Method for producing sublimation printing heat sealable appliqué

Abstract

A method of manufacturing a non-discoloring thermal appliqué using a polyester fabric blank, printing a graphic image on the fabric blank by dye sublimation, and laminating by calendering or thermocompression a multilayer composite consisting of two opposing outer layer polyurethane adhesive surfaces having an intermediate layer of a die-blocking and absorbing polymer adhered to the non-printed surface of the printed fabric blank. The multi-zone composite includes a first layer of transparent or colored polyurethane adhesive, next, a layer of colored dispersed die-blocking and absorbing polymer, and a third transparent layer of polyurethane adhesive. The first of the three layers of adhesive is fused to the polyester blank under combined temperature and pressure until the first layer is impregnated into the fabric blank. Thereafter, the fabric blank is cut into individual finished appliqués.

Description

Technical Field

[0001] (Cross - Reference to Related Applications) This application claims priority to U.S. Provisional Patent Application No. 63 / 336,642, filed Apr. 29, 2022, and is a continuation of U.S. Serial No. 17 / 487,638, filed Sep. 28, 2021 (which is a continuation of U.S. Serial No. 16 / 166,457, filed Oct. 22, 2018, and is currently U.S. Patent No. 11,130,364).

[0002] The present invention relates to the production of transfers and appliqués on heat - activated fabrics, and more particularly to heat transfers composed of numbers, letters, logos, graphics, and other displays that maintain graphic integrity by suppressing the migration of disperse dyes from the fabric transfer to the apparel fabric or vice versa.

Background Art

[0003] “Performance wear” is often composed of polyester fabrics that are color - dyed using a sublimation process. The dye - sublimation process uses high heat to permanently fuse the colorant to the polyester fabric. To thermally fix the dye - sublimation ink to the polyester material, a temperature in the range of 370 - 420°F (188 - 216°C) and a dwell time of about 1 minute are typically required. Heat provides two important functions. First, by opening the pores of the polyester fabric, it enables the material to accept the dye. Second, heat converts the solid ink dye into a gas and diffuses it into the fibers of the fabric. Also, manufacturers of performance wear, uniforms, swimwear, and sports accessories use various methods to apply a variety of displays such as text, numbers, logos, graphics, and other displays to clothing and textiles, especially for decoration and identification. Common application techniques include silk - screen printing, screen printing, and sublimation fabric heat - activated transfer.

[0004] Typically, silk screen printing of logos or emblems is used, but in this process, products that can withstand repeated stretching cannot be obtained, and it is complex and time-consuming. Also, designs created by silk screen printing are flat and lack texture, and cannot withstand repeated stretching or washing in industry or at home. As a result, many companies prefer heat transfer fabrics appliqués as the main method of applying decoration or identification. Also, thermally activated adhesive coatings are also used to apply appliqués to clothing and textiles. A typical type of appliqué typical for numbering and lettering on sports jerseys and uniforms is a layered appliqué that includes a hard first base layer that defines numbers and letters, and one or more top layers that are smaller than the layer below but of the same shape, thereby creating a three-dimensional appearance. Typically, each layer is made of dyed fabric, and each top layer is sewn to the layer below it. There is a heat adhesive layer on the back surface of the hard base layer that covers the entire back surface. As disclosed in the applicant's U.S. Patent No. 11,130,364, the thermally activated adhesive can be provided with a filler that provides opacity to prevent the color of the clothing material from showing through the decoration.

[0005] Problems can arise when an appliqué is heat-pressed onto a pre-colored substrate using dye sublimation. Heat can move to the appliqué by releasing the dye, causing discoloration.

[0006] Another problem that can occur due to the use of opaque adhesive dies is that the edges of the opaque adhesive remain visible along the edges of the decoration. Aesthetically, this visible adhesive edge is undesirable and degrades the appearance of the decoration. It would be highly advantageous to provide a lightweight heat-sealable sublimation-printed appliqué that can be applied to any clothing or textile without loss of graphics caused by dye migration from the printed appliqué or the substrate material to which heat is applied. Also, it would be beneficial to minimize the visible adhesive edge and provide appropriate opacity to prevent the clothing material from showing through, while improving the overall appearance of the appliqué. SUMMARY OF THE INVENTION

[0007] Therefore, an object of the present invention is to provide a heat-sealable appliqué that forms displays such as text, numbers, logos, graphics, and other displays that do not deteriorate graphically under normal use conditions.

[0008] Another object of the present invention is to provide a heat-sealable appliqué that prevents the underlying clothing pattern from being seen through and prevents the transfer of dyes from the clothing fabric to the appliqué.

[0009] Another object of the present invention is to prevent the transfer of dyes and pigments from the graphic to under the back surface in order to avoid color fading or discoloration.

[0010] Another object of the present invention is to provide a heat-sealable appliqué that prevents a visible adhesive edge from occurring around the appliqué during the process of adhering to the clothing.

[0011] Another object of the present invention is to provide a heat-sealable appliqué similar to traditional laminated appliqués often used for relettering and numbering of sports jerseys and uniforms.

[0012] Furthermore, yet another object of the present invention is to provide a heat-sealable appliqué that can be manufactured cost-effectively.

[0013] According to the present invention, the above-described object and other objects are achieved by an appliqué cut to include a base fabric material of a suitable woven fabric, non-woven fabric or knitted polyester fiber composition, the base fabric being a two-layer transparent or colored polyurethane adhesive sandwiching one or more colored polymer layers configured to prevent the movement of dyes by any of a migration barrier, a dye-absorbing polymer, or some combination thereof. The polymer barrier layer may be composed of polyurethane or other suitable thermoplastic resin such as polyester-based, polyolefin-based, or polyaramid-based, and includes absorbent materials such as activated carbon, clay, siliceous materials, zeolites, and alumina. Further, it includes pigments for opacity 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 appliqué includes a three-layer adhesive coating composed of a transparent or colored thermoplastic resin having a melting range of 100 to 140 °C, laminated to a second layer of a colored dye migration-resistant and / or absorbent thermoplastic resin having a melting range of 150 to 210 °C. A third transparent layer of a thermoplastic resin having a melting range of 100 to 140 °C is laminated to the second layer. This third layer is used as an adhesive for fixing the appliqué to other products. The appliqué is die-cut or laser-cut from a sheet or roll into individual predetermined displays (text, numbers, logos, graphics, etc.).

[0014] The foregoing appliqué is manufactured by printing graphics on an appliqué base material. Thereafter, the three-layer composite is fused under temperature and pressure conditions necessary to activate and fluidize the first adhesive layer on the non-printed surface of the base fabric material. Next, the printed and laminated material is cut using a laser or other mechanical cutting means. Next, the product can be utilized to decorate clothing or other products by adhering the appliqué with a third adhesive layer. This layer is activated at the same or lower heat and pressure as when laminating the adhesive to the printed layer.

[0015] As a result, a decorated clothing or other item with an appliqué that does not substantially change the physical and visual properties of the clothing is obtained. In the three-layer structure, the selection of at least two different thermoplastic materials is achieved by the following.

[0016] 1) A transparent or colored low-melting-point bonding layer that binds to the non-printed surface of the printed polyester fabric base layer

[0017] 2) A colored layer that is used for opacity and also serves as a dye migration barrier / absorbent

[0018] 3) A third transparent layer that is ensured for heat-sealing properties to clothing or other types of products, having an opacity necessary to prevent the color of the clothing from being seen through, reducing the visible edges of the opaque adhesive material, and serving to maintain the integrity of the printed graphic by suppressing the movement of ink or dye in any direction. In summary, it is an appliqué with excellent visual appearance.

[0019] Other objects, features, and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiments and their certain modifications, when considered in conjunction with the accompanying drawings.

Brief Description of the Drawings

[0020]

Figure 1

Figure 2

Figure 3

Figure 4

Mode for Carrying Out the Invention

[0021] The present invention is a method for producing a heat-activated appliqué that maintains the integrity of a graphic by preventing the movement of dye from a transfer material or the movement of dye from the underlying clothing fabric through the transfer material. Also, an opaque layer adhesive composite provides a minimal visible opaque adhesive at the edge of the appliqué and prevents the clothing fabric from being seen through. A preferred embodiment of the heat-activated appliqué includes a graphic laminated with a three-layer heat-activated adhesive after being printed on an appliqué base fabric.

[0022] Referring to both FIGS. 1 and 2, the heat-activated appliqué 10 of the present invention includes a base fabric layer 14 laminated to a three-layer thermally bonded composite including two heat-activated adhesive layers 11, 13 sandwiching a dye migration barrier layer 12, with one side printed and the other side laminated. The lower heat-activated adhesive layer 11 bonds the appliqué 10 to a substrate 15 that can be any fabric, leather, or textile substrate. The graphic image 9 is printed on the appliqué 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 appliqué base fabric layer 14 by sublimation printing that thermally transfers dye to the surface of the fabric layer. The three composite heat adhesive layers 11, 12, 13 collectively block the movement of disperse dye to or from the substrate 15 or the printed appliqué layer 14 from the substrate 15.

[0023] In a preferred embodiment, the intermediate layer 12 comprises a white-colored polyurethane layer mixed with one or more dye-absorbing materials, preferably aluminum silicate, and has a melting point in the range of 150 to 210 °C, which is higher than those of the upper layer and the lower layer 11, 13. A preferred white pigment in the intermediate adhesive layer 12 is titanium dioxide (TiO 2 ). The lower adhesive layer 11 comprises a polyurethane transparent layer having a melting point in the range of 100 to 140 °C. The lower adhesive layer 11 is used as an adhesive for fixing the appliqué 10 to the substrate 15 (clothing or other products), while the upper adhesive layer 13 comprises a transparent polyurethane layer having a melting point in the range of 110 to 140 °C, which is secured for fixing the printed appliqué to the base fabric layer 14. The intermediate polymer layer 12 serves to provide an opaque or semi-transparent layer, and the white pigment serves as light-reflective suspension-insoluble particles that do not tend to move by themselves. The thermoplastic resin in this intermediate layer 12 has excellent dye migration resistance by means of barrier and / or absorption, as well as high temperature resistance and UV resistance. When all three layers 11, 12, 13 are bonded together, a robust migration barrier is provided that suppresses the movement of ink or dye to and from the substrate 15.

[0024] The appliqué 10 is suitable for application to any fabric or leather substrate, including coarse non-woven fabrics such as felt or fleece (as used herein, "substrate" is defined as any woven or non-woven fabric, any leather or fabric, or any other flexible material used in clothing, display boards, banners, pennants or the like, and as used herein, "non-woven fabric" is defined as any fabric substrate manufactured by a process other than a woven fabric).

[0025] Figure 3 is a process diagram of the method for manufacturing the appliqué 10 in Figures 1-2. The above process starts by obtaining its components.

[0026] Specifically, in step 100, a polyester fabric blank is obtained.

[0027] In step 110, a three-layer polymer thermo-bonding composite material having an adhesive laminate layer (bonding layers 11, 12, 13) is obtained. The triple-layer composite laminate layers 11, 12, 13 are preferably pre-produced for application to the appliqué base fabric layer 14 as a ready-made product. Those skilled in the art will readily understand that although the individual layers 11, 12, 13 can be individually applied to the appliqué base fabric layer 14 or the substrate 15 so as to obtain the same result, it is more efficient and economical to pre-manufacture the triple-layer composite laminate for application to the appliqué base fabric layer 14 as a ready-made product. The triple-layer composite laminate layer (bonding layers 11, 12, 13) is pre-manufactured as follows.

[0028] In step 120, the lower adhesive layer 11 of transparent or colored ink-resistant polyurethane is preferably laminated to the white intermediate polymer layer 12 at a first temperature within the range of 100°C to 140°C, and (preferably carried out simultaneously with 120, but not essential) in step 122, the upper adhesive layer 13 of transparent polyurethane is laminated to the intermediate adhesive layer 12 at the first temperature. The lower adhesive layer 11 has a melting range of 100 to 140°C, and the upper adhesive layer 13 has a melting range of 110 to 140°C. The first temperature is sufficient to melt the lower adhesive layer and the upper adhesive layers 11, 13. Thereby, the lower adhesive layer and the upper adhesive layers 11, 13 are fused to the intermediate polymer layer 12, but the first temperature is lower than the melting range of the white intermediate layer 12. This lower adhesive layer 11 is used as an adhesive for fixing the appliqué 10 to the substrate 15 or other products, while the upper adhesive layer 13 is secured for fixing to the appliqué base fabric layer 14. This step 120 effectively forms a triple-layer composite polyurethane adhesive laminate, which can be sandwiched between release paper sheets for later use. Upon cooling, as a result of step 120, a triple-layer polymer composite laminate layer including the bonding layers 11, 12, and 13 is obtained.

[0029] Returning to the appliqué base fabric layer 14, in step 130, the graphic 9 is printed on one side of the base fabric layer 14.

[0030] In step 140, the triple-layer composite adhesive laminate produced in step 120, which includes the adhesive layers 11, 13, and the polymer-dispersed dye blocking / absorbing layer 12, is fused to the printed fabric appliqué layer 14. The upper layer 13 is directly fused to the non-printed surface of the base fabric layer 14 under conditions of bonding temperature and pressure sufficient to activate the transparent upper layer of the adhesive 13 and cause it to flow into the base fabric layer 14. Typically, 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.

[0031] In step 150, the now printed and laminated base fabric layer 14 is cut into individual appliqués 10 using a laser or other mechanical cutting means. The appliqués 10 can then be utilized for decoration, clothing, or other products by bonding the appliqués 10 using the transparent adhesive layer 11, which is activated with heat and pressure lower than that required to melt and flow the intermediate white layer polymer 12.

[0032] As a result, a decorative appliqué 10 utilizing a base fabric layer 14 with printed graphic 9 is obtained. At least two different polymers containing at least one adhesive are selected and arranged in three layers 11, 12, 13, where two of such layers 11, 13 are transparent adhesives, and one layer 11 is secured for heat-sealing purposes to a clothing substrate 15. Further, providing one colored layer 12 therebetween serves to maintain the integrity of the printed graph by blocking the movement of disperse dyes in any direction. The decorated appliqué 10 can be processed under conditions suitable for its intended use and function. The migration resistance of the bonded triple-layer composite 11, 12, 13 is measured under both wet and dry conditions according to American Association of Textile Chemists and Colorists (AATCC) 163 (Colorfastness to Dye Transfer during Storage), providing an average ΔE < 0.5 over the range of the 20 sublimation hues of red, orange, yellow, green, blue, indigo, and violet (ROYGBIV). ΔE is the deviation of the spectroscopic colorfastness standard measurement value. ΔE < 0.5 is hardly perceptible to the average person, and conventional adhesives used for similar purposes could not achieve better than ΔE < 0.7. Also, this new adhesive formulation provides an application means with reduced visible adhesive edges and the opacity necessary to prevent the color of the clothing from showing through. The adhesive edges were measured to be an average < 0.2 mm. For adhesives requiring opacity that were used prior to such developments, the adhesive edges could reach 0.4 mm.

[0033] As a result, a color-printed and / or highlighted appliqué 10 as shown in FIGS. 1 - 2 30 is obtained, and it is now apparent that this appliqué can be aesthetically pleasingly embossed or give an appearance of color contrast in a form that is easily applicable to clothing or other textiles.

[0034] In an alternative embodiment as shown in FIG. 4, the composite adhesive laminate is composed of four layers 11, 12, 13, and 16. The transparent first adhesive layer 11 is secured for adhering to the non-printing surface of the base fabric layer 14 having a melting point of 110 to 135°C. The first layer 11 is laminated to the white-colored second layer 12 having a melting point of 155 to 210°C, and as a result, is laminated to the black or dark-colored third barrier layer 16 of polyurethane having a melting point of 155 to 210°C. The third layer 16 is laminated to the transparent adhesive layer 13 having a melting point of 110 to 135°C and is secured for adhering to clothing or other textiles. In this embodiment, the transparent adhesive layers 11, 13 melt at a much lower temperature and are secured for adhesion, so the colored polymer layers 12, 16 do not melt even when heat-sealed to the fabric appliqué layer 14 or clothing or textiles. Since the colored layers 12, 16 do not flow during application, a visible adhesive edge around the appliqué is prevented. Further, the black or dark-colored layer not only prevents the intrusion of dyes into the white-colored layer, but also performs a dual function of blocking color non-uniformity in clothing, for example, when the clothing has a pattern. Thus, the white-colored layer is maintained completely uniformly regardless of the pattern or movement of the clothing, and serves to brighten the appearance of the appliqué compared to the case of using only a single 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, an appliqué of a heat-sealable fabric suitable for patterned clothing or textiles, or clothing or textiles prone to considerable movement, can be obtained.

[0035] In this specification, since the preferred embodiments and certain modifications of the underlying concepts of the present invention have been fully described, it will be apparent to those skilled in the art that various other embodiments and certain changes and modifications thereto can occur if one is familiar with the underlying concepts. Therefore, it should be understood that the present invention can be implemented in ways other than those specifically described herein.

Industrial Applicability

[0036] When thermally pressure-bonding a thermal transfer onto a pre-colored base substrate using dye sublimation, the dye can be released and move to the transfer, resulting in color change. Also, the thermal transfer can produce an undesirable opaque adhesive edge along the edge of the decoration. It is also another object to provide an improved manufacturing method capable of manufacturing the transfer efficiently in terms of cost.

Claims

1. a base fabric printed with a dye on one side, a hot melt adhesive laminated to the opposite side of the base fabric, a first layer of polyurethane adhesive having a melting temperature in the range of 100 to 140°C, a third layer of polyurethane adhesive having a melting temperature in the range of 100 to 140°C, and a second polymer barrier layer between the first layer and the third layer, configured to prevent the movement of the dye therethrough and having a melting temperature lower than that of the first layer and the third layer and in the range of 150 to 210°C, a hot melt adhesive comprising a multilayer composite material including the second polymer barrier layer, A heat-sealable appliqué comprising: The first layer is directly fused to the non-printed surface opposite to the base fabric, separating the second layer and the third layer from the base fabric, and the second layer prevents the movement of the dye from the base fabric layer to the third layer and vice versa. A heat-sealable appliqué.

2. The heat-sealable appliqué according to claim 1, wherein the second polymer barrier layer comprises any one or more of the group consisting of polyurethane, polyester, polyolefin, and polyaramide.

3. The heat-sealable appliqué according to claim 1, wherein the second polymer barrier layer comprises a dye-absorbing material.

4. The heat-sealable appliqué according to claim 3, wherein the second polymer barrier layer comprises activated carbon.

5. The heat-sealable appliqué according to claim 1, wherein the second polymer barrier layer comprises an opaque pigment.

6. The heat-sealable appliqué according to claim 5, wherein the opaque pigment comprises any one or more of the group consisting of titanium dioxide, antimony oxide, zinc oxide, magnesium silicate, calcium sulfite, barium sulfate, zinc borate, anhydrous sodium potassium aluminum silicate, calcium carbonate, and carbon black.

7. The heat-sealable appliqué according to claim 6, wherein the opaque pigment comprises particles suspended in a polymer.

8. The heat-sealable appliqué according to claim 7, wherein the opaque pigment comprises particles colored white and particles colored black.

9. a base fabric printed with a dye on one side, a hot melt adhesive laminated to the opposite side of the base fabric, a first layer of polyurethane adhesive having a melting temperature in the range of 110 to 135°C, A second layer of polyurethane adhesive having a melting temperature within the range of 110 to 135 °C, A polymer barrier layer colored white between the first layer and the second layer, and A multilayer composite material including a polymer barrier layer colored black between the first layer and the second layer, The polymer barrier layer colored white and the polymer barrier layer colored black are lower than the first layer and the second layer and have a melting temperature within the range of 155 to 210 °C, and a heat adhesive, A heat-sealable appliqué comprising, The first layer is directly fused to the non-printed surface opposite to the base fabric, separating the polymer barrier layer colored white, the polymer barrier layer colored black, and the second layer from the base fabric, and the polymer barrier layer colored white and the polymer barrier layer colored black prevent the transfer of dyes from the base fabric layer to the second layer and vice versa. A heat-sealable appliqué.

10. The polymer barrier layer colored white and the polymer barrier layer colored black each include any one or more of the group consisting of polyurethane, polyester, polyolefin, and polyaramide. The heat-sealable appliqué according to claim 10.

11. The polymer barrier layer colored black includes a dye-absorbing material. The heat-sealable appliqué according to claim 10.

12. The dye-absorbing material includes activated carbon. The heat-sealable appliqué according to claim 11.

13. The polymer barrier layer colored white includes titanium dioxide particles suspended in the polymer. The heat-sealable appliqué according to claim 10.

14. A step of printing a graphic on one side of a base fabric by dye sublimation printing, A step of obtaining a multilayer composite adhesive film having a first layer of polyurethane adhesive having a melting temperature within the range of 100 to 140 °C, a second layer of polyurethane adhesive having a melting temperature within the range of 100 to 140 °C, and a polymer barrier between the first layer and the second layer, wherein the polymer barrier prevents the transfer of dyes therethrough and is lower than the first layer and the second layer and has a melting temperature within the range of 150 to 210 °C. A step of obtaining a multilayer composite adhesive film configured as such. The step of directly fusing the first layer of the multilayer composite adhesive film to the non-printing surface opposite to the base fabric, and separating the polymer barrier layer and the second layer from the base fabric; A method for producing a heat-sealable appliqué, comprising: The polymer barrier layer prevents the transfer of dyes from the base fabric layer to the second layer and vice versa. A method for producing a heat-sealable appliqué.

15. The step of obtaining the multilayer composite adhesive film further includes a multilayer polymer barrier layer having a white-colored layer and a black-colored layer. The method for producing a heat-sealable appliqué according to claim 14.

16. The white-colored layer contains titanium dioxide particles suspended in a polymer, and the black-colored layer contains carbon black particles suspended in a polymer. The method for producing a heat-sealable appliqué according to claim 15.

17. The step of directly fusing the first layer of the multilayer composite adhesive film to the non-printing surface opposite to the base fabric includes the step of applying pressure. The method for producing a heat-sealable appliqué according to claim 14.

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