Manufacturing process of sublimation printing heat-sealable decal

Abstract

The invention relates to a fadeless thermosensitive decal production process, which comprises the following steps of: printing a graphic image on a polyester fiber fabric gray fabric by using a dye sublimation method, and laminating a plurality of layers of composite materials by using a calender or a hot press, the composite material is composed of two opposite outer polyurethane adhesive layers and one or more dye blocking and absorbing polymer middle layers, and the composite material is adhered to the non-printed surface of printed fabric grey cloth. The multi-zone composite includes a first layer of transparent or colored polyurethane adhesive followed by one or more colored dispersive dye hindering and absorbing polymer layers, and a third layer of transparent polyurethane adhesive. The first layer of the three-layer adhesive is fused with the polyester gray fabric under the combined action of temperature and pressure until the first layer permeates into the fabric gray fabric. The fabric grey cloth is then cut into dispersed finished decals, and when the decals are attached to the fabric substrate, the physical and visual characteristics of the fabric substrate, including the functional fabric substrate to which the decals are attached, are not significantly changed.

Description

[0001] Cross-references to related patent applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 336,642 filed on April 29, 2022, and is a continuation of U.S. Patent Application No. 17 / 487,638 filed on September 28, 2021 (which is a continuation of U.S. Patent Application No. 16 / 166,457 filed on October 22, 2018 (now U.S. Patent No. 11,130,364)). Technical Field

[0003] The present invention relates to the production of heat activated fabric transfers and appliques, and more particularly to heat transfers including numbers, letters, logos, graphics and other indicia, by inhibiting the migration of disperse dyes from the fabric transfer to the garment fabric or from the garment fabric to the transfer, thereby maintaining the integrity of the graphics. Background Art

[0004] “Performance apparel” is typically comprised of polyester fabric that has been dyed using a sublimation process. The dye sublimation process uses high heat to permanently fuse the colorant into the polyester fabric. Temperatures in the 370-420°F (188-216°C) range and a dwell time of about 1 minute are typically required to heat-set the sublimation ink into the polyester material. The heat has two key effects: first, it causes the pores of the polyester fabric to open so that the material can absorb the dye, and second, the heat converts the solid ink dye into a gas, allowing it to diffuse into the fabric fibers. Manufacturers of performance apparel, uniforms, swimwear, and athletic accessories also use a variety of methods to apply a variety of markings such as text, numbers, logos, graphics, and other markings to garments and textiles for decoration and identification. Common application techniques include silk screen printing, screen printing, and sublimation fabric heat activated transfer.

[0005] The commonly used process is silk screen printing of logos or emblems, but the products produced by this process cannot withstand repeated stretching, are complex and time-consuming. In addition, the pattern designs created by the silk screen process are relatively flat and lack texture, and cannot withstand repeated stretching or industrial or home washing. Therefore, many companies prefer to use sublimation printed fabric appliques as their primary method of applying decoration and identification. Appliques can also be applied to clothing and textiles using heat-activated adhesive coatings. One common type of applique is a layered applique, especially numbering and lettering on sports jerseys and uniforms. The layered applique includes a solid first base layer that defines the number or letter and one or more top layers of the same shape but smaller than the layer below to create a three-dimensional effect. Typically, each layer is made of dyed fabric, and each additional top layer is sewn to the next layer. The back of the solid bottom layer is a layer of heat-sensitive adhesive that covers the entire back. According to the disclosure of applicant's US Patent No. 11,130,364, the heat-activated adhesive can use a filler that can provide opacity to prevent the color of the clothing material from showing through the decoration.

[0006] A problem can occur if a decal is heat pressed onto an underlying substrate that was pre-colored using the dye sublimation method. The heat releases the dye, which migrates into the decal and fades it.

[0007] Another problem that can arise from the application of opaque adhesive to dyes is that a visible edge of opaque adhesive can be left at the edge of the decoration. This visible edge is undesirable from an aesthetic point of view and can result in an unattractive appearance to the decoration. It would be very beneficial to provide a lightweight heat seal sublimation printed applique that can be applied to any garment or textile without loss of the graphic due to dye migration from the printed applique or to the underlying material to which the printed applique is heat attached. It would also be beneficial to minimize the visible edge of adhesive, thereby improving the overall appearance of the applique while providing the appropriate opacity to prevent print-through through the garment material. Summary of the invention

[0008] It is therefore an object of the present invention to provide a heat sealable decal which can form markings, such as text, numbers, logos, graphics, etc., which will not graphically degrade under normal use conditions.

[0009] Another object of the present invention is to provide a heat seal applique that prevents print-through of the underlying garment pattern and prevents dye migration from the garment fabric to the applique.

[0010] Another object of the present invention is to prevent the migration of dyes or pigments from the graphic into the underlying substrate to avoid color loss or fading.

[0011] It is another object of the present invention to provide a heat seal applique that, during the process of being adhered to a garment, prevents a visible edge of adhesive from forming around the applique.

[0012] Another object of the present invention is to provide a heat seal applique that is similar to the traditional layered appliques commonly used for lettering and numbering on sports jerseys and uniforms.

[0013] Another object of the present invention is to provide a heat seal decal that is inexpensive to manufacture.

[0014] According to the present invention, an applique achieves the above and other objects, the applique comprising a base fabric material composed of a suitable woven, non-woven or knitted polyester fiber composition and a cut portion, one side of the base fabric having a heat activated adhesive coating, using a multi-layer composite material, the multi-layer composite material comprising two layers of clear or pigmented polyurethane adhesive sandwiching one or more pigmented polymer layers for preventing dye migration by a migration barrier layer, a dye absorbing polymer, or some combination. The polymer barrier layer can be composed of polyurethane or other suitable thermoplastics, can be polyester, polyolefin or polyaramid based materials, including absorbent materials such as activated carbon, clay, siliceous materials, zeolites and aluminum oxide, and also includes opaque pigments such as titanium dioxide, antimony oxide, zinc oxide, magnesium silicate (talc), calcium sulfite, barium sulfate, zinc borate, anhydrous sodium potassium aluminum silicate, calcium carbonate or carbon black. A preferred embodiment of the decal comprises three layers of adhesive coatings consisting of a clear or pigmented thermoplastic having a melting range of between 100-140°C laminated to a second layer of pigmented anti-dye migration and / or absorbing thermoplastic having a melting range of between 150-210°C. Laminated to the second layer is a third layer of clear thermoplastic having a melting range of between 100-140°C. The third layer acts as an adhesive to secure the decal to other products. The decal is made by die cutting or laser cutting a sheet or roll into discrete predetermined indicia (text, numbers, logos, graphics, etc.).

[0015] The above-mentioned decal is produced by printing the graphic onto the decal substrate. The three layers of the composite material are then fused together under certain temperature and pressure conditions to activate the first layer of adhesive and allow it to flow into the unprinted side of the base fabric material. The printed laminate is then cut using a laser or other mechanical cutting means. This product can then be used to decorate a garment or other product by adhering the decal to the garment or other product through the third adhesive layer. The heat and pressure at which the adhesive layer is activated is less than or equal to the temperature and pressure at which the adhesive layer is pressed onto the printed layer.

[0016] As a result, the physical and visual characteristics of the garment are not significantly altered after the decoration of the appliqued garment or other article. The selection of at least two different thermoplastic materials in the three-layer structure can be achieved by using the following layers:

[0017] 1) A transparent or colored low melting point adhesive layer for bonding the unprinted surface of the printed polyester fabric base layer;

[0018] 2) Pigment layer, used to achieve opacity and as a dye migration blocker / absorber;

[0019] 3) A third transparent layer, used for heat sealing of garments or other types of products, helps maintain the integrity of the printed graphics by inhibiting the migration of ink or dye in either direction while providing the desired opacity, preventing the color of the garment from showing through and reducing the visible edge of the opaque adhesive material. In summary, this is a decal with excellent visual effects. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Other objects, features and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiments and certain modifications thereof when read in conjunction with the accompanying drawings, in which:

[0021] Figure 1 FIG. 1 is a top view of the applique badge 10 according to the present invention applied to clothing.

[0022] Figure 2 is Figure 1 A cross-sectional view of an embodiment of the present invention selected at line xx.

[0023] Figure 3 yes Figure 1-2 A flow chart of the process of making the decal 10 is shown.

[0024] Figure 4 It is a cross-sectional view of another embodiment of the present invention. DETAILED DESCRIPTION

[0025] The present invention is a process for producing a heat activated applique that prevents dye migration from the transfer paper or through the transfer paper from the underlying garment fabric, thereby maintaining the integrity of the graphic. The opaque layered adhesive composite also prevents print-through of the garment fabric while providing a minimal amount of visually opaque adhesive at the edges of the applique. The preferred embodiment of the heat activated applique includes printing the graphic onto the applique base fabric and then laminating it with three layers of heat activated adhesive.

[0026] Combination Figure 1 and Figure 2As can be seen, the heat activated decal 10 of the present invention includes a base fabric layer 14 printed on one side and laminated with three layers of thermal adhesive composite material on the other side, wherein the three layers of thermal adhesive composite material include two layers of heat activated adhesive layers 11, 13, and a dye migration barrier layer 12 in between. The lower layer of heat activated adhesive layer 11 bonds the decal 10 to the substrate 15, which can be any fabric or leather or textile substrate. The graphic image 9 is printed on the top of the applique base fabric layer 14. The graphic 9 can be any decorative image or shape, including alphanumeric characters, logos or images. The graphic 9 can be printed on the top of the applique base fabric layer 14 by sublimation printing, and during the sublimation printing process, the dye is thermally transferred to the surface of the fabric layer. The three layers of composite thermal sensitive adhesive layers 11, 12, 13 together prevent the disperse dye from migrating to the substrate 15 or migrating from the substrate 15 to the printed applique layer 14.

[0027] In a preferred embodiment, the middle layer 12 comprises a layer of white pigmented polyurethane into which one or more dye absorbing materials, preferably aluminum silicate, are incorporated, and the melting point of the middle layer 12 is higher than that of the upper and lower layers 11, 13 and is in the range of 150-210°C. The preferred white pigment in the middle adhesive layer 12 is titanium dioxide (TiO2). The lower adhesive layer 11 comprises a layer of transparent polyurethane with a melting point in the range of 100-140°C. The lower adhesive layer 11 is used as an adhesive to fix the applique 10 to the substrate 15 (garment or other product), while the upper adhesive layer 13 comprises a layer of transparent polyurethane with a melting point in the range of 110-140°C for fixing the printed applique to the substrate fabric layer 14. The middle polymer layer 12 is used to provide an opaque or translucent layer, and the white pigment acts as a light reflecting suspended insoluble particle, which itself has no tendency to migrate. Through blocking and / or absorption, the thermoplastic in the middle layer 12 has good resistance to dye migration, as well as high temperature resistance and UV resistance. All three layers 11, 12, 13, when combined, act as a robust migration barrier, inhibiting the migration of ink or dye to the substrate 15, and vice versa.

[0028] Applique 10 is well suited for use with any fabric or leather substrate, including coarser nonwoven fabrics such as felt and fleece ("substrate" as used herein refers to any leather or fabric, whether woven or nonwoven, or any other flexible material used for apparel, signs, banners, flags, or similar applications, and "nonwoven" as used herein refers to any fabric substrate produced by a process other than weaving).

[0029] Figure 3 yes Figure 1-2 Flow chart of the process of making decal 10 shown. The process first requires obtaining the components of the decal.

[0030] Specifically, in step 100, a polyester fabric grey cloth is obtained.

[0031] In step 110, a three-layer polymer thermosensitive adhesive composite material is obtained using an adhesive lamination layer (combined layers 11, 12, 13). Preferably, the three-layer composite laminate 11, 12, 13 is made in advance so that it can be applied to the applique fabric base layer 14 at any time. It will be easily understood by those skilled in the art that the individual layers 11, 12, 13 can be applied to the applique base fabric layer 14 or the base 15 separately, and the same results can be obtained, but it is more efficient and more economical to pre-fabricate the three-layer composite laminate in advance so that it can be applied to the applique base fabric layer 14 at any time. The pre-fabrication of the three-layer composite laminate (combined layers 11, 12, 13) is completed as follows:

[0032] In step 120, a lower adhesive layer 11 of transparent or colored ink-resistant polyurethane is laminated with a white intermediate polymer layer 12 at a first temperature (preferably in the range of 100° C.-140° C.), and in step 122 (preferably but not necessarily performed simultaneously with step 120), an upper adhesive layer 13 of transparent polyurethane is laminated with the intermediate adhesive layer 12 at the first temperature. The melting range of the lower adhesive layer 11 is 100-140° C., and the melting range of the upper adhesive layer 13 is 110-140° C. The first temperature is sufficient to melt the lower and upper adhesive layers 11, 13. This causes the lower and upper adhesive layers 11, 13 to fuse with the intermediate polymer layer 12, but the first temperature is lower than the melting range of the white intermediate layer 12. The lower adhesive layer 11 acts as an adhesive to secure the applique 10 to a substrate 15 or other product, while the upper adhesive layer 13 is used to secure to the applique base fabric layer 14. Step 120 can effectively form a composite three-layer polyurethane adhesive laminate that can be sandwiched between release papers for use. After cooling, the result of step 120 is a three-layer polymer composite laminate layer including the combined layers 11, 12 and 13.

[0033] Returning to the applique base fabric layer 14 , in step 130 , the graphic 9 is printed onto one side of the base fabric layer 14 .

[0034] In step 140, the three-layer composite adhesive laminate (including adhesive layers 11, 13 and polymer disperse dye blocking and absorbing layer 12) produced in step 120 is fused to the printed fabric applique layer 14. The upper layer 13 is directly fused to the non-printed surface of the base fabric layer 14 under a combination of temperature and pressure conditions sufficient to activate the transparent upper layer adhesive 13 and allow it to flow into the base fabric layer 14. Generally, suitable heat sealing conditions use a temperature 10°C higher than the melting point of the adhesive layer and a pressure of 30-80 psi.

[0035] In step 150, the now printed and laminated base fabric layer 14 is cut into discrete appliques 10 using a laser or other mechanical cutting means. The appliques 10 can then be attached to the garment or other product using a clear adhesive layer 11 that is activated with less heat and pressure than is required to melt flow the intermediate white layer polymer 12.

[0036] As a result, a decorative applique 10 is made from a base fabric layer 14 with a printed graphic 9. At least two different polymers are selected, including at least one adhesive, arranged in three layers 11, 12, 13, two of which are transparent adhesives, one layer 11 for heat sealing to the garment base 15, plus a middle layer of pigment 12 to help maintain the integrity of the printed graphic by preventing the disperse dye from migrating in any direction. The decorative applique 10 can be processed under conditions consistent with its use and function. The combined three-layer composite material 11, 12, 13 was tested for migration resistance under both dry and wet conditions according to American Association of Textile Chemists and Colorists (AATCC) 163 (Color Fastness - Dye Transfer in Storage) to provide 20 colors of red, orange, yellow, green, blue, indigo and violet (ROYGBIV) in the sublimation range with an average ΔE < 0.5. ΔE is a standard measurement of spectral color fastness of color difference. The average person is barely perceptible to a ΔE value of <0.5, whereas previous adhesives used for similar applications could not achieve values ​​better than ΔE <0.7. The new adhesive formulation also provides an application method with a reduced visible adhesive edge while still providing the required opacity to prevent color from showing through the garment. The average adhesive edge was measured to be less than 0.2mm. Prior adhesives used with the required opacity had adhesive edges as high as 0.4mm.

[0037] Now it should be clear that the above method can be used to obtain Figure 1-2 The colorful printed and / or highlighted applique 10 shown has an aesthetically pleasing embossed or other color contrasting appearance and is easily applied to clothing or other textiles.

[0038] exist Figure 4In another embodiment shown, the composite adhesive laminate is composed of four layers 11, 12, 13 and 16, wherein the first transparent adhesive layer 11 is used to bond the unprinted side of the base fabric layer 14, and has a melting point of 110-135°C. The first layer 11 is laminated with a white colored second layer 12 having a melting point of 155-210°C, and the second layer 12 is laminated with a third black or dark colored polyurethane barrier layer 16 having a melting point of 155-210°C. The third layer 16 is laminated with a transparent adhesive layer 13 having a melting point of 110-135°C for bonding clothing or other textiles. In this embodiment, the transparent adhesive layers 11, 13 have a much lower melting temperature and are reserved for bonding, so that the colored polymer layers 12, 16 will not melt when heat sealing to the fabric applique layer 14 or the garment or textile. Since the colored layers 12, 16 do not flow during application, a visible adhesive edge around the applique is prevented. In addition, the black or dark colored layer also serves a dual function of preventing dye from entering the white colored layer and blocking any color unevenness in the garment, such as if there is a pattern. Therefore, the white colored layer can remain completely uniform regardless of the pattern or migration of the garment, and can also brighten the appearance of the applique relative to using only a single layer of black or dark colored layer. In this embodiment, the preferred white pigment is titanium dioxide and the preferred black pigment is activated carbon. As a result, the heat sealable fabric applique is very suitable for garments and textiles with patterns, or garments and textiles that are prone to obvious migration.

[0039] After fully describing the preferred embodiments of the present invention and some modifications to the basic concepts of the present invention, it will be apparent to those skilled in the art who are familiar with the basic concepts that various other embodiments and some variations and modifications thereof may occur to them. Therefore, it will be appreciated that the present invention may be implemented in ways other than those expressly provided for in the present invention.

[0040] Industrial Applicability

[0041] Heat pressing a heat sensitive decal onto an underlying substrate pre-colored using dye sublimation releases the dye, causing it to migrate into the decal and fade. In addition, heat sensitive decals can produce an undesirable opaque adhesive edge along the edge of the decoration. Another object is to provide an improved production process by which the production cost of the decal can be effectively reduced.

Claims

1. A heat sealable decal, include: Base fabric, printed with dye on one side; as well as A heat-sensitive adhesive is laminated on the opposite side of the base fabric, the heat-sensitive adhesive comprising a multi-layer composite material, wherein the multi-layer composite material comprises: The first layer of polyurethane adhesive has a melting temperature in the range of 100°C to 140°C; A third layer of polyurethane adhesive having a melting temperature in the range of 100°C to 140°C; and The second polymer barrier layer is located between the first layer and the third layer. The second polymer barrier layer can prevent the dye from migrating through the second polymer barrier layer, and its melting temperature is lower than that of the first layer and the third layer and is within the range of 150°C-210°C. The first layer is fused directly into the opposite unprinted side of the base fabric and isolates the second and third layers from the base fabric, and the second layer prevents dye migration from the base fabric layer to the third layer and vice versa.

2. The heat sealable decal according to claim 1, wherein: The second polymer barrier layer comprises any one or more of polyurethane, polyester, polyolefin and polyaramid.

3. The heat sealable decal of claim 1, wherein: The second polymeric barrier layer includes a dye absorbing material.

4. The heat sealable decal according to claim 3, wherein: The second polymeric barrier layer includes activated carbon.

5. The heat sealable decal of claim 1, wherein: The second polymeric barrier layer includes an opaque pigment.

6. The heat sealable decal of claim 5, wherein: The opaque pigment includes any one or more of titanium dioxide, antimony oxide, zinc oxide, magnesium silicate, calcium sulfite, barium sulfate, zinc borate, anhydrous potassium sodium aluminum silicate, calcium carbonate and carbon black.

7. The heat sealable decal of claim 6, wherein: The opacifying pigment comprises particles suspended in a polymer.

8. The heat sealable decal of claim 7, wherein: The opaque pigment includes white colored particles and black colored particles.

9. A heat sealable decal, include: Base fabric, printed with dye on one side; as well as A heat-sensitive adhesive is laminated on the opposite side of the base fabric, the heat-sensitive adhesive comprising a multi-layer composite material, wherein the multi-layer composite material comprises: The first layer of polyurethane adhesive has a melting temperature in the range of 110-135°C; The second layer of polyurethane adhesive has a melting temperature in the range of 110-135°C; a white pigmented polymeric barrier layer disposed between the first and second layers; and A black pigmented polymer barrier layer located between the first and second layers, The melting temperatures of the white colored polymer barrier layer and the black colored polymer barrier layer are lower than those of the first layer and the second layer and are in the range of 155° C. to 210° C., The first layer is directly fused into the opposite unprinted side of the base fabric and separates the white colored polymer barrier layer, the black colored polymer barrier layer and the second layer from the base fabric, and the white colored polymer barrier layer and the black colored polymer barrier layer can prevent the migration of dye from the base fabric layer to the second layer and vice versa.

10. The heat sealable decal of claim 10, wherein: The white colored polymer barrier layer and the black colored polymer barrier layer each include any one or more of polyurethane, polyester, polyolefin, and polyaramid.

11. The heat sealable decal of claim 10, wherein: The black pigmented polymeric barrier layer includes a dye absorbing material.

12. The heat sealable decal of claim 11, wherein: The dye absorbing material includes activated carbon.

13. The heat sealable applique of claim 10, wherein: The white pigmented polymer barrier layer includes titanium dioxide particles suspended in a polymer.

14. A process for making a heat sealable decal, comprising the following steps: The graphics are printed on one side of the base fabric using dye sublimation printing; A multilayer composite adhesive film is obtained, wherein the multilayer composite adhesive film comprises a first layer of polyurethane adhesive, a second layer of polyurethane adhesive, and a polymer barrier layer between the first layer and the second layer, wherein the melting temperature of the first layer of polyurethane adhesive is within the range of 100° C.-140° C., the melting temperature of the second layer of polyurethane adhesive is within the range of 100° C.-140° C., the polymer barrier layer can prevent dyes from migrating through the polymer barrier layer, and the melting temperature of the polymer barrier layer is lower than that of the first layer and the second layer and is within the range of 150° C.-210° C.; and fusing the first layer of the multi-layer composite adhesive film directly into the opposite unprinted side of the base fabric, separating the polymeric barrier layer and the second layer from the base fabric, The polymeric barrier layer prevents dye migration from the base fabric layer to the second layer and vice versa.

15. The process for making a heat sealable decal according to claim 14, wherein: The step of obtaining the multi-layer composite adhesive film further includes the multi-layer polymer barrier layer having a white colored layer and a black colored layer.

16. The process for making a heat sealable decal according to claim 15, wherein: The white pigmented layer includes titanium dioxide particles suspended in a polymer, and the black pigmented layer includes carbon black particles suspended in a polymer.

17. The process for making a heat sealable decal according to claim 14, wherein: The step of fusing the first layer of the multi-layer composite adhesive film directly into the opposite unprinted side of the base fabric includes applying pressure.

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