CA2124736C - Method of manufacturing appliqued tree skirt - Google Patents
Method of manufacturing appliqued tree skirtInfo
- Publication number
- CA2124736C CA2124736C CA002124736A CA2124736A CA2124736C CA 2124736 C CA2124736 C CA 2124736C CA 002124736 A CA002124736 A CA 002124736A CA 2124736 A CA2124736 A CA 2124736A CA 2124736 C CA2124736 C CA 2124736C
- Authority
- CA
- Canada
- Prior art keywords
- layer
- layers
- mold
- adhesive
- temperature
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
Landscapes
- Decoration Of Textiles (AREA)
- Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
Abstract
A method of producing an appliqued construction which includes providing a mold of predetermined shape at least part of the mold having an embossed pattern.
Sequentially inserting into the mold a plurality of layers of material including a base layer, one or more additional layers with adhesive for securing the layer to its adjacent layer. At least one of the additional layers has a smaller dimension than the base layer. A three-dimensional resilient layer is trapped by a covering layer, also with adhesive means. Heat and pressure are applied to the multilayer construction to activate the adhesive and to secure each layer. The embossed pattern in the mold being transferred to one or more of the layers, to produce an appliqued construction from the mold having a plurality of layers at least one of which is a resilient three-dimensional layer and at least one of which has an embossed pattern on a portion thereof.
Sequentially inserting into the mold a plurality of layers of material including a base layer, one or more additional layers with adhesive for securing the layer to its adjacent layer. At least one of the additional layers has a smaller dimension than the base layer. A three-dimensional resilient layer is trapped by a covering layer, also with adhesive means. Heat and pressure are applied to the multilayer construction to activate the adhesive and to secure each layer. The embossed pattern in the mold being transferred to one or more of the layers, to produce an appliqued construction from the mold having a plurality of layers at least one of which is a resilient three-dimensional layer and at least one of which has an embossed pattern on a portion thereof.
Description
2 212~736 BACRGROUND OF THB lNV~ lON
This invention relates to a process of producing a three-dimensional raised letter and/or design affect on a textile decoration which is intended to be used but not necessarily limited to Christmas decorations, such as tree skirts, table covers, wall hangings and the like.
Briefly, the process involves cutting of textile fabrics by various standard methods which may be die-cut methods or power knife methods, and compressing these cut-out parts into a cavity mold formed with a 3-D effect. Some of these component parts are coated with a heat activated adhesive and pressed utilizing a heat transfer machine calibrated to specific pressures and temperatures as required by the particular components and design.
~UMMARY OF THE l~.v~.~lON
Accordingly, a principal object of the invention is to provide a method of producing a three-dimensional applique construction wherein multiple layers of textiles are nested in a cavity mold and thereafter subjected to suitable temperatures and pressures causing the various layers to be bonded one to another.
Another object of the invention is to provide a layered product with raised 3-D affect capable of being mass produced.
The invention consists of certain novel features and a combination of parts hereinafter fully described, illustrated in the accompanying drawings, and particularly pointed out in the appended claims, it being understood that various changes in the details may be made without departing from the spirit, or sacrificing any of the advantages of the present invention.
BRIEF DESCRIPTION OF THE DRAWING~
For the purpose of facilitating an understanding of the invention, there is illustrated in the accompanying drawings a preferred embodiment thereof, from an inspection of which, when considered in connection with the following description, the invention, its construction and operation, _ 3 and many of its advantages should be readily understood and appreciated.
FIGURE 1 is a top view of a representative table covering or tree skirt incorporating the invention; and FIG. 2 is a side view of the 3-D textile product of Fig. 1 showing the relationship of the various layers.
DETAILED DESCRIPTION OF THE l~.v~..,lON
The appliqued product 10 is comprised of a series of layers secured by a method to be described. Base layer 15 shown in Fig. 1 is provided with scalloped edges 16 having an upper surface 17 and opposed lower surface 18. As seen in Fig. 2, the background layer 20 which overlies a portion of the base layer 15 has an upper surface 22 and a lower opposed surface 23 with adhesive 24 intermediate the layers 15 and 20. Generally, the adhesive 24 is carried on the back of layer 20 but that is not required. An embossed portion 25 is shown particularly on the background layer 20 but it should be understood that an embossment may be on the base layer 15 or portions thereof if desired, or on other layers as hereinafter set forth.
A 3-dimensional layer 30 is shown for purposes of illustration in sequence above the background layer 20. The 3-dimensional layer 30 is preferably a resilient material such as an open cell polyurethane foam which gives the 3-D
effect to the construction or applique 10. The three-dimensional layer 30 has an upper surface 32 and a lower surface 33, the lower surface 33 resting on the upper surface 22 of the background layer 20. A cover layer 35 overlays the three-dimensional layer 30 and is larger in dimension than the three-dimensional layer 30 so as to fix same with respect to the entire construction 10. The cover layer 35 has an upper surface 37 and a lower surface 38 which carries an adhesive 39 so as adhesively to secure the cover layer 35 to the background layer 20 while at the same time positioning and fixing the three-dimensional layer 30 with respect to the applique 10 and more particularly to the background layer 20. As seen, the cover layer 35 is preferably constructed with an adhesive backing 39 and is larger in extent than the three-dimensional layer 30 so that when the mold compresses the covering layer 35, the adhesive backing 39 secures the three-dimensional layer 30 in place while for instance, the lettering or other indicia formed by the mold and the cover layer 35 is formed.
The individual components of the applique 10 are formed by the following process wherein the mold is opened and the cover or lettering component of the applique 10 in the form of cover layer 35 which may have already been attached to the three-dimensional die cut layer 30 that may be in the form of letters or other indicia or ornamentation is placed face down into a cavity in the mold which is designed specifically to accept and produce the desired product 10. The cover layer 35 with the three-dimensional layer 30 attached thereto is positioned in the mold by known pins which may be retractable. The background layer 20 is placed face down over the cover layer 35 and three-dimensional layer 30 and is positioned in place with a spray adhesive which permits a certain amount of repositioning of the background layer 20 until all of the component parts in the mold are in the correct position. After all the parts have been aligned properly and the primary layer or base layer 15 is positioned on top of the background layer 20 and again held in place with spray adhesive which permits a certain amount of repositioning, then the cavity mold is closed or with a tabletop mold the tabletop is settled under the heat transfer machine which compresses the various layers into the mold while heating same.
In a preferred method, the layers are heated to a temperature of about 400~F at a pressure of about 125 pounds per square inch and maintained at that temperature and pressure for about 25 seconds. Thereafter, a cool down is accomplished until the temperature of the components reaches about 250~F where the components are held at that temperature for approximately another 25 seconds. The spray adhesive used is a styrene butadiene rubber spray and the permanent adhesive on the backs of the various layers are also any rubber heat activated adhesive but also may be of 212~7~
the styrene butadiene type. The exact chemical compound of the adhesive is not a part of the invention with the exception that it must be activated by heat. It is within the skill of the art to determine the various temperatures and pressures at which specific adhesives must be maintained in order properly to bond the various layers one upon the other. In the preferred construction, the textile layers, that is the base layer 15, the background layer 20 and the cover layer 35 are synthetic organic resins of the non-woven type which may be acrylates or polyesters or combinations of both with the acrylate being the front face and the polyester being the rear surface, in one construction.
While there has been disclosed what is considered to be the preferred embodiment of the present invention, it is understood that various changes in the details may be made without departing from the spirit, or sacrificing any of the advantages of the present invention.
This invention relates to a process of producing a three-dimensional raised letter and/or design affect on a textile decoration which is intended to be used but not necessarily limited to Christmas decorations, such as tree skirts, table covers, wall hangings and the like.
Briefly, the process involves cutting of textile fabrics by various standard methods which may be die-cut methods or power knife methods, and compressing these cut-out parts into a cavity mold formed with a 3-D effect. Some of these component parts are coated with a heat activated adhesive and pressed utilizing a heat transfer machine calibrated to specific pressures and temperatures as required by the particular components and design.
~UMMARY OF THE l~.v~.~lON
Accordingly, a principal object of the invention is to provide a method of producing a three-dimensional applique construction wherein multiple layers of textiles are nested in a cavity mold and thereafter subjected to suitable temperatures and pressures causing the various layers to be bonded one to another.
Another object of the invention is to provide a layered product with raised 3-D affect capable of being mass produced.
The invention consists of certain novel features and a combination of parts hereinafter fully described, illustrated in the accompanying drawings, and particularly pointed out in the appended claims, it being understood that various changes in the details may be made without departing from the spirit, or sacrificing any of the advantages of the present invention.
BRIEF DESCRIPTION OF THE DRAWING~
For the purpose of facilitating an understanding of the invention, there is illustrated in the accompanying drawings a preferred embodiment thereof, from an inspection of which, when considered in connection with the following description, the invention, its construction and operation, _ 3 and many of its advantages should be readily understood and appreciated.
FIGURE 1 is a top view of a representative table covering or tree skirt incorporating the invention; and FIG. 2 is a side view of the 3-D textile product of Fig. 1 showing the relationship of the various layers.
DETAILED DESCRIPTION OF THE l~.v~..,lON
The appliqued product 10 is comprised of a series of layers secured by a method to be described. Base layer 15 shown in Fig. 1 is provided with scalloped edges 16 having an upper surface 17 and opposed lower surface 18. As seen in Fig. 2, the background layer 20 which overlies a portion of the base layer 15 has an upper surface 22 and a lower opposed surface 23 with adhesive 24 intermediate the layers 15 and 20. Generally, the adhesive 24 is carried on the back of layer 20 but that is not required. An embossed portion 25 is shown particularly on the background layer 20 but it should be understood that an embossment may be on the base layer 15 or portions thereof if desired, or on other layers as hereinafter set forth.
A 3-dimensional layer 30 is shown for purposes of illustration in sequence above the background layer 20. The 3-dimensional layer 30 is preferably a resilient material such as an open cell polyurethane foam which gives the 3-D
effect to the construction or applique 10. The three-dimensional layer 30 has an upper surface 32 and a lower surface 33, the lower surface 33 resting on the upper surface 22 of the background layer 20. A cover layer 35 overlays the three-dimensional layer 30 and is larger in dimension than the three-dimensional layer 30 so as to fix same with respect to the entire construction 10. The cover layer 35 has an upper surface 37 and a lower surface 38 which carries an adhesive 39 so as adhesively to secure the cover layer 35 to the background layer 20 while at the same time positioning and fixing the three-dimensional layer 30 with respect to the applique 10 and more particularly to the background layer 20. As seen, the cover layer 35 is preferably constructed with an adhesive backing 39 and is larger in extent than the three-dimensional layer 30 so that when the mold compresses the covering layer 35, the adhesive backing 39 secures the three-dimensional layer 30 in place while for instance, the lettering or other indicia formed by the mold and the cover layer 35 is formed.
The individual components of the applique 10 are formed by the following process wherein the mold is opened and the cover or lettering component of the applique 10 in the form of cover layer 35 which may have already been attached to the three-dimensional die cut layer 30 that may be in the form of letters or other indicia or ornamentation is placed face down into a cavity in the mold which is designed specifically to accept and produce the desired product 10. The cover layer 35 with the three-dimensional layer 30 attached thereto is positioned in the mold by known pins which may be retractable. The background layer 20 is placed face down over the cover layer 35 and three-dimensional layer 30 and is positioned in place with a spray adhesive which permits a certain amount of repositioning of the background layer 20 until all of the component parts in the mold are in the correct position. After all the parts have been aligned properly and the primary layer or base layer 15 is positioned on top of the background layer 20 and again held in place with spray adhesive which permits a certain amount of repositioning, then the cavity mold is closed or with a tabletop mold the tabletop is settled under the heat transfer machine which compresses the various layers into the mold while heating same.
In a preferred method, the layers are heated to a temperature of about 400~F at a pressure of about 125 pounds per square inch and maintained at that temperature and pressure for about 25 seconds. Thereafter, a cool down is accomplished until the temperature of the components reaches about 250~F where the components are held at that temperature for approximately another 25 seconds. The spray adhesive used is a styrene butadiene rubber spray and the permanent adhesive on the backs of the various layers are also any rubber heat activated adhesive but also may be of 212~7~
the styrene butadiene type. The exact chemical compound of the adhesive is not a part of the invention with the exception that it must be activated by heat. It is within the skill of the art to determine the various temperatures and pressures at which specific adhesives must be maintained in order properly to bond the various layers one upon the other. In the preferred construction, the textile layers, that is the base layer 15, the background layer 20 and the cover layer 35 are synthetic organic resins of the non-woven type which may be acrylates or polyesters or combinations of both with the acrylate being the front face and the polyester being the rear surface, in one construction.
While there has been disclosed what is considered to be the preferred embodiment of the present invention, it is understood that various changes in the details may be made without departing from the spirit, or sacrificing any of the advantages of the present invention.
Claims (17)
1. A method of producing an appliqued construction, comprising providing a mold of predetermined shape, sequentially inserting into the mold a plurality of layers of material including a base layer, one or more additional layers with adhesive means for securing the layer to its adjacent layer, at least one of the additional layers having a smaller dimension than the base layer, a three-dimensional resilient layer, a covering layer with adhesive means, said covering layer being larger than and overlying the three-dimensional resilient layer, and applying heat and pressure to the multilayer construction to activate the adhesive and to secure each layer to its adjacent layer, whereby an appliqued construction is produced from the mold having a plurality of layers at least one of which is a resilient three-dimensional layer.
2. The method of claim 1, wherein the layers are heated at a temperature of about 400°F for a predetermined time .
3. The method of claim 1, wherein the layers are heated to an elevated temperature and pressure of about 125 psi is applied for a predetermined time.
4. The method of claim 1, wherein the base layer is a non-woven synthetic fabric.
5. The method of claim 4, wherein the base layer is a combination of polyacrylic and polyester.
6. The method of claim 5, wherein the layers are heated to a temperature of about 400°F for a period of about 25 seconds at a pressure of about 125 psi and thereafter cooled to a temperature of about 250°F and maintained at that temperature for a time of about 25 seconds and thereafter cooled to ambient temperature.
7. The method of claim 1, wherein the three-dimensional resilient layer is an open cell polyurethane foam.
8. The method of claim 1, wherein the layers are sprayed with an adhesive to maintain their relative positions during the heat and pressure treatment steps.
9. A method of producing an appliqued construction, comprising providing a mold of predetermined shape at least part of said mold having an embossed pattern therein, sequentially inserting into the mold a plurality of layers of material including a base layer, one or more additional layers with adhesive means for securing the layer to its adjacent layer, at least one of the additional layers having a smaller dimension than the base layer, a three-dimensional resilient layer, a covering layer with adhesive means, said covering layer being larger than and overlying the three-dimensional resilient layer, and applying heat and pressure to the multilayer construction to activate the adhesive and to secure each layer to its adjacent layer, said embossed pattern in said mold being transferred to one or more of the layers, whereby an appliqued construction is produced from the mold having a plurality of layers at least one of which is a resilient three-dimensional layer and at least one of which has an embossed pattern on a portion thereof.
10. The method of claim 9, wherein a portion of the layer next to the base layer is embossed.
11. The method of claim 9, wherein the base layer is embossed.
12. The method of claim 9, wherein the base layer and the adjacent layer are both embossed.
13. The method of claim 12, wherein the base layer is a combination of polyacrylic and polyester.
14. The method of claim 13, wherein the layers are heated to a temperature of about 400°F for a period of about 25 seconds at a pressure of about 125 psi and thereafter cooled to a temperature of about 250°F and maintained at that temperature for a time of about 25 seconds and thereafter cooled to ambient temperature.
15. The method of claim 9, wherein the three-dimensional resilient layer is an open cell polyurethane foam.
16. The method of claim 9, wherein the layers are sprayed with an adhesive to maintain their relative positions during the heat and pressure treatment steps.
17. The method of claim 16, wherein the adhesive spray is a styrene butadiene rubber adhesive.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US18978994A | 1994-02-01 | 1994-02-01 | |
| US08/189,789 | 1994-02-01 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2124736A1 CA2124736A1 (en) | 1995-08-02 |
| CA2124736C true CA2124736C (en) | 1998-12-15 |
Family
ID=22698785
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002124736A Expired - Fee Related CA2124736C (en) | 1994-02-01 | 1994-05-31 | Method of manufacturing appliqued tree skirt |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2124736C (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2592423A (en) * | 2020-02-27 | 2021-09-01 | Siukstiene Natalija | The use of a 3D printing technology with fabrics, textiles and leather |
-
1994
- 1994-05-31 CA CA002124736A patent/CA2124736C/en not_active Expired - Fee Related
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2592423A (en) * | 2020-02-27 | 2021-09-01 | Siukstiene Natalija | The use of a 3D printing technology with fabrics, textiles and leather |
Also Published As
| Publication number | Publication date |
|---|---|
| CA2124736A1 (en) | 1995-08-02 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| MKLA | Lapsed | ||
| MKLA | Lapsed |
Effective date: 20030602 |