyester flock fibers, such as poly(ethylene terephthalate), can hold the dye but have a low deformation temperature, little loft retention, poor shape memory and flatten out during sublimation ink printing and are not heat-settable or soft.
Other polyester flock fibers typicall

Method used

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  • Process for high and medium energy dye printing a flocked article
  • Process for high and medium energy dye printing a flocked article
  • Process for high and medium energy dye printing a flocked article

Examples

Experimental program
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first embodiment

The Process and Article of the First Embodiment

[0066] Referring to FIGS. 1 and 2, the process and article of the first embodiment of the present invention will now be described.

[0067] In the first step 100, the adhesive-coated substrate 104 is direct flocked by known techniques using the flock of the present invention. The PCT-containing flock is typically white in color or contains little pigment and can be flocked by any suitable technique, with electrostatic flocking being preferred. The adhesive may be applied discontinuously to the substrate in a desired (direct) image.

[0068] The adhesive used in adhesive layer 108 may be any suitable permanent adhesive (as opposed to a release adhesive) that is thermally compatible with the sublimation ink printing temperature used in step 112. “Thermal compatibility” depends on the process configuration. When the adhesive is cured (e.g., fully activated, set, cross-linked, fused, otherwise fully bonded) 116 before sublimation ink printing i...

second embodiment

The Process and Article of the Second Embodiment

[0076] Referring to FIGS. 3 and 4, the process and article of the second embodiment of the present invention will now be described.

[0077] In step 200, the carrier sheet 204 containing a temporary release adhesive 208 (such as wax) in the reverse of the desired pattern or image is flocked by suitable techniques, preferably electrostatically, with the flock of the present invention. The carrier locates temporarily the flock fibers and then hold flock fibers in the desired position for subsequent processing.

[0078] The carrier sheet 204 can be any suitable transfer carrier, such as dimensionally stable paper, processed paper, plastic film, resin sheets, and metal foils. Depending on the desired effect and the sheet materials employed, the carrier can be transparent, translucent, or opaque, but is typically transparent. Typically (but not always), the primary carrier is a discontinuous sheet as opposed to a continuous sheet on a running w...

third embodiment

The Process and Article of the Third Embodiment

[0090] Referring to FIGS. 7-10, a third process embodiment will now be described.

[0091] In step 700, the sublimation ink is printed onto the carrier 804 by known techniques, such as lithography, letterpress, gravure, flexography, screen printing, and jet printing. As can be seen in FIG. 8, the sublimation ink 808 is positioned on top of the release adhesive 812 and carrier sheet 816. Both the sublimation ink 808 and release adhesive 812 are printed on the carrier sheet 816 in the reverse of the desired pattern / design.

[0092] The preferred release adhesive is preferably a pressure-sensitive and soft film adhesive (such as an acrylic adhesive) and a hot melt adhesive (such as a compounded block rubber adhesive and a silicon rubber adhesive). Silicon release adhesives can withstand thermofixing temperatures if used properly. Acrylic and silicon release adhesives are applied to the carrier sheet 816 and cured before using them to hold the ...

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Abstract

The processes and articles of the present invention use thermally stable and loft retentive polymers in sublimation printed flock fibers, which are particularly attractive for forming molded and heat laminated articles. The process and articles use high, medium and low energy dyes on the fibers. A preferred polymer for use in the fibers is poly(cyclohexylene-dimethylene terephthalate).

Description

CROSS REFERENCE TO RELATED APPLICATIONS [0001] The present application claims the benefits under 35 U.S.C. Section 119(e) of U.S. Provisional Patent Application Ser. Nos. 60 / 574,784, filed May 26, 2004; 60 / 586,640, filed Jul. 9, 2004; 60 / 592,822, filed Jul. 30, 2004; and 60 / 598,969, filed Aug. 4, 2004, all entitled “Process of High and Medium Energy Dye Printing and Molding a Flocked Article” and all to Abrams, each of which is incorporated herein by this reference.FIELD OF THE INVENTION [0002] The present invention is related generally to printing of flocked articles and specifically to sublimation ink printing of flocked articles. BACKGROUND OF THE INVENTION [0003] Flock is used in the manufacture of numerous types of articles, such as textiles. Such articles are typically manufactured by electrostatically depositing the flock onto the desired surface. In one process, the desired surface is a release-adhesive coated sacrificial carrier sheet. The free ends of the flock are then co...

Claims

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Application Information

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IPC IPC(8): D06P3/00
CPCD06P5/004D06P5/2066D21H15/02D06Q1/10D06Q1/14D06P5/30
Inventor ABRAMS, LOUIS BROWN
Owner ABRAMS LOUIS BROWN
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