CA2023153A1 - Printed embossed fabric and method of making the same - Google Patents

Abstract

ABSTRACT OF THE DISCLOSURE

The flexible material is provided with an image-forming embossed zone. It is formed with three laminations, namely: a cover layer made of two-way stretchable fabric, a backing layer made of thermo-plastic material and an intermediate adhesive layer adhering the two other layers one to the other. The three layers form a flat zone and an embossed wrinkle-free zone, the latter defining an image surrounded by the flat zone, the flat zone and at least the margin of the embossed zone being non-stretchable because the backing layer impregnates the cover layer and is in non-stretchable state. The resulting fabric is colour printed by means of a heat-transfer paper. A multicoloured fabric can be obtained by effecting two or more printing steps using transfer papers with differently coloured pigments. The resulting ornamenting fabric can be used in the making of crests, sweaters, handbags, labels and other uses.

Description

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The present invention relates to an ornamenting fabric, more particularly to an image-forming embossed fabric and to a --method of making the same.
BACKGROUND OF THE INVENTION
Applicant's prior U.S. Patent 4,585,684, dated April 29, 1986, describes a laminated fabric including an embossed zone forming an image. In this patent, the image has to be printed flrst and then the die-cut foamed synthetic resin inserted in position underneath the printed cover layer, resulting in poor matching of the embossing foam with the printed image. Also, a stiff backing layer has to be provided to press the foam against the cover fabric, so as to maintain the embossing. Also, with the method in accordance with this invention, it was not possible to form a narrow and precise embossing, such as embossed lettering.
OBJECT OF THE INVENTION ~ ~ .
It is the general object of the present invention to provide an ornàmenting embossed fabric in which the embossing can have a very precise outline and be very narrow. -~
Another object of the invention is to provide a fabric of the character described, which is much less expensive and much faster to make than the fabric in accordance with the above-noted patent.
Another object of the present invention is to provide a fabric of the character described, in which the embossed zone can be printed in a precise manner. ;

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,, '-Another object of the present invention is to provide a fabric of the character described which can be used to make ~ ~ -crests, labels, handbags, wallets, foot-wear, head-wear, wall hangings, clothing and any fabric where embossed ornamentation is 5- desired.
SUMMARY OF THE INVENTION
The ornamenting embossed fabric of the invention is a laminated flexible material with an image forming embossed zone, -comprising a cover layer made of woven or knitted fabric, stretchable in two perpendicular directions, a backing layer and an adhesive layer made of a thermoplastic material, the adhesive layer located between the two other layers and adhering the same, the three layers forming a flat zone and an embossed wrinkle-free zone defining the image and surrounded by the flat zone, the flat zone and at least the marginal part of the embossed zone being non-stretchable with said backing and adhesive layers impregnating the cover layer and being in a non-stretchable ~ ~ ;
state, the embossed non-stretchable marginal part being in a more qtretched state than the flat zone. Preferably, the flat zone and the embossed marginal part are made non-stretchable by heat treatment to a temperature above the melting poing of the thermo-plastic material of the backing and adhesive layers, so as to cause the material to melt and then solidify to a continuous state filling the interstices between the yarns of the fabric of the cover layer. Preferably, the backing layer is a polyurethane foam, while the adhesive layer is a polyurethane film.

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Preferably, the cover layer is a woven fabric made of synthetic yarns such as nylon; cotton can also be used. The cover layer of the resulting fabric can be printed with one or more colors, and the color of the embossed zone can be different from the color of the flat background ~one. The invention comprises also the methods of producing the fabric of the invention and of printing the same.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
Figure 1 is a plan view of the laminated embossed flexible material of the invention, in the form of a crest;
Figure 2 is a cross-section along line 2-2 of Figure 1; ~-Figure 3 is a partial cross-section, on an enlarged scale, of the area enclosed by circle 3 in Figure 2;
Figure 4 is a partial exploded cross-section of the three layers for constituting the fabric of the invention; -Figure 4A is a cross-section similar to that of Figure 4, but showing an alternate arrangement wherein the intermediate adhesive layer is already adhered to the backing layer;
Figure 5 is a perspective view of the press and die-plates used for making the laminated material of Figure 1;
Figure 6 is a cross-section of the press and die-plates in material pressing and embossing position;
Figure 7 is a partial cross-section, on an enlarged scale, of the area encircled in circle 7 of Figure 6;

, ' ,: ' :- "''' ' . , . ' , : , ' ~' ~' -- 2~3~ 53 Figure 8 is a top view of embossed material obtained from the pressing step;
Figure 9 is an exploded perspective view of the elements of the printing press;
Figure 10 is a partial cross-section of the opened printing press with the material to be printed and the color transfer paper in proper superposed position;
Figure 11 is a view similar to that of Figure 10, shown at the completion of the printing stroke of the press; and Fi~ure 12 is a section, or an enlarged scale, of the area in circle 12 of figure 11.
DETAILED DESCRIPTION OF THE PREFERRED EMBODI~ENT
Referring to Figures 1 to 4 inclusive, the embossed flexible laminated material of the invention is shown at 1, in .-the form of a crest, and is made with a cover layer 3, anintermediate adhesive layer 5, and a backing layer 7 (Figure 4).
The cover layer 3 is a flexible sheet, of woven or knitted yarns, -~preferably synthetic yarn such as nylon, which is stretchable in two perpendicular directions and has a uniform initial color, -such as white. The adhesive layer 7 is in the form of a continuous film, preferably a thermo-plastic film, such as polyurethane. The backing layer 7 is made of a stretchable thermo-plastic material, preferably a foamed synthetic resin, such as foamed polyurethane. The three layers are superposed and pressed in a heated press. The three layers can be initially ,: -.
separate, as shown in Figure 4, or the adhesive layer already - -,~

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adhering to the backing layer 7, as shown in Figure 4A. Thethree layers, in the form of sheets, are disposed in superposed position over a male die-plate 9, fixed to a bottom press plate 11, of a press, which is provided with a top press plate 13, to which is fixed a female die-plate 15. Both press plates 11 and 13 are heated, for instance by an electric resistance wire 17, so as to heat the metallic die-plates 9 and 15. The male die-plate 9 is formed with a flat pressing surface 19, from which protrude, as shown in Figure 7, narrow ribs 21 and wider bosses 23. The flat pressing face 25 of the female die-plate 15 is provided with narrower grooves 27 registering with and conforming to the ribs 21, and wider cavities 29 registering with the bosses 23 and conforming to the same. As shown in Figure 7, when the press is in closed position, the spacing between the flat faces 19 and 25, and also between the ribs 21 and the grooves 27, is substantially uniform throughout; but the spacing between the bosses 23 and the cavities 29 is much greater.
To make the material 1, the assembly of the three layers are superposed between the open heated die-plates 9 and 15. Then the press is closed and arranged to exert a pressure of about 2000 pounds per square inch, with the die-plates heated to a temperature between 300 and 430F and, at any rate, to such a temperature as to at least soften but preferably melt the material of the backing layer 7 o~ also the adhesive layer 5 which are caused to impregnate the cover layer by filling the interstices between its yarns and then to solidify to a cell-less , "~. . . : ., :

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continuous non-stretchable yet flexible state. Thus, the foamed material of layer 7 is completely flattened between the flat faces 19 and 25 of the die-plates and between the ribs 21 and grooves 27, and also along the marginal zones 31 surrounding the bosses 23. However, the foam 33 within cavities 29 remains in a foamed stretchable and compressible state~ The resulting material 1 therefore comprises a flat zone 35 and an embossed .....
zones 37 and 39, which are surrounded by the flat zone 35. The embossed zones 37 are very narrow and precisely defined. The wider embossed zones 39 are surrounded by a marginal embossed ~. ~
zone 41. In the flat zones 35, in the narrow embossed zone 39 and in the marginal zone 41, the foamed plastic backing layer 7 ;~
is converted to a solid state and both layers 5 and 7 impregnate :
the cover layer 3 to form a very thin but unstretchable zone. In the marginal zone 41, the cover layer 3 is in a more stretched state than in the flat zone 35. In the wider embossed zone 39, the cover layer 3 remains completely stretchable since it is not impregnated by layers 5 and 7 and is maintained wrinkle-free by the compressible foam backing 33. Backing 33 is adhered to cover layer 3 by adhesive layer 5 which has only been softened in this area during pressing. The result is a wrinkle-free embossing. Also, the narrow embossed zone 37, such as the zone forming the lettering shown in Figure 1, can be very precise.
The material, when pressed conserves its embossed state ~ 25 forming the required image.

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The material is thereafter preferably printed to the desired color or colors, using a printing press and color-transfer papers in the manner shown in Figures 9 to 11.
The material, as it comes out of the embossing press, is shown in plan view in Figure 8. To provide for the crest shown in Figure 1, it is die-cut to the required size, as indicated by the dimensions X and Y.
The printing press includes a bottom press plate 43 and a top press plate 45, which is heated by an electric resistance wire 47. A support frame 49 is positioned onto the bottom press plate 43 and a backing plate 51 is inserted within the support 49.
It will be noted that the top press plate 45 has dimensions which are about equal to those of support frame 49, so as to make substantially gas proof contact with said support frame 49. The backing plate 51 has dimensions X', Y' which are such that the backing plate 51 has a sliding fit within the support frame 49. The material 1 to be printed or coloured is die-cut to the dimensions X, Y which substantially correspond to the dimensions X', Y' and placed over the backing plate 51, with the cover layer 3 and the embossing facing upwardly. The backing plate 51 is hollowed out at 53 in register with at least the wider embossed zone 39. Once the die-cut material 1 is in position in the press, a color transfer paper sheet 55 is placed on top of the material 1 to be printed, and the heated top press plate 45 is lowered to effect the printing. The paper 55 is of ~3~ ~

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conventional type and contains one or more coloring agents of the -~
type which are transferred by sublimation to the cover layer 3 when heated. The coloured gases are trapped within the space delimited by closed top press plate 45 and frame 49. Obviously, the amount of color transferred to the cover layer is ~: .
proportional to the duration of pressing and, to a certain extent, to the localized pressure exerted on the material by the top press plate 45. Hollowed out portion ~3 of backing plate 51 causes the smaller embossing 37 forming the lettering to be pressed against paper sheet 55 under substantially the same pressure as the higher embossing 39.
The flat zone 35 as well as the embossed zones 37, 39 are colored. Printing can be repeated using differenly coloured transfer papers 55.
A finished colored material 1 can be obtained with an embossing of one color and a background, namely: the flat zone 35 of a different color.
The printing step is preferably carried out with a 10 to 16-pound press pressure, with the top heated plate maintained at a temperature between 300 and 450~F to effect effective transfer of the pigments from the paper sheet 55 to the cover : .- :
layer 3. The coloring pigments used are preferably all transparent, except black pigment. Colour transfer by sublimation is possible when the cover layer 3 is made of synthetic yarns. Other known types of colour printing is used when cover layer 3 is made of cotton, wool or other natural 2 ~

yarns. It is important that the embossing step, as shown in Figures 5 and 6, be effected before the printing step; otherwise, it is practically impossible to obtain good matching of the desired color with the embossed portion of the material 1, because of the stretching of the cover layer 3 in the embossed zones during the embossing step. Obviously, the die-cutting of the material 1, after the embossing step, along the line defined by X and Y in Figure 8, can be effected by providing the printing press with suitable cutting blades. In this manner, die-cutting could be effected simultaneously with the first printing operation.

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Claims (13)

The embodiments of the invention in which an exclusive property or privilege is claimed, are defined as follows:

1. A laminated flexible material with an image forming an embossed zone, comprising: a cover layer made of woven or knitted fabric, stretchable in two perpendicular directions, a backing layer and an adhesive layer made of a thermo-plastic material, the adhesive layer located between and adhering the cover layer to the backing layer, the three layers forming a flat zone and an embossed wrinkle-free zone defining an image and surrounded by said flat zone, said flat zone and at least the marginal part of said embossed zone being non-stretchable with said backing and adhesive layers impregnating said cover layer and being in a non-stretchable state, said embossed non-stretchable marginal part being in a more stretched state than said flat zone.

2. A laminated flexible material as defined in claim 1, wherein said embossed non-stretchable marginal part forms a margin outlining the embossed zone, located adjacent said flat zone and extending at an angle with respect to said flat zone.

3. A laminated flexible material as defined in claim 2, wherein said embossed zone further includes a part which is surrounded by said margin and which is fully stretchable, the portions of said cover, backing and adhesive layers included in said part being stretchable, said portion of said cover layer not impregnated by the registering portions of said adhesive and backing layers.

4. A laminated flexible material as defined in claim 1, wherein said non-stretchable flat zone and said embossed non-stretchable marginal part are made non-stretchable by heat treatment to a temperature above the melting point of said thermo-plastic material, so as to cause said last-named material to melt and then solidify to a continuous state impregnating the fabric of said cover layer.

5. A laminated flexible material as defined in claim 1, wherein said backing layer is initially a polyurethane foam and said adhesive layer is made of a polyurethane cell-less film.

6. A laminated flexible material as defined in claim 1, wherein the areas of the cover layer located in said flat zone and the areas of said cover layer located in said embossed zones, are printed with different colors.

7. A method of producing a laminated flexible material, with an image forming embossed zones surrounded by a flat zone, comprising: providing a male and a female die engraved to form said image, inserting between said dies an assembly of three superposed sheets, namely: a cover sheet next to said female die, an intermediate adhesive sheet and a backing sheet, said cover sheet made of woven or knitted fabric stretchable in two perpendicular directions, said adhesive and backing sheets made of a stretchable thermo-plastic material;
heating said die to a temperature sufficient to melt said adhesive sheet and said backing sheet when said sheets are pressed by said dies;
pressing said assembly of three sheets between said heated dies for a time sufficient to melt the backing and adhesive sheets at least in part and cause the same to impregnate the cover sheet and to cause said adhesive sheet to produce adhesion of said cover sheet to said backing sheet;
releasing said dies and allowing said assembly to cool to room temperature.

8. A method as defined in claim 7, wherein said cover sheet is a fabric made of a yarn selected from group consisting of a synthetic resin and cotton, said adhesive sheet is a polyurethane film, and said backing sheet is a polyurethane foam.

9. A method as defined in claim 8, wherein said dies are heated to a temperature between 300°F and 450°F, and the pressing step is effected at a pressure of about 2,000 pounds per square inch and for a duration varying between 10 and 12 seconds.

10. A method as defined in claim 7, wherein said die-plates are formed with flat areas and with image areas surrounded by said flat areas, said image areas including image-shaped protrusions protruding from the flat area of said main die and corresponding image-shaped cavities made in the flat area of said female die, at least a portion of said protrusions and cavities mating and contacting each other when the die flat areas are in contact.

11. A method as defined in claim 10, wherein another portion of said protrusions and cavities are spaced from one another when the die flat areas are in contact.

12. A method as defined in claim 7, further including coloring said cover sheets by pressing and heating a color transfer paper onto said cover sheet.

13. A method as defined in claim 12, wherein said pressing and heating is effected in an enclosed space, said color transfer paper containing a colouring pigment capable of sublimation at the temperature obtained in said space, the cover layer made of a fabric consisting of yarns of synthetic resin.