CN1486223A - 包括用热塑性聚合物薄膜施加转移物的植绒转移物及制品 - Google Patents

包括用热塑性聚合物薄膜施加转移物的植绒转移物及制品 Download PDF

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CN1486223A
CN1486223A CNA018218857A CN01821885A CN1486223A CN 1486223 A CN1486223 A CN 1486223A CN A018218857 A CNA018218857 A CN A018218857A CN 01821885 A CN01821885 A CN 01821885A CN 1486223 A CN1486223 A CN 1486223A
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路易斯·B·艾布拉姆斯
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Abstract

通过将脱膜剂涂在可除粘合片材上，再在可脱膜剂上施加植绒(15)可以生产植绒的转移物(1)。与传统方法不同，在植绒背面加上粘合剂和热塑性热熔薄膜。通过将一片热塑性热熔薄膜(13)放在衬底(15)上；将转移物放在热熔薄膜上，使植绒与热熔薄膜接触；并加上热量和压力，可将主要由可除粘合片材组成的转移物(1)加在衬底(如衣服、橡胶垫等)(15)上。热量使热塑性热熔薄膜熔化，将植绒粘接在衬底上，并将植绒绒毛粘接在一起。这种方法可降低生产植绒制品的成本，特别是连续生产制品的成本。

Description

包括用热塑性聚合物薄膜施加 转移物的植绒转移物及制品
技术领域
本发明涉及植绒转移物(flocked transfer)，更具体地说，涉及包括热塑性聚合物薄膜的制造植绒转移物的改进方法，这种方法可将制造转移物的成本和所需的时间减少很多。
背景技术
以前，植绒转移物一般是将脱膜剂(release agent)涂在可除粘合片材(release sheet)上制造的。以所希望的图形将植绒绒毛加在可除粘合片材上。将粘合剂和永久的热熔性粘接剂涂在植绒的背面，并使转移物干燥。需要粘合剂来保持所希望的植绒图形。作为粉末加在转移物上的热熔性粘接剂，用于将转移物粘接在衬底(例如，衣服、橡胶垫等)上。通过将转移物设置在衬底上，使干燥的热熔性粘接剂与衬底接触，可将转移物加在衬底上。将诸如熨斗来的热量加在可除粘合片材上。热量将热熔性粘接剂熔化，使热熔性粘接剂流动，与衬底紧密接触，并与衬底形成机械或物理的粘接。然后，脱膜剂将可除粘合片材从转移物上清除掉，使植绒绒毛在衬底上露出。
这个传统方法一直使用了多年。然而，该方法可以改善，以降低制造转移物的成本和包括转移物的物品的成本。
在我们正在审查中的申请中，说明了利用热固性薄膜代替粘合剂和粉末进行粘接。该薄膜受热时，可粘接在衬底上，起到粘接植绒的作用。本发明对这个过程作了进一步的改进，使用热塑性薄膜来粘接植绒转移物。
发明内容
一般来说，根据本发明，本发明的植绒转移物是通过将脱膜剂涂在可除粘合片材上，再将植绒加在脱膜剂上制成的。与传统方法不同，不将粘合剂和粘接剂涂在植绒的末端，而相反，利用热塑性聚合物薄膜来代替粘合剂和粘接剂。
为了制造带有植绒转移物的制品，将热熔薄膜(切成一定形状的片材形式)放置在要加上转移物的衬底上。该热熔薄膜最好为坯料或坯料薄膜，但可以使用热塑性类型的聚合物薄膜。带有可脱膜粘接剂和可除粘合片材(即，转移物)的植绒，放置在热熔薄膜片材上，使可除粘合片材在上面，这样，植绒绒毛可与热熔薄膜接触。再将热加在转移物上。热量使热熔薄膜熔化，并将植绒固定在衬底上。因为薄膜是热塑性的，因此即使接着在某一具体温度以下受热作用，也不会再熔化，也不会发粘。这样，纤维没有被任何这种形式的粘接剂缠结的危险，而这种缠结会损坏长毛绒的绒毛效果。众所周知，热塑性材料的粘接力大，因为热塑性材料是交联性材料，可以粘接植绒纤维，用化学方法固定植绒纤维。通过使用本发明，因为比目前所用的使用筛网印花胶乳的方法，有更多的纤维露出和向上伸出在粘接剂外面，因此最终的植绒表面更像长毛绒，更柔软。另外，因为在使用过程中，纤维/粘接剂很少与植绒缠结在一起，因此清洗或清洁过程中能更好地去除污物。
使用热塑性类型的薄膜来将转移物粘接在表面上可以在热转移工序之前或之后，或在利用热形成转移物时进行。可以在制造转移物的任何阶段，将热塑性薄膜放入工序中。最实际的方法是，在加热制成转移物之前，以方便和轻便的方式放入热熔薄膜，而这种工作在先前使用热固性薄膜的情况下是不可能的，因为热固性薄膜被加热后会固化，并不可能重新加热。
另外，可以使用二部分式的热塑性薄膜，例如通常在工业中所用的那样。这种薄膜每一部分的熔点和结构的粘性等性质不同。这样，可以在与植绒纤维接触的一侧，使用熔点较高的热熔性热塑材料薄膜，使转移物开始能以较大的热量放在一起，以便将纤维安放就位；然后在接下去将转移物加在纺织品上过程中，可用较低的温度进行，以激活在衬底上的热熔薄膜，但不能太热，以致使固定植绒的薄膜重新熔化。另外，固定植绒的热熔薄膜的粘性可以非常高，即当熔化时，流动性不是很好，以便将纤维保持在规定位置，并不会缠结在一起。同时，衬底上的薄膜的粘性可以较低，使它容易流动，这样，薄膜可渗透转移物，并使转移物或格栅能与加上转移物的任何衬底很好地机械粘接在一起。
本发明的目的是要提供一种可以暂时将植绒粘接在由热塑性薄膜制成的可脱膜的薄膜载体上的方法。本发明的另一个目的是提供一种在开始形成转移物时，可以使用热熔薄膜作为中间层，将纤维固定在衬底上的方法。
附图说明
图1为现有技术的植绒转移物的横截面图；
图2为本发明的植绒转移物的横截面图；
图3为用于制造制品的转移物、热熔性片材和衬底的分解图；
图4为使用本发明的转移物的制品的横截面图，它表示加在一部分衬底上的一部分转移物，和与衬底隔开的一部分转移物和热熔薄膜；
图5为用于连续生产制品(例如鼠标垫、垫子、加在衣服上的转移物等)的过程的示意图。
在几个附图中都使用相应的附图标记。
具体实施方式
下面，用例子来详细说明本发明，这些例子不是对本发明的限制。这个说明可使本领域的技术熟练的人可以使用本发明，包括本发明的优选实施例。
图1表示现有技术的植绒转移物101。如图所示，这种转移物包括一个尺寸稳定的可除粘合片材103，在该片材上施加传统的植绒转移物的可脱膜的粘接剂105，施加的图形与要植绒的总图像相对应。然后，用静电方法将植绒107涂覆在可除粘合片材105上。将粘合性粘接剂109涂在植绒的露出的末端上，将植绒像一个整体一样粘接在一起。最后，涂上热熔性粘接剂111。然后使转移物干燥。通过将转移物放在衬底(例如，衬衣、外套或衣服的其它部件)上，同时使热熔性粘接剂与衬底接触，并将该粘接剂涂在转移物上，而将转移物加在衬底上。热量可激活热熔性粘接剂，将转移物粘接在衬底上。这样过程在本人先前的专利-美国专利4810549号，以及本人2000年4月13日提出的，序列号为09/548839的正在审查中的申请中作了说明。这里引入两个专利供参考。
另外，在本人2000年7月24日提出的、序列号为09/621830的申请中，说明了一种使用热固性薄膜的、与本发明的转移物相似的转移物。这里介绍该申请的内容供参考。
本发明的植绒转移物1如图2所示。本发明的转移物1包括一个可除粘合片材3，在其上涂上传统的脱膜剂(例如，蜡)或其他粘合剂。脱膜剂按照植绒图形的形状涂在该可除粘合片材上。然后，将植绒绒毛7加在脱膜剂和可除粘合片材上，以形成转移物，植绒绒毛7可按本人先前的专利和申请中所述的方法加上去，这里引入这些专利和申请供参考。与现有技术的过程不同，不使用粘合性粘接剂或热熔性粘接剂来制造转移物1。如以下所述，利用热塑性薄膜将转移物粘接在衬底上。
根据本发明可以制造一种制品，例如：加上转移物1的衣服的部件，或鼠标垫、垫子，或任何其他许多具有植绒表面的大量物品。利用转移物1很容易制造这些制品。通过将热熔性片材13放在衬底15和植绒的可除粘合片材之间，即可制成物品11。热熔性片材为(例如)包括聚酯的热塑性聚合物片，这种聚合物由Bostik公司销售。热熔性片材也可由热塑性聚亚胺酯制成。任何其他热塑性薄膜也可用。衬底15可以为衣服的部件、橡胶垫(例如，用于生产鼠标垫或垫子)等。可以预先切割热熔性片材，使它与转移物的形状相适应。再将转移物1放在热熔性片材上，使植绒5在热熔性片材13上。将热量通过可除粘合片材加在转移物上，以激活热熔性片材。热熔性片材可以将植绒5粘接在一起，并且可以基本上永久地将植绒5粘接在衬底15上。最好，组装制品时，将植绒的可除粘合片材、热塑性薄膜和衬底放在一起，并且通过热层叠压力机压紧。在该压力机中，三个零件在大约300°F～350°F(一般超过150℃)温度和压力(大约40～50磅/平方英寸)下，压制大约30秒。在组装这种形式的长毛绒似的植绒转移物时，最好压力为中至较大值。压力和热量可使热熔性片材粘接在植绒和衬底上。另外，热熔薄膜可物理粘接或固化，使植绒牢固地固定在衬底上。
在使用热将转移物加在衬底上后，使用半固化的热塑性薄膜的基本前提是，在加热后，如果转移物的温度没有升高至特定的热量水平，则转移物不会再熔化。换句话说，目的是要使用熔点相当高的热熔薄膜，使得当给转移物加热时，它可粘接在衬底上；但当转移物和要加上转移物的衬底不暴露在过热之中时，即使聚合物薄膜为热塑性的，转移物也不会再熔化。在实际使用中，因为没有这样高的温度，因此薄膜不会再熔化。换句话说，如果热塑性薄膜的熔点为350°F，而植绒的最终产品遇到的最高温度(例如，在被太阳光晒热的汽车内)只为250°F，除非遇到了过高的温度，则理论上不会有热塑性薄膜再熔化的问题。
使用热塑性薄膜的另一个好处是，当希望从衣服的部件上除去植绒的转移物时，将转移物再次放在高温下就可以除去植绒。
诸如鼠标垫或垫子一类整个顶面都被植绒绒毛覆盖的物品，可用图5所示的连续方法生产。在该生产方法中，利用植绒的可除粘合片材1的辊子21、23和25，热塑性热熔薄膜13和衬底15。在层叠工作站33中，将该三种零件放在一起。在工作站33的前面放置辊子，使得在零件进入层叠工作站时，使三个零件互相靠近。在层叠工作站中，对三个片材(植绒的可除粘合片材、热熔薄膜和衬底)施加热和压力，使热熔薄膜熔化。如上所述，该熔化的热熔薄膜固化或交联，将植绒粘接在衬底上。幅片35从层叠工作站送出，然后再冷却幅片35。最后，将幅片35送至切割站，切成单个制品。在幅片35冷却后，可以立即将它送至切割站(在幅片35冷却以后)；或卷缠在一个直立的辊子上，晚些时候或在不同的位置再切成单个物品。在切割站，将可除粘合片材从植绒上除去，并将可除粘合片材收集在卷取辊上，或抛弃。在将可除粘合片材从植绒上除去后，切割粘有植绒的衬底，形成物品11。可以在模切工序以前或以后除去可除粘合片材。
最好，如图5所示，将可除粘合片材植绒，并成卷地供应。可除粘合片材的植绒可以是该连续生产过程的一部分。
为了生产诸如衬底、夹克、装运动物品的袋子等一类不容易连续植绒的植绒产品，可以在将转移物加在衬底上之前，将热熔性片材加在转移物1上。为了做到这点，可使热塑性热熔薄膜与转移物的植绒接触，并将转移物和可除粘合片材加热至热塑性热熔薄膜变得发粘的温度，但低于热塑性热熔薄膜开始固化或实际粘接的温度。这样，可将热塑性热熔薄膜粘接在转移物1上，形成后来可加在物品上的转移物。该转移物加在物品上的方法是：将带有热熔薄膜的转移物放置在物品(例如，一件衣服)的规定位置上，并利用熨斗对转移物加热和加压力，使热熔薄膜熔化，再使该热熔薄膜固化或实际粘接把植绒粘接和固定在衣服上。
该方法消除了现有技术方法的二个步骤：(1)涂敷粘合性粘接剂，和(2)涂敷、清洁、烧结和干燥热熔性粘接剂。在连续过程中，本方法也不需要涂敷热熔性粘接剂的粘合剂的工作站，以及干燥完成的转移物的工作站。因为不需要将粘合剂和热熔性粘接剂涂在(即，印在)作为转移物的一部分的植绒绒毛上的工作站，因此，生产制品11的机械价格非常低廉(实际成本和维护成本)。另外，因为不使用粘合性粘接剂和热溶性粘接剂，制品的成本也合理降低。
为了提高制造本发明的转移物的性能，热塑性薄膜可以为双层薄膜层叠形式。例如，薄膜的上表面可以包括熔点温度较高的聚酯。层叠的下层薄膜可以为熔点温度较低的聚乙烯薄膜。因此，当在层叠薄膜的上表面上植绒时，用静电方法或其他方法加热可使植绒稍微嵌入该薄膜中。当在转移物冷却后，层叠的薄膜的底面软化时，薄膜结构中的所有薄膜结构再一次变得坚固。当为了将转移物加在纺织品、橡胶或其他表面上，而向转移物施加较低的热量时，底部的聚乙烯或EVA薄膜会稍微软化或熔化，起到将整个转移物加在其支承衬底或表面上的粘接剂的作用。这是一个如何不仅将本发明的热塑性薄膜用于制造转移物，而且可使用双层该薄膜，在其最后施加过程中将转移物加在衬衫、袋或其他材料上的例子。
在制造植绒转移物时使用热塑性材料的另一个优点是，在植绒过程中先前使用的粘合性粘接剂一般含有丙烯酸或其他易燃材料。而热塑性材料可以避免这个问题。另外，热塑性类型的粘合剂耐清洗，在严酷的清洗条件下仍能将植绒保持在规定位置上。此外，热塑性薄膜的弹性比热固性或其他现在正使用的热熔性系列的其它粘合剂的弹性好。另外，当用于衣服或其他防织品时，使用热塑性薄膜可使最终产品的外形较轻薄，使植绒转移物在加到衣物或其他纺织品上时看起来和结构上不太笨重。例如，根据本发明制造的植绒转移物可以用在极薄的衣服幅片上。使用本发明的热塑性薄膜不需要施加先前使用的粘合剂。另外，在现有技术中，为了使植绒交联，而在先前使用的粘合剂中含有甲醛或其他不希望的化学物品。相对于使用粘合剂与热熔性粉末的组合，使用热塑性薄膜可以提高薄膜的其他各种性质，而薄膜的这些性质是粘合剂-粉末系统不能得到的或所没有的。例如，使用热塑性薄膜时，可与皮草或其他难以粘附的表面粘接，使产品拉伸强度较大，拉伸时不会裂开。
技术熟练的人，在研究本发明后，可对所述的本发明的内容作一些改变或改进。在本发明范围内的这种改变都包括在本发明的权利要求书内。附图所示的优选实施例的说明只是说明性的。

Claims (15)

1.一种植绒转移物，它主要由可除粘合片材、在该可除粘合片材上的脱膜剂和在脱膜剂上的植绒组成；植绒形成所希望的图形；脱膜剂将植绒保持在可除粘合片材上，转移物粘接在衬底上，衬底上涂上热塑性热熔薄膜片材。
2.如权利要求1所述的植绒转移物，其中，热塑性薄膜为热塑性坯料或热塑性坯料薄膜。
3.一种生产具有植绒表面的制品的方法，该方法包括：
送入一块包括粘接有植绒的可除粘合片材的植绒的可除粘合片材；
将热塑性热熔薄膜粘接在植绒的可除粘合片材的植绒上；和
将热塑性热熔薄膜粘接在衬底上，以便将植绒粘接在衬底上。
4.如权利要求3所述的方法，其中，将热塑性热熔薄膜粘接在植绒的可除粘合片材上的步骤包括：将热塑性热熔薄膜加热至热熔薄膜变得发粘的温度，但低于热熔薄膜开始固化或实际上粘接的温度。
5.如权利要求3所述的方法，其中，将热塑性热熔薄膜粘接在衬底上的步骤包括：将热熔薄膜加热至它固化和交联的温度。
6.如权利要求5所述的方法，其中，将热熔薄膜加热至大约300°F。
7.如权利要求3所述的方法，其中，将热塑性热熔薄膜粘接在植绒的可除粘合片材上的步骤和将热塑性热熔薄膜粘接在衬底上的步骤，基本上可同时在一道工序中进行。
8.如权利要求3所述的方法，其中，该方法是连续的。
9.如权利要求3所述的方法，其中，热塑性薄膜为热塑性聚亚胺酯坯料或热塑性聚酯坯料。
10.一种连续生产具有植绒表面的制品的方法，该方法包括：
提供主要由加上植绒的可除粘合片材组成的植绒的可除粘合片材；
提供热塑性热熔薄膜；
提供衬底；
在可除粘合片材和衬底之间将衬底、热塑性热熔薄膜和植绒的可除粘合片材以及热熔薄膜放在一起；并使植绒与热塑性热熔薄膜接触，生产预备组件；
将热量加在预备组件上，以便将植绒绒毛粘接在衬底上；和
将可除粘合片材从植绒绒毛上除去，以制成植绒的衬底。
11.如权利要求10所述的方法，它包括将压力加在预备组件上的步骤。
12.如权利要求11所述的方法，其中，施加热量的步骤包括将预备组件加热至大约300°F。
13.如权利要求10所述的方法，其中，热塑性热熔薄膜为热塑性聚酯或热塑性聚亚胺酯。
14.如权利要求10所述的方法，它包括将植绒的衬底切成所希望的形状以形成制品的步骤。
15.如权利要求10所述的方法，它包括将植绒的衬底收集在产品辊子上的步骤。
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ATE416041T1 (de) 2008-12-15
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