EP2616583B1 - Applications of indicia designed with flocks to garments - Google Patents
Applications of indicia designed with flocks to garments Download PDFInfo
- Publication number
- EP2616583B1 EP2616583B1 EP11776867.1A EP11776867A EP2616583B1 EP 2616583 B1 EP2616583 B1 EP 2616583B1 EP 11776867 A EP11776867 A EP 11776867A EP 2616583 B1 EP2616583 B1 EP 2616583B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- flock
- applique
- recycled
- fibres
- adhesive
- 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.)
- Not-in-force
Links
- 244000144992 flock Species 0.000 title claims description 137
- 239000000853 adhesive Substances 0.000 claims description 65
- 230000001070 adhesive effect Effects 0.000 claims description 65
- 239000004753 textile Substances 0.000 claims description 32
- 239000000758 substrate Substances 0.000 claims description 19
- 238000013461 design Methods 0.000 claims description 17
- 239000004744 fabric Substances 0.000 claims description 15
- 239000012790 adhesive layer Substances 0.000 claims description 13
- 239000011888 foil Substances 0.000 claims description 13
- 239000000463 material Substances 0.000 claims description 11
- 230000004888 barrier function Effects 0.000 claims description 9
- 238000013508 migration Methods 0.000 claims description 8
- 230000005012 migration Effects 0.000 claims description 8
- 239000003086 colorant Substances 0.000 claims description 7
- 239000002131 composite material Substances 0.000 claims description 7
- 239000000835 fiber Substances 0.000 claims description 6
- 239000002184 metal Substances 0.000 claims description 5
- 239000000976 ink Substances 0.000 description 21
- 238000000034 method Methods 0.000 description 19
- 239000012943 hotmelt Substances 0.000 description 15
- 238000012546 transfer Methods 0.000 description 14
- 239000010410 layer Substances 0.000 description 10
- 230000008901 benefit Effects 0.000 description 8
- 238000007639 printing Methods 0.000 description 8
- 238000004519 manufacturing process Methods 0.000 description 7
- 229920000728 polyester Polymers 0.000 description 6
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 6
- 229920001169 thermoplastic Polymers 0.000 description 5
- 239000004416 thermosoftening plastic Substances 0.000 description 5
- 239000002365 multiple layer Substances 0.000 description 4
- 239000000843 powder Substances 0.000 description 4
- 229920001187 thermosetting polymer Polymers 0.000 description 4
- 229920002635 polyurethane Polymers 0.000 description 3
- 239000004814 polyurethane Substances 0.000 description 3
- 238000000859 sublimation Methods 0.000 description 3
- 230000008022 sublimation Effects 0.000 description 3
- 229920000742 Cotton Polymers 0.000 description 2
- 239000004831 Hot glue Substances 0.000 description 2
- 239000004952 Polyamide Substances 0.000 description 2
- 229920000297 Rayon Polymers 0.000 description 2
- 125000001931 aliphatic group Chemical group 0.000 description 2
- 125000003118 aryl group Chemical group 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 239000000945 filler Substances 0.000 description 2
- 239000003292 glue Substances 0.000 description 2
- 229920002647 polyamide Polymers 0.000 description 2
- 229920000098 polyolefin Polymers 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 238000007650 screen-printing Methods 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- 238000003466 welding Methods 0.000 description 2
- 241000196324 Embryophyta Species 0.000 description 1
- 239000004593 Epoxy Substances 0.000 description 1
- 235000010469 Glycine max Nutrition 0.000 description 1
- 244000068988 Glycine max Species 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 229920002472 Starch Polymers 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- 238000007605 air drying Methods 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 230000001010 compromised effect Effects 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000000151 deposition Methods 0.000 description 1
- 230000005686 electrostatic field Effects 0.000 description 1
- 238000004049 embossing Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 150000002148 esters Chemical class 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- -1 polypropylene Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 229920001296 polysiloxane Polymers 0.000 description 1
- 229920003226 polyurethane urea Polymers 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 238000004064 recycling Methods 0.000 description 1
- 239000008107 starch Substances 0.000 description 1
- 235000019698 starch Nutrition 0.000 description 1
- 239000010784 textile waste Substances 0.000 description 1
- 239000002918 waste heat Substances 0.000 description 1
Images
Classifications
-
- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- A41D27/00—Details of garments or of their making
- A41D27/08—Trimmings; Ornaments
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
- D06P5/00—Other features in dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form
- D06P5/003—Transfer printing
- D06P5/004—Transfer printing using subliming dyes
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06Q—DECORATING TEXTILES
- D06Q1/00—Decorating textiles
- D06Q1/12—Decorating textiles by transferring a chemical agent or a metallic or non-metallic material in particulate or other form, from a solid temporary carrier to the textile
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06Q—DECORATING TEXTILES
- D06Q1/00—Decorating textiles
- D06Q1/12—Decorating textiles by transferring a chemical agent or a metallic or non-metallic material in particulate or other form, from a solid temporary carrier to the textile
- D06Q1/14—Decorating textiles by transferring a chemical agent or a metallic or non-metallic material in particulate or other form, from a solid temporary carrier to the textile by transferring fibres, or adhesives for fibres, to the textile
Definitions
- the invention relates to application of designs to garments and other fabrics.
- Conventional appliques or transfers comprise man-made fibres that do not decompose and therefore are not susceptible to recycling.
- the invention is directed towards achieving more environmentally-friendly fabrics.
- GB2245220 , GB1597907 , US2008/302772 and US 4 396 662 disclose multilayer flock appliques comprising a substrate, a flock, an ink in the flock and an adhesive for adhering the applique to a fabric.
- an applique comprising:
- fibres are arranged in predefined areas extending uniformly across the carrier or substrate.
- the fibres are in groups comprising of a random number of fibres which have been flocked in a primarily uniform vertical orientation using an electrostatic flocking machine.
- the flock is printed with ink according to a design.
- the applique comprises at least two adhesive layers.
- the recycled flock applique is inserted into a flock print, to create a combination of surface textures.
- the recycled flock applique is inserted into a recycled flock print, to create a combination of surface textures.
- the applique comprises flock fibres of a plurality of colours and/or various recycled flock materials.
- the applique further comprises a recycled flock applique insert.
- the flock is over a textile substrate whereby textile creates structure for the print.
- the flock is over sublimated textile.
- the flock is over a foil, metal or foil film.
- the foil comprises a holographic pattern.
- the flock is over a migration-resistant barrier or migration-resistant barrier composite.
- a method of manufacturing an applique as described above comprising the steps of depositing the flock onto a carrier or substrate and applying an ink to the flock.
- the carrier or substrate is a disposable carrier.
- the flock is deposited onto a release adhesive.
- the method comprises forming a printed single colour or multicoloured recycled flocked surface using recycled flock fibres.
- the flock is applied by electrostatic flocking machine and flock fibres are flocked onto the release adhesive which is still wet.
- the fibres are in groups comprising of a random number of fibres which have been flocked in a primarily uniform vertical orientation using an electrostatic flocking machine, vertical flock orientation typically ranging from 60° to 120°.
- the method comprises the step of drying in an oven and removing any surplus and loose excess flock.
- a recycled flock applique is created using recycled textiles, inks and adhesive systems.
- the applique is "eco friendly" due to the recycled flock fibre surface and with water-based adhesive binder. Therefore, fewer raw materials are used in the manufacture of the applique.
- the substrate or carrier may be in any suitable flat sheet format, including a backing film or parchment.
- a recycled flock transfer includes a release flock adhesive which holds one end of the flock fibres which have been colour printed, while a permanent flocking adhesive binds the fibres together at the other end of the fibre filaments.
- a method of manufacturing a recycled flock applique includes the steps of:
- Figs. 1 to 10 show various manufacturing methods and constituents of appliques of the invention, indicated in the legends to the right side of the diagrams.
- Fig. 1(a) shows a disposable carrier 5 and a release adhesive 4 printed onto the carrier 5.
- the carrier 5 is of polyester, which also may be recycled.
- Fig. 1(b) shows recycled flock 2 deposited into the flock release adhesive 4. This is performed electrostatically, to achieve a high flock density.
- the recycled flock fibres have a sufficient electrical conductivity to respond to the electrostatic flocking process. Good flocking can only be achieved with correct humidity and temperature conditions, which are preferably 21°C and 65% relative humidity.
- the flock is applied into the wet adhesive using an electrostatic flocking machine.
- the flocking procedure is carried out with an electrostatic flocking machine, which charges the flock fibres with a voltage of 40 to 100 kV, enabling the fibres to be shot from the equipment to any grounded surface.
- This process is enabled using open screens to adhere onto the release adhesive.
- the flock fibres jump along the electrostatic field lines from the flocking chamber to any earthed surface. To ensure an evenly flocked surface this requires that the flocking chamber is moved over the surface of the substrate with always the same speed and distance for each flock chamber.
- the period of time during which the flocking has to be completed is called the "open time" of the release adhesive.
- the flock is dried in an oven or on a conveyor oven and any surplus flock (excess flock) is cleaned from the flock surface.
- the recycled textile materials are ground and sieved to textile length, typically 0.1mm to 1.2mm. These fibres, unlike conventional fibres, can be of random shape.
- the non-recycled material content averages 10% - 75 % of the weight of the transfer.
- the flock skeleton framework helps to provides vertical structure. It is compromised of recycled flock fibres and/or non-recycled flock fibres, typically known in the industry as double indexing.
- Fig. 1(c) shows how the applique is coloured using ink deposits 1 on recycled flock fibres.
- Colours can be applied to the design using silk screen printing ink application methods with a water base and/or digitally printing designs and/or sublimating digital images onto the recycled flock material. If a multi-colour design is printed, graphic items are allowed to dry between colours (using a batch oven or a conveyor oven), to allow water and/or solvent to evaporate from the ink. The graphic is then printed with a different colour. This process is repeated until all colours in the graphics have been printed. Water based ink and/or eco friendly inks such as soya-based inks can be used.
- the flock is printed using digital print technology according to the design requirements. Graphic items are allowed to dry after printing, either by air drying at room temperature or at elevated temperature in a conventional batch oven or a conveyor oven. Water-based digital inks and/or eco friendly digital inks can be used in this process
- sublimation printing is employed for ink application
- the flock is sublimated using sublimation print technology according to the design requirements. Graphic items are allowed to cool after sublimating, before sublimation transfer paper is removed.
- Fig. 1(d) shows an adhesive layer 3 is screen-printed onto the flock 2.
- a two-component flocking adhesive system is used during adhesive printing.
- This flocking adhesive may contain fillers. Fillers used in the adhesive printing preferably come from recycled materials. The period of time during which a two-component mixture of adhesive and catalyst has to be used up, is called "pot life”.
- a flocking adhesive is printed on top of the coloured graphics according to a design, using silk screen printing techniques. In order to achieve a sturdy and abrasion-resistant recycled flock product, it is necessary to ensure that tips of the flock fibres and part of the flock fibre strand length is immersed in flock adhesive, during the printing process. This means that the thickness of the dried adhesive has to be typically a fifth of the flock length.
- the adhesive is dried in an oven or on a conveyor oven; this step allows water and/or solvent to evaporate from the flocking adhesive. After drying has been completed the adhesive system can by cross-linked in an oven or a conveyor oven.
- a starch-based adhesive may be employed, so that it may be recycled.
- the adhesive layer 3 (and also the adhesive layers 21, 24, 31, and 40 of other embodiments) may be a permanent adhesive. It comprises of a thermoplast adhesive combined with a thermoset adhesive.
- the ratio of thermoplastic adhesive to thermoset adhesive is in the range of 0:100 to 100:0, preferably 0.1: 99.1 to 99.9:0.1, and most preferably 0.25:99.75 to 99.75:0.25
- thermoset adhesive coupled with thermoplastic powder.
- the powder can be made from an aromatic or aliphatic thermoplastic.
- the thermoset adhesive can include one or more (but not limited to) acrylic, polyamide; epoxy, polyester; polyolefin; polyurethane; and silicone and combinations thereof.
- the applique of this or the other embodiments is placed on the textile ( Fig. 1(e) ) heat is applied, and the disposable carrier (5, in this embodiment) is removed ( Fig. 2 ), leaving the adhesive layer 3 in contact with the textile. Heat and pressure are applied so that the hot-melt adhesive layer 3 softens onto the fabric (F) to adhere the applique in place, once above the film's initial glue line temperature.
- applications can be carried out using high frequency welding or ultrasonic bonding.
- the applique is applied by pressing under heat, in this example 160°C and 2 Bar for 20 seconds, allowed to cool, and the disposable carrier is peeled from the applique.
- a heat transfer or applique may incorporate customised ink layers to create a textured motif.
- the invention uses waste fibres from textile waste streams to create a recycled "environmentally responsible flock" heat transfer or applique.
- Recycled flock can be manufactured from recycled textiles (for example cotton, polyester, polypropylene, biological, composite, mineral or viscose rayon) and/or post industrial plastics converted into textiles and/or natural plant materials converted into textiles and/or renewable textile materials and/or a combination of any of the above which has been converted into textiles which in turn have been converted into flock.
- recycled textiles for example cotton, polyester, polypropylene, biological, composite, mineral or viscose rayon
- the raw materials can be used as a single source fibre or in hybrid format.
- Single or multicolour images can be digitally printed and screen printed onto the surface of the design which may use a range of environmentally-friendly ink systems.
- the design can be further enhanced by using a variety of artwork effects and techniques. Examples include embossing, encapsulating, and engraving.
- the product can also incorporate waste material from a number of in-house manufacturing streams. For example, a milled waste heat transfer may be recycled by incorporation into the adhesive layer.
- the heat transfer can be designed to incorporate a biodegradable carrier.
- a single or multicolour design insert may be added to the heat transfer.
- the design insert may be made from a range of conventional, alternative or convertible fabrics including organic textiles, Fig. 5(c) .
- An applique of Fig. 3 comprises a disposable carrier 25, and has a similar arrangement to Figs. 1 and 2 except that there is a recycled flock insert bonded to the flock applique.
- the recycled flock applique provides a background texture which can be applied in any graphic format.
- the various layers are applied as follows:
- An applique of Fig. 4 comprises a disposable carrier 35 and has a similar arrangement to Fig. 1(d) except that there is a recycled flock insert bonded to the recycled flock applique.
- the recycled flock applique provides a background texture which can be applied in any graphic format.
- the layers are applied as follows:
- An advantage of this system is that it is possible to create a multiple-layer recycled flock graphic.
- An applique of Fig. 5(a) .a comprises a disposable carrier 48 and has a similar arrangement to Fig. 1(d) except that multiple recycled flock fibres 41, 42 can be flocked during the flocking process.
- These flock fibres can be the same type of recycled flock but in different colours or flocks from different sources, for example. a recycled cotton flock, recycled viscose rayon flock, a recycled polyester flock, all flocked from different flocking chambers or stations.
- An adhesive layer is printed on top of all flock fibres to bond these together.
- An applique of Fig. 5(b) comprises a disposable carrier 48 and has a similar arrangement to Fig. 4 except that the recycled flock fibres are made up of different flock colour flock fibres or different types of flock fibres 41, 42.
- a recycled flock insert is bonded to the recycled flock applique (45, 46, 47).
- the recycled flock applique provides a background texture which can be applied in any graphic format.
- the various layers are applied as follows:
- An advantage of this system is that it is possible to create a multiple layer recycled flock graphic.
- An applique of Fig. 5(c) comprises a disposable carrier 48. It has a similar arrangement to that of Fig. 4 except that the recycled flock fibres are made up of different colour flock fibres or different types of flock fibres 41, 42. There a recycled fabric composite 49 insert bonded to the recycled flock applique.
- the recycled fabric composite provides a background texture and/o colour which can be applied in any graphic format.
- the various layers are applied as follows:
- An advantage of this system is that it is possible to create a multiple layer recycled flock graphic incorporating recycled fabric.
- a hotmelt film 52 is applied to a disposable carrier 53.
- Recyclable adhesive 51 is applied to the hotmelt, and this is flocked with flock 50.
- the hotmelt adhesive layer (51, 61, 71, 81, 91) comprises of a thermoplastic film made from an aromatic or aliphatic thermoplastic.
- the hotmelt film can include one or more (but not limited to) polyamide; polyester; polyolefin; polyurethane; polyurethane urea and polyurethane ester.
- the hot-melt film can be 76 micron Bemis Polyester Hotmelt Film 5250.
- the applique (59, 69, 79, 89, 99) is simply placed on the textile after removing the disposable carrier (53, 64, 74, 84, 94) with the hotmelt film adhesive layer in contact with the textile. Heat and pressure are applied so the hot-melt softens onto the fabric (F) to adhere the applique in place, once above the film's initial glue line temperature.
- applications can be carried out using the high frequency welding method or ultra sonic bonding method.
- FIG. 7 there is a similar arrangement except that there is textile (or alternatively another textile) on the hotmelt film.
- the satin provides a background so that the recycled flock can be applied in any desired pattern.
- a hotmelt film 63 is applied to a textile 62 (through a heat application process), adhesive 61 is applied to the textile prior to flocking and while adhesive is wet flock 60 is deposited into the wet adhesive.
- FIG. 8 An arrangement is shown in Fig. 8 in which there is no disposable carrier, and sublimated textile acts as a substrate.
- the textile is sublimated with a colour and/or pattern, a hotmelt film 73 is applied to a textile 72 (through a heat application process), adhesive 71 is applied to the textile prior to flocking and while the adhesive is wet flock 70 is deposited into the wet adhesive.
- FIG. 9 An arrangement is shown in Fig. 9 in which a foil, metal or holographic film acts as a substrate.
- a hotmelt film 83 is applied to a foil (through a heat application process), metal or holographic foil/film 82, adhesive 81 is applied to the foil prior to flocking and while the adhesive is wet flock 80 is deposited into the wet adhesive.
- a migration resistant barrier or composite barrier acts as a substrate.
- a hotmelt film 93 is applied to a barrier (through a heat application process) 92, adhesive 91 is applied to the barrier prior to flocking and while adhesive is wet flock 90 is deposited into the wet adhesive.
- the flock can be applied in a variety of positions in the layers to achieve the desired effects.
- recycled fibres may be flocked in-house onto a disposable carrier to produce a heat transfer in a number of steps.
- the steps include coating a disposable carrier film with release adhesive followed by flocking with recycled fibres.
- the pre-flocked sheets are then screen printed using environmentally friendly "eco" inks.
- An adhesive layer/hotmelt powder layer is screen printed to complete the applique.
- the resulting transfer is then applied to the garment using heat and pressure.
- the steps include coating disposable carrier film with release adhesive followed by flocking with recycled fibres.
- the pre-flocked sheets are then sublimated with inks.
- An adhesive layer/hotmelt powder layer is screen printed to complete invention.
- the resulting transfer is then applied to the garment using heat and pressure.
- recycled flock fibres are flocked in-house onto a substrate which includes a hotmelt film. There is application of an adhesive on the substrate followed by flocking with recycled fibres. The pre-flocked sheets are then screen printed using inks to complete the process. The resulting design can then be either laser or die cut and applied to the garment using heat and pressure.
- the benefit of an applique is that no additional disposable carrier is necessary, which adds to the environmental benefits of this product.
Description
- The invention relates to application of designs to garments and other fabrics.
- Conventional appliques or transfers comprise man-made fibres that do not decompose and therefore are not susceptible to recycling.
- The invention is directed towards achieving more environmentally-friendly fabrics.
-
GB2245220 GB1597907 US2008/302772 andUS 4 396 662 disclose multilayer flock appliques comprising a substrate, a flock, an ink in the flock and an adhesive for adhering the applique to a fabric. - According to the invention, there is provided an applique comprising:
- a substrate or carrier,
- flock derived from recycled material,
- ink in the flock, and
- an adhesive for adhering the applique to a fabric;
- wherein the flock comprises fibres of random length.
- In a further embodiment, fibres are arranged in predefined areas extending uniformly across the carrier or substrate.
- In one embodiment, the fibres are in groups comprising of a random number of fibres which have been flocked in a primarily uniform vertical orientation using an electrostatic flocking machine.
- In another embodiment, the flock is printed with ink according to a design.
- In a further embodiment, the applique comprises at least two adhesive layers.
- In one embodiment, the recycled flock applique is inserted into a flock print, to create a combination of surface textures.
- In another embodiment, the recycled flock applique is inserted into a recycled flock print, to create a combination of surface textures.
- In a further embodiment, the applique comprises flock fibres of a plurality of colours and/or various recycled flock materials.
- In one embodiment, the applique further comprises a recycled flock applique insert.
- In another embodiment, the flock is over a textile substrate whereby textile creates structure for the print.
- In a further embodiment, the flock is over sublimated textile.
- In one embodiment, the flock is over a foil, metal or foil film.
- In another embodiment, the foil comprises a holographic pattern.
- In a further embodiment, the flock is over a migration-resistant barrier or migration-resistant barrier composite.
- In another aspect, there is provided a method of manufacturing an applique as described above, comprising the steps of depositing the flock onto a carrier or substrate and applying an ink to the flock.
- In one embodiment, the carrier or substrate is a disposable carrier.
- In another embodiment, the flock is deposited onto a release adhesive.
- In a further embodiment the method comprises forming a printed single colour or multicoloured recycled flocked surface using recycled flock fibres.
- In one embodiment, the flock is applied by electrostatic flocking machine and flock fibres are flocked onto the release adhesive which is still wet.
- In another embodiment, the fibres are in groups comprising of a random number of fibres which have been flocked in a primarily uniform vertical orientation using an electrostatic flocking machine, vertical flock orientation typically ranging from 60° to 120°.
- In a further embodiment, the method comprises the step of drying in an oven and removing any surplus and loose excess flock.
- The invention will be more clearly understood from the following description of some embodiments thereof, given by way of example only with reference to the accompanying drawings in which:-
-
Figs. 1(a) to (e) are a series of cross-sectional diagrams showing stages of manufacturing of an applique of the invention, in whichFig. 1(a) shows a release adhesive on a disposable carrier,Fig. 1(b) shows application of recycled flock,Fig. 1(c) shows application of ink into the flock fibres, andFig. 1(d) shows the stage after adhesive has been bonded to the flock fibres to complete the applique; andFig 1.(e) is a view after heat application bonding to fabric; -
Fig. 2 is a view after removal of the disposable carrier; -
Figs. 3 to 10 are diagrammatic cross-sectional views showing appliques of various embodiments, in which:-
Fig. 3 shows use of an eco flock encapsulated by a flock print, -
Fig. 4 shows an eco flock encapsulated by a recycled flock transfer, -
Figs. 5(a) ,(b), and (c) show stages of manufacture of an applique with a mixed fibre eco flock transfer, -
Fig. 6 shows flocking directly onto an adhesive layer, -
Fig. 7 shows flocking directly onto a satin or textile material, -
Fig. 8 shows flocking directly onto a sublimated satin textile mat, -
Fig. 9 shows flocking directly onto a metal foil or holographic foil film, and -
Fig. 10 shows flocking directly onto a migration resistant barrier.
-
- A recycled flock applique is created using recycled textiles, inks and adhesive systems. The applique is "eco friendly" due to the recycled flock fibre surface and with water-based adhesive binder. Therefore, fewer raw materials are used in the manufacture of the applique.
- The substrate or carrier may be in any suitable flat sheet format, including a backing film or parchment. A recycled flock transfer includes a release flock adhesive which holds one end of the flock fibres which have been colour printed, while a permanent flocking adhesive binds the fibres together at the other end of the fibre filaments.
- A method of manufacturing a recycled flock applique includes the steps of:
- (i) providing a substrate or carrier comprising of recycled flock fibres and a flock adhesive,
- (ii) providing a substrate or carrier comprising of skeleton flock fibres and a flock adhesive,
- (ii) providing a coloured image in the design, and
- (iii) providing a permanent adhesive layer to bind recycled flock fibres.
-
Figs. 1 to 10 show various manufacturing methods and constituents of appliques of the invention, indicated in the legends to the right side of the diagrams. -
Fig. 1(a) shows adisposable carrier 5 and a release adhesive 4 printed onto thecarrier 5. Thecarrier 5 is of polyester, which also may be recycled. -
Fig. 1(b) shows recycledflock 2 deposited into the flock release adhesive 4. This is performed electrostatically, to achieve a high flock density. The recycled flock fibres have a sufficient electrical conductivity to respond to the electrostatic flocking process. Good flocking can only be achieved with correct humidity and temperature conditions, which are preferably 21°C and 65% relative humidity. The flock is applied into the wet adhesive using an electrostatic flocking machine. The flocking procedure is carried out with an electrostatic flocking machine, which charges the flock fibres with a voltage of 40 to 100 kV, enabling the fibres to be shot from the equipment to any grounded surface. This process is enabled using open screens to adhere onto the release adhesive. The flock fibres jump along the electrostatic field lines from the flocking chamber to any earthed surface. To ensure an evenly flocked surface this requires that the flocking chamber is moved over the surface of the substrate with always the same speed and distance for each flock chamber. - The period of time during which the flocking has to be completed is called the "open time" of the release adhesive. The flock is dried in an oven or on a conveyor oven and any surplus flock (excess flock) is cleaned from the flock surface.
- The recycled textile materials are ground and sieved to textile length, typically 0.1mm to 1.2mm. These fibres, unlike conventional fibres, can be of random shape. The non-recycled
material content averages 10% - 75 % of the weight of the transfer. - The flock skeleton framework helps to provides vertical structure. It is compromised of recycled flock fibres and/or non-recycled flock fibres, typically known in the industry as double indexing.
-
Fig. 1(c) shows how the applique is coloured usingink deposits 1 on recycled flock fibres. Colours can be applied to the design using silk screen printing ink application methods with a water base and/or digitally printing designs and/or sublimating digital images onto the recycled flock material. If a multi-colour design is printed, graphic items are allowed to dry between colours (using a batch oven or a conveyor oven), to allow water and/or solvent to evaporate from the ink. The graphic is then printed with a different colour. This process is repeated until all colours in the graphics have been printed. Water based ink and/or eco friendly inks such as soya-based inks can be used. - Where digital printing is used for ink application, the flock is printed using digital print technology according to the design requirements. Graphic items are allowed to dry after printing, either by air drying at room temperature or at elevated temperature in a conventional batch oven or a conveyor oven. Water-based digital inks and/or eco friendly digital inks can be used in this process
- Where sublimation printing is employed for ink application the flock is sublimated using sublimation print technology according to the design requirements. Graphic items are allowed to cool after sublimating, before sublimation transfer paper is removed.
-
Fig. 1(d) shows anadhesive layer 3 is screen-printed onto theflock 2. A two-component flocking adhesive system is used during adhesive printing. This flocking adhesive may contain fillers. Fillers used in the adhesive printing preferably come from recycled materials. The period of time during which a two-component mixture of adhesive and catalyst has to be used up, is called "pot life". A flocking adhesive is printed on top of the coloured graphics according to a design, using silk screen printing techniques. In order to achieve a sturdy and abrasion-resistant recycled flock product, it is necessary to ensure that tips of the flock fibres and part of the flock fibre strand length is immersed in flock adhesive, during the printing process. This means that the thickness of the dried adhesive has to be typically a fifth of the flock length. - The adhesive is dried in an oven or on a conveyor oven; this step allows water and/or solvent to evaporate from the flocking adhesive. After drying has been completed the adhesive system can by cross-linked in an oven or a conveyor oven.
- A starch-based adhesive may be employed, so that it may be recycled.
- The adhesive layer 3 (and also the
adhesive layers - Alternatively, it comprises of a thermoset adhesive coupled with thermoplastic powder. The powder can be made from an aromatic or aliphatic thermoplastic. The thermoset adhesive can include one or more (but not limited to) acrylic, polyamide; epoxy, polyester; polyolefin; polyurethane; and silicone and combinations thereof.
- To apply a design to a textile, the applique of this or the other embodiments is placed on the textile (
Fig. 1(e) ) heat is applied, and the disposable carrier (5, in this embodiment) is removed (Fig. 2 ), leaving theadhesive layer 3 in contact with the textile. Heat and pressure are applied so that the hot-melt adhesive layer 3 softens onto the fabric (F) to adhere the applique in place, once above the film's initial glue line temperature. Alternatively, applications can be carried out using high frequency welding or ultrasonic bonding. - The applique is applied by pressing under heat, in this example 160°C and 2 Bar for 20 seconds, allowed to cool, and the disposable carrier is peeled from the applique.
- In various embodiments a heat transfer or applique may incorporate customised ink layers to create a textured motif. The invention uses waste fibres from textile waste streams to create a recycled "environmentally responsible flock" heat transfer or applique.
- Recycled flock can be manufactured from recycled textiles (for example cotton, polyester, polypropylene, biological, composite, mineral or viscose rayon) and/or post industrial plastics converted into textiles and/or natural plant materials converted into textiles and/or renewable textile materials and/or a combination of any of the above which has been converted into textiles which in turn have been converted into flock.
- The raw materials can be used as a single source fibre or in hybrid format. Single or multicolour images can be digitally printed and screen printed onto the surface of the design which may use a range of environmentally-friendly ink systems.
- The design can be further enhanced by using a variety of artwork effects and techniques. Examples include embossing, encapsulating, and engraving. The product can also incorporate waste material from a number of in-house manufacturing streams. For example, a milled waste heat transfer may be recycled by incorporation into the adhesive layer. The heat transfer can be designed to incorporate a biodegradable carrier. A single or multicolour design insert may be added to the heat transfer. The design insert may be made from a range of conventional, alternative or convertible fabrics including organic textiles,
Fig. 5(c) . - An applique of
Fig. 3 comprises adisposable carrier 25, and has a similar arrangement toFigs. 1 and2 except that there is a recycled flock insert bonded to the flock applique. The recycled flock applique provides a background texture which can be applied in any graphic format. In this embodiment, the various layers are applied as follows: - A
release adhesive 21 is printed onto thecarrier 25 andflock 20 is deposited onto the release adhesive, and apermanent adhesive 21 is screen printed onto the back of the flock in areas where a graphic is required. A pre-manufactured recycled flock graphic (22, 23 & 24) such as shown inFig. 7 is bonded onto the graphic through heat application, to create a multilayer graphic. An advantage of this system is that it is possible to create a multiple layer graphic. - An applique of
Fig. 4 comprises adisposable carrier 35 and has a similar arrangement toFig. 1(d) except that there is a recycled flock insert bonded to the recycled flock applique. The recycled flock applique provides a background texture which can be applied in any graphic format. In this embodiment, the layers are applied as follows: - A release adhesive is printed onto a
carrier 35 andflock 30 is deposited onto the release adhesive, and apermanent adhesive 31 is screen printed onto the back of the flock in areas where a graphic is required. A pre-manufactured recycled flock graphic (22, 23 & 24) such as shown inFig. 7 is bonded onto the graphic through heat application, to create a multilayer graphic. - An advantage of this system is that it is possible to create a multiple-layer recycled flock graphic.
- An applique of
Fig. 5(a) .a comprises adisposable carrier 48 and has a similar arrangement toFig. 1(d) except that multiplerecycled flock fibres - An applique of
Fig. 5(b) comprises adisposable carrier 48 and has a similar arrangement toFig. 4 except that the recycled flock fibres are made up of different flock colour flock fibres or different types offlock fibres - A release adhesive is printed onto a
carrier 48 andflock permanent adhesive 40 is screen printed onto the back of the flock in areas where a graphic is required. A pre-manufactured recycled flock graphic (22, 23 & 24) such as shown inFig 7 is bonded onto the graphic through heat application, to create a multilayer graphic. - An advantage of this system is that it is possible to create a multiple layer recycled flock graphic.
- An applique of
Fig. 5(c) comprises adisposable carrier 48. It has a similar arrangement to that ofFig. 4 except that the recycled flock fibres are made up of different colour flock fibres or different types offlock fibres recycled fabric composite 49 insert bonded to the recycled flock applique. The recycled fabric composite provides a background texture and/o colour which can be applied in any graphic format. In this embodiment, the various layers are applied as follows: - A release adhesive is printed onto a
carrier 48 andflock permanent adhesive 40 is screen-printed onto back of the flock in areas where graphic is required. A pre-manufacturedrecycled fabric composite 49 is bonded onto the graphic through heat application, to create a multilayer recycled applique. - An advantage of this system is that it is possible to create a multiple layer recycled flock graphic incorporating recycled fabric.
- Referring to
Fig. 6 ahotmelt film 52 is applied to adisposable carrier 53. Recyclable adhesive 51 is applied to the hotmelt, and this is flocked withflock 50. - The hotmelt adhesive layer (51, 61, 71, 81, 91) comprises of a thermoplastic film made from an aromatic or aliphatic thermoplastic. The hotmelt film can include one or more (but not limited to) polyamide; polyester; polyolefin; polyurethane; polyurethane urea and polyurethane ester. For example, the hot-melt film can be 76 micron Bemis Polyester Hotmelt Film 5250.
- To apply a design to a textile, the applique (59, 69, 79, 89, 99) is simply placed on the textile after removing the disposable carrier (53, 64, 74, 84, 94) with the hotmelt film adhesive layer in contact with the textile. Heat and pressure are applied so the hot-melt softens onto the fabric (F) to adhere the applique in place, once above the film's initial glue line temperature. Alternatively, applications can be carried out using the high frequency welding method or ultra sonic bonding method.
- Referring to
Fig. 7 , there is a similar arrangement except that there is textile (or alternatively another textile) on the hotmelt film. The satin provides a background so that the recycled flock can be applied in any desired pattern. Ahotmelt film 63 is applied to a textile 62 (through a heat application process), adhesive 61 is applied to the textile prior to flocking and while adhesive iswet flock 60 is deposited into the wet adhesive. - An arrangement is shown in
Fig. 8 in which there is no disposable carrier, and sublimated textile acts as a substrate. The textile is sublimated with a colour and/or pattern, ahotmelt film 73 is applied to a textile 72 (through a heat application process), adhesive 71 is applied to the textile prior to flocking and while the adhesive iswet flock 70 is deposited into the wet adhesive. - An arrangement is shown in
Fig. 9 in which a foil, metal or holographic film acts as a substrate. Ahotmelt film 83 is applied to a foil (through a heat application process), metal or holographic foil/film 82, adhesive 81 is applied to the foil prior to flocking and while the adhesive iswet flock 80 is deposited into the wet adhesive. - In an arrangement shown in
Fig. 10 foil, a migration resistant barrier or composite barrier acts as a substrate. Ahotmelt film 93 is applied to a barrier (through a heat application process) 92, adhesive 91 is applied to the barrier prior to flocking and while adhesive iswet flock 90 is deposited into the wet adhesive. - Advantages of this arrangement are that this creates a fully dye migration resistant applique for use of fabrics which have dye migration issues, thereby preventing the applique from becoming coloured by the fabric dye over time.
- It will be appreciated from the embodiments above that the flock can be applied in a variety of positions in the layers to achieve the desired effects. For example recycled fibres may be flocked in-house onto a disposable carrier to produce a heat transfer in a number of steps. The steps include coating a disposable carrier film with release adhesive followed by flocking with recycled fibres. The pre-flocked sheets are then screen printed using environmentally friendly "eco" inks. An adhesive layer/hotmelt powder layer is screen printed to complete the applique. The resulting transfer is then applied to the garment using heat and pressure.
- Alternatively, the steps include coating disposable carrier film with release adhesive followed by flocking with recycled fibres. The pre-flocked sheets are then sublimated with inks. An adhesive layer/hotmelt powder layer is screen printed to complete invention. The resulting transfer is then applied to the garment using heat and pressure.
- In another alternative recycled flock fibres are flocked in-house onto a substrate which includes a hotmelt film. There is application of an adhesive on the substrate followed by flocking with recycled fibres. The pre-flocked sheets are then screen printed using inks to complete the process. The resulting design can then be either laser or die cut and applied to the garment using heat and pressure. The benefit of an applique is that no additional disposable carrier is necessary, which adds to the environmental benefits of this product.
- The invention is not limited to the embodiments described but may be varied in construction and detail.
Claims (15)
- An applique comprising:a substrate or carrier,flock derived from recycled material,ink in the flock, andan adhesive for adhering the applique to a fabric;wherein the flock comprises fibres of random length.
- An applique as claimed in claim 1, wherein the flock fibre length is in the range of 0.1 mm to 1.2 mm.
- An applique as claimed in claims 1 or 2, wherein fibres are arranged in predefined areas extending uniformly across the carrier or substrate.
- An applique as claimed in any preceding claim, wherein the fibres are in groups comprisinga random number of fibres which have been flocked using an electrostatic flocking machine with flock orientation ranging from 60° and 120° with respect to the substrate.
- An applique as claimed in any preceding claim, wherein the flock is printed with ink according to a design.
- An applique as claimed in any preceding claim, wherein the applique comprises at least two adhesive layers.
- An applique comprising the applique as claimed in any preceding claim inserted into a flock print, to create a combination of surface textures.
- An applique comprising the applique as claimed in any preceding claim inserted into a recycled flock print, to create a combination of surface textures.
- An applique as claimed in any preceding claim, comprising flock fibres of a plurality of colours and/or various recycled flock materials.
- An applique as claimed in any preceding claim, further comprising a recycled flock applique insert.
- An applique as claimed in any preceding claim, wherein the flock is over a textile substrate whereby textile creates structure for the print.
- An applique as claimed in any of claims 1 to 10, wherein the flock is over sublimated textile.
- An applique as claimed in any of claims 1 to 10, wherein the flock is over a foil, metal or foil film.
- An applique as claimed in claims 13, wherein the foil comprises a holographic pattern.
- An applique as claimed in any preceding claim, wherein the flock is over a migration-resistant barrier or migration-resistant barrier composite.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
IE20100578 | 2010-09-15 | ||
PCT/IB2011/054026 WO2012035505A2 (en) | 2010-09-15 | 2011-09-14 | Applications of designs to garments |
Publications (2)
Publication Number | Publication Date |
---|---|
EP2616583A2 EP2616583A2 (en) | 2013-07-24 |
EP2616583B1 true EP2616583B1 (en) | 2016-12-28 |
Family
ID=44903294
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP11776867.1A Not-in-force EP2616583B1 (en) | 2010-09-15 | 2011-09-14 | Applications of indicia designed with flocks to garments |
Country Status (5)
Country | Link |
---|---|
US (1) | US20130160193A1 (en) |
EP (1) | EP2616583B1 (en) |
CN (1) | CN103119216B (en) |
BR (2) | BR212013005576U2 (en) |
WO (1) | WO2012035505A2 (en) |
Families Citing this family (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN102307675B (en) * | 2008-12-22 | 2016-09-28 | 伊利诺斯工具制品有限公司 | Fabric applies pattern |
US9719206B2 (en) | 2012-09-14 | 2017-08-01 | Under Armour, Inc. | Apparel with heat retention layer and method of making the same |
USD766599S1 (en) | 2013-03-11 | 2016-09-20 | Under Armour, Inc. | Lower body garment with inner surface ornamentation |
USD758745S1 (en) | 2013-03-11 | 2016-06-14 | Under Armour, Inc. | Lower body garment with outer surface ornamentation |
USD765427S1 (en) | 2013-03-11 | 2016-09-06 | Under Armour, Inc. | Upper body garment with areas of interior surface ornamentation |
US9193204B2 (en) | 2013-08-28 | 2015-11-24 | Avery Dennison Corporation | Heat transfers suitable for application on dye sublimation apparel |
US10492550B2 (en) | 2014-01-28 | 2019-12-03 | Under Armour, Inc. | Article of apparel including thermoregulatory textile |
KR20170047601A (en) * | 2015-10-23 | 2017-05-08 | 박희대 | Skin film for upper of footwear |
WO2024075113A1 (en) * | 2022-10-03 | 2024-04-11 | Kornit Digital Ltd. | Printed fabric |
Family Cites Families (15)
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GB1368083A (en) * | 1972-05-03 | 1974-09-25 | Monsanto Ltd | Pile-bearing materials |
US3979538A (en) * | 1975-02-13 | 1976-09-07 | The Gilman Brothers Company | Flocked web and method of producing same |
FR2393688A1 (en) * | 1977-06-06 | 1979-01-05 | Troyenne Impression | ORNAMENTAL PATTERN IN RELIEF FIXABLE BY TRANSFER, AND ITS PROCESS FOR OBTAINING |
US4300267A (en) * | 1980-02-06 | 1981-11-17 | Cotton, Incorporated | Total fiber recovery method and apparatus |
JPS56141877A (en) * | 1980-04-03 | 1981-11-05 | Tokyo Houraishiya:Kk | Production of body planted with implanting short fiber |
IT215987Z2 (en) * | 1988-08-12 | 1991-03-26 | Puccini Simona | A TEXTILE OR EQUIVALENT MANUFACTURE DECORATED WITH FLOCKING BOTH OF THE BOTTOM AND OF SUPERIMPOSED DECORATIONS |
GB2245220B (en) * | 1990-06-22 | 1993-11-03 | Electroscope Limited | A transfer sheet |
US5778492A (en) * | 1997-05-14 | 1998-07-14 | Johns Manville International, Inc. | Scrap fiber refeed system and method |
AUPP281998A0 (en) * | 1998-04-03 | 1998-04-30 | Griffith, Ross Ernest | Fibre reinforced thermoplastic sheet |
US20030171056A1 (en) * | 2001-11-05 | 2003-09-11 | Gustavo Palacio | Hydroentangled nonwoven web containing recycled synthetic fibrous materials |
ES2203303B1 (en) * | 2001-11-29 | 2005-02-16 | Rafael Pascual Bernabeu | MACHINE TO CALENDAR, STAMP, LOCK, RECORD AND BRUSH SIMULTANEOUSLY. |
CA2431607C (en) * | 2002-06-10 | 2012-10-16 | Playtex Products, Inc. | Electrostatic flocking and articles made therefrom |
FR2916994B1 (en) * | 2007-06-05 | 2009-07-31 | Enduction Et De Flockage Socie | "METHOD FOR LASER CUTTING OF A PATTERN FOR DECORATING TEXTILE ARTICLES" |
CN101585028A (en) * | 2008-05-23 | 2009-11-25 | 林计洪 | A kind of flock spraying technology of shoes |
CN102307675B (en) * | 2008-12-22 | 2016-09-28 | 伊利诺斯工具制品有限公司 | Fabric applies pattern |
-
2011
- 2011-09-14 EP EP11776867.1A patent/EP2616583B1/en not_active Not-in-force
- 2011-09-14 US US13/820,900 patent/US20130160193A1/en not_active Abandoned
- 2011-09-14 WO PCT/IB2011/054026 patent/WO2012035505A2/en active Application Filing
- 2011-09-14 BR BR212013005576U patent/BR212013005576U2/en active IP Right Grant
- 2011-09-14 CN CN201180044438.4A patent/CN103119216B/en not_active Expired - Fee Related
- 2011-09-14 BR BR112013005576-6A patent/BR112013005576B1/en not_active IP Right Cessation
Non-Patent Citations (1)
Title |
---|
None * |
Also Published As
Publication number | Publication date |
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WO2012035505A3 (en) | 2012-05-10 |
EP2616583A2 (en) | 2013-07-24 |
WO2012035505A2 (en) | 2012-03-22 |
US20130160193A1 (en) | 2013-06-27 |
BR212013005576U2 (en) | 2015-11-03 |
CN103119216B (en) | 2015-09-16 |
BR112013005576B1 (en) | 2019-07-30 |
CN103119216A (en) | 2013-05-22 |
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