GB2358371A - Manufacturing and printing process - Google Patents

Manufacturing and printing process Download PDF

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Publication number
GB2358371A
GB2358371A GB9927067A GB9927067A GB2358371A GB 2358371 A GB2358371 A GB 2358371A GB 9927067 A GB9927067 A GB 9927067A GB 9927067 A GB9927067 A GB 9927067A GB 2358371 A GB2358371 A GB 2358371A
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GB
United Kingdom
Prior art keywords
layer
fabric
printed
process according
article
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.)
Withdrawn
Application number
GB9927067A
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GB9927067D0 (en
Inventor
Terence Michael Hedley
Sousa Neville De
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Walk Off Mats Ltd
Original Assignee
Walk Off Mats Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Walk Off Mats Ltd filed Critical Walk Off Mats Ltd
Publication of GB9927067D0 publication Critical patent/GB9927067D0/en
Priority to AU75353/00A priority Critical patent/AU7535300A/en
Priority to PCT/GB2000/003708 priority patent/WO2001025524A1/en
Publication of GB2358371A publication Critical patent/GB2358371A/en
Withdrawn legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
    • B32B25/04—Layered products comprising a layer of natural or synthetic rubber comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
    • B32B25/04—Layered products comprising a layer of natural or synthetic rubber comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B25/042—Layered products comprising a layer of natural or synthetic rubber comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material of natural rubber or synthetic rubber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
    • B32B25/10—Layered products comprising a layer of natural or synthetic rubber next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
    • B32B25/14—Layered products comprising a layer of natural or synthetic rubber comprising synthetic rubber copolymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/14—Printing or colouring
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M5/00—Duplicating or marking methods; Sheet materials for use therein
    • B41M5/025—Duplicating or marking methods; Sheet materials for use therein by transferring ink from the master sheet
    • B41M5/035—Duplicating or marking methods; Sheet materials for use therein by transferring ink from the master sheet by sublimation or volatilisation of pre-printed design, e.g. sublistatic
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06B—TREATING TEXTILE MATERIALS USING LIQUIDS, GASES OR VAPOURS
    • D06B11/00—Treatment of selected parts of textile materials, e.g. partial dyeing
    • D06B11/0076—Transfer-treating
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B2038/0052—Other operations not otherwise provided for
    • B32B2038/0076—Curing, vulcanising, cross-linking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/14—Mixture of at least two fibres made of different materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/18—Fabrics, textiles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2319/00—Synthetic rubber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2471/00—Floor coverings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2471/00—Floor coverings
    • B32B2471/04—Mats
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/02—Synthetic macromolecular fibres
    • D06N2201/0254—Polyolefin fibres
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/02—Synthetic macromolecular fibres
    • D06N2201/0263—Polyamide fibres
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2203/00—Macromolecular materials of the coating layers
    • D06N2203/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N2203/045—Vinyl (co)polymers
    • D06N2203/048—Polyvinylchloride (co)polymers
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2203/00—Macromolecular materials of the coating layers
    • D06N2203/06—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N2203/061—Polyesters
    • 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
    • D06P1/00—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed
    • D06P1/0036—Dyeing and sizing in one process

Abstract

A process is provided for manufacturing a printed article such as floor mats, rugs, carpets, carpet tiles, bar runners and rubber mat labels having a primary layer (10) and a rubber backing layer (8). The primary layer is bonded to the backing layer under heat and pressure and a printed image is transferred under heat and pressure onto the primary layer from a transfer sheet (12) carrying an image printed on the transfer sheet in sublimatic dyes. The bonding and the image transfer process are carried out simultaneously by pressing the primary layer, the rubber backing layer and the transfer sheet simultaneously in a heated press (2,16) which may include an inflatable diaphragm (figure 4). The primary layer may be a tufted fabric, a felt fabric, a non woven fabric spun bonded fabric, or a woven fabric. Alternatively the primary layer may be a PVC/nitrile rubber blend. The rubber backing sheet may extend beyond the primary layer on at least one side of the article to provide an extended border section onto which a printed image is transferred from a transfer sheet carrying an image in sublimatic dye. A sheet (20) of ink receptive fabric may be bonded to the upper surface of the extended border section. The printed article may be cut into tiles.

Description

2358371 MANUFACTURING AND PRINTING PROCESS The present invention relates
to a process for manufacturing printed articles, in particular but not exclusively mats, rugs, carpet tiles and similar articles, and to printed articles manufactured by the process.
In the following description and claims, the term "mat" is intended to cover floor mats and also other products such as rugs, carpets, carpet tiles, bar runners, rubber mat labels and so on, in which a primary layer, normally but not always a fabric layer, is bonded to a rubber backing under heat and pressure.
In a known mat manufacturing process, a natural or synthetic rubber backing sheet is cured and heat-bonded under pressure to the back of a fabric layer in a heated press. Such a process is described for example in our European patent application No. 0847327, the contents of which are incorporated by reference herein.
It is known to print an image onto such a mat by first screen printing the image onto a paper transfer sheet using sublimatic dyes and then transferring the dyes under heat and a vacuum onto the manufactured mat. The heat causes the dyes to evaporate and the vacuum helps the sublimation process and also ensures good penetration of the dyes into the fabric of the mat. Until recently, this process has only been possible using white polyester mats with a relatively short pile. If a longer pile mat is used, the dye generally difruses excessively, degrading the quality ofthe printed image. The process also requires a separate printing step after completion of the mat manufacturing process.
It is an object of the present invention to provide a process for manufacturing printed articles, such as mats, rugs, carpet tiles and similar items, and printed articles manufactured by the process, that mitigate at least some of the aforesaid problems.
It has recently become possible to produce a transfer sheet by a new process, in which sublimatic dyes are printed onto a transfer sheet by means of a digital printer under the control of a computer. We have found that using such a transfer sheet it is possible to print an image of acceptable quality onto both long and short pile mats as well as a range of other fabrics.
2 According to the present invention there is provided a process for manufacturing a priot( article having a primary layer and a rubber backing layer, in which the primary layer is botio( to the backing layer under heat and pressure and a printed image is transferred under heal,4'1 pressure onto the primary layer from a transfer sheet carrying an image printed on the tratif - sheet in sublimatic dyes, said bonding process and said image transfer process being carried 10 simultaneously by pressing the primary layer, the rubber backing layer and the transfer sle t together in a heated press.
By carrying out the bonding process and the image transfer process simultaneously, the i. for separate manufacturing and printing processes is avoided. The process allows prit(O images of satisfactory quality to be printed on a wide range of articles, including long and she tt pile mats, smooth fabric, felt and PVC/rubber blends.
Advantageously, the primary layer is a fabric layer. Preferably, the fabric layer is a tiiffi fabric. Alternatively, the fabric layer may be a felt fabric, a non woven spun bonded fabri,.,., ex: a woven fabric.
Advantageously, the fabric layer includes polyester fibres, as these give the best wash fast with the printing dyes. the fabric layer be may be either 100% polyester or a blend of pol ir yt and other fibres, for example cotton or nylon. Alternatively, the fabric layer may include nl(iin fibres, for example Nylon 6 or 6.6, and may be either 100% nylon or a blend of nylon and fibres.
Alternatively, the primary layer may be a PVC/Nitrile rubber blend, for example for u: l rubber mat labels.
Advantageously, the transfer sheet is a digitally printed transfer sheet.
Advantageously, the heated press is heated to a temperature of approximately 160C to 1,7.( and, preferably, the primary layer, the rubber backing layer and the transfer sheet are pres,.d in the heated press for a time of approximately 20 minutes.
Advantageously, a frame member is used to form the edge of the rubber backin g layer dt ' + I [ the pressing process. Preferably, the transfer sheet is aligned with the frame member, prir to being placed the heated press.
3 Advantageously, the rubber backing layer extends beyond the primary layer on at least one side of the article to provide an extended border section, onto which a printed image is transferred from a transfer sheet carrying an image in sublimatic dye. A sheet of ink-receptive fabric may be bonded to the upper surface of the extended border section. The extended border section may be removable by cutting the rubber backing layer adjacent an edge of the primary layer.
The printed article may be cut into a plurality of tiles, and each tile may have a printed border.
Advantageously, the printed article is a mat, preferably a dust control mat.
According to a further aspect of the invention there is provided a printed article having a primary layer printed with an image and a rubber backing layer bonded to the primary layer, said article having been manufactured by a process according to one of the preceding paragraphs.
The article may include an extended border section that carries a printed image.
The article may be divided into a plurality of tiles, each tile having a printed border.
Advantageously, the article is a mat, preferably a dust control mat.
Advantageously, the primary layer is a fabric layer of polyester tufted fabric.
Embodiments of the invention will now be described by way of example with reference to the accompanying drawings, in which:
Figure I is an exploded cross-sectional view of a laid-up mat in a heated press; Figure 2 is a side view of a mat with an extended border section made according to the process; Figure 3 is a plan view of a tiled mat made according to the process, and Figure 4 is an exploded cross-sectional view of a tiled mat laid-up in a heated press.
In a typical mat manufacturing process, a natural or synthetic rubber backing sheet is cured and heat-bonded under pressure to the back of a fabric layer in a heated press. The fabric layer typically consists of a tufted polyester pile on a non-woven polyester substrate. The rubber backing is normally slightly larger than the fitbric layer to form a rubber border, which is - - ---------------- - -- - - -------- 4 typically about 2cm wide. The rubber backing layer and the fabric layer are laid up on a iK stick release sheet, for example of PTFE-coated woven glass fabric, and are covered with a t p cover, also of PTFE-coated woven glass. The mat is then placed in the press for the bondi: 1 and curing process.
Figure 1 is a schematic exploded cross-section of a laid up mat in a press. The press inclqd Is an inflatable diaphragm 2 upon which there is placed a bottom release sheet 4 of PTFE-cot woven glass. An aluminium frame 6 the size of the finished mat may optionally be place( i the bottom release sheet 4 to shape the edge of the rubber backing sheet and provide a reinforced border, as described in our European patent application No. 0847327.
The mat, which is laid up on the bottom release sheet 4, consists of a rubber backing shol 8 and a tufted fabric layer 10. The rubber backing sheet 8 is normafly slightly larger thai) t fabric layer 10 so as to form a rubber border, and also overlaps the inner edge of the fraite 6 so that, during the bonding and curing process, the edge of the backing sheet is cut ofir by, t C frame. Alternatively, the rubber backing sheet may be accurately cut before being laid up, f j,r example by means of a dye cutter, to fit just inside the frame.
When the mat has been laid up, a transfer sheet 12 that has previously been printed with desired image using sublimatic dyes is placed face down on top of the fabric layer 10. dimensions of the transfer sheet 12 are preferably matched to the outer periphery of the fil r b 6 so that the frame can be used to ensure correct alignment. A top cover 14, of PTFE-co 1 woven glass, is placed on top ofthe laid up mat, and the mat is then placed in the press bet,,vej a heated metal platen 16 and the inflatable diaphragm 2 for the bonding and curing proc(sf.:
The press is typically heated to a temperature of about 160-170'C. The diaphragm is inflated, for example to a pressure of 30 pounds per square inch, pressing the mat againslti e heated platen for a cycle time of approximately 20 minutes. The heat from the platen soe and cures the rubber backing, and the pressure from the diaphragm presses the fabric layer the rubber backing, bonding the two layers together. At the same thne, the dyes on the trail: 'r ima sheet 12 evaporate and are transferred onto the fabric of the mat to form a printed g(.
The process therefore has the advantage that the mat is manufactured and printed in a single step, rather than two separate steps. There is thus no need for a separate printing step and the manufacturing and printing process is therefore quick and simple.
The mat manufacturing and printing process described above is applicable to a wide range of mat and carpet materials. Some example are provided below:
1. Polyester tufted fabric. The process may be used for printing dust control mats, which typically have a polyester tufted fabric made from a yam of 100% polyester Cotton Count 1.3's semi worsted spun, two ply twisted and heat set, in a fabric having a pile weight of 900g/in cut pile. t this is our standard specification for a dust control 10 mat, variations on yam count and tufting specification including loop pile would also be suitable. The polyester fabric gives good wash fastness for the dyes used and this feature makes the fabric ideal for laundered products, such as washable dust control mats. 2. Polyester felt. For example, the process may be used to print 100% polyester needled 15 felt having a weight of 500g/iif. Other weights would also be suitable. 3. Non woven spun bonded polyester. This material is normally used as a primary backing material for tufted carpets at weights of 80-160gIrW, or for roofing felt at weights up to 230g/rif. A weight of 230g/rif has been found to give the best results, because at lower weights the rubber backing flows through to the surface of the materiat giving 20 a poor quality print definition. Other weights lighter than this might be suitable, and the rubber can be prevented from flowing through to the surface by decreasing the pressure ofthe press during manufacturing and/or by adjusting the rubber formulation to restrict the flow. 4. Woven polyester fabric. Any woven polyester fabric or polyester cotton blend is 25 suitable, providing that the weight and weave are suitable to prevent the rubber flowing through to the surface. For example, a suitable material comprises polyester-cotton blend having a polyester:cotton ratio of 67:33 and a weight of 270g/rn. 5. White PVC/Nitrile blend. This is the material we use to make rubber labels, which we normally screen print using PVC based coloured inks to produce edge or back labels
6 forourmats. A suitable material comprises a PVC/Nitrile blend having a ratio of A: 0 and a thickness of 0. 0 15 (0. 3 8mm).
The above are intended only as examples and we believe that any fabric or sheet materialit contains or consists of polyester and that bonds to a rubber backing would also be suita11, The process may be employed to manufacture a wide range of products, including dust co Olt] 01 mats, other loose-laid mats (for example carrying promotional and advertising material) "0 mats, printed domestic mats (for example bearing the badges of sports teams) and bar runde as well as carpet tiles and other products.
lhV I' Although polyester or polyester blend fabrics are the best for launderable products, owing the wash fastness of the dyes when printed onto polyester, the process also produces go'bo results when printing onto other fabrics such as Nylon 6 or 6.6, which may be suitablO I r products that do not require repeated laundering.
Figure 2 is a side view of a mat with an extended border section made according to the pro The mat includes a rubber backing sheet 8 of nitrile rubber and a tufted fabric layer I 0: r ximately 2cm. beyondt, t ie example of polyester. The rubber backing sheet 8 extends appro fabric layer 10 around three sides of the mat to form a narrow rubber border 16, and ol t e fourth side extends much further beyond the fabric layer (for example, approximately 10-41c j to form an extended border section 18. A sheet of ink-receptive fabric 20, for exat.
41C polyester fabric, is bonded to the upper surface of the extended border section 18 durin?, t ie pressing and curing process.
The provision ofthe extended border section 18 and the sheet of inkreceptive fabric 20 s it possible to print a separate message, design or logo on the extended border section 1 addition to the main design printed on the tufted fabric layer 10. This may be particularly u,e.I for displaying temporary messages, advertisements or promotions. When the tempo message is no longer required, the extended border section 18 can be cut offwith a sharp n fe along the inner edge 22 of the fabric layer 20, leaving a mat of conventional design lAi. tl a continuous narrow rubber border.
Figure 3 is a plan view of a tiled mat made and printed according to the process descM'd above. The tiled mat consists of a large mat 24 that is divided into a number of separate, t S 1 7 26, each of which has a printed border 28 that is approximately 2cm wide. The tiled mat can be cut up into separate small mats by cutting along the edges of the borders 28. Thus, several small mats can be manufactured and printed with identical or different designs in a single process. Each of those small mats will have a black border and will therefore be similar in appearance to a conventional mat with a rubber border, except that the tufted fabric layer win extend to the edges of the mat.
Figure 4 is an exploded cross-sectional view of a tiled mat laid-up in a heated press. The press includes an inflatable diaphragm 32 upon which there is placed a bottom release sheet 34 of PTFE-coated woven glass. The mat, which is laid up on the bottom release sheet 34, consists of a rubber backing sheet 38 and a tufted fabric layer 40 that extends up to the edges of the rubber backing sheet 3 8. A transfer sheet 42 that has previously been printed using sublimatic dyes with the desired image and the tile borders is placed face down on top of the fabric layer 40. A top cover 44, of PTFE-coated woven glass, is placed on top of the laid up mat, which is placed in the press between a heated metal platen 46 and the inflatable diaphragm 32.
The two layers of the mat are bonded together under heat and pressure in the press and, at the same tirne, the dyes on the transfer sheet 12 are transferred onto the fabric of the mat to form the printed image and the borders 28. After removal from the press, the tiled mat is cut into separate mat tiles by cutting around the edges of the borders 28, for example with a guillotine or a stamp cutter.
8

Claims (27)

  1. A process for manufacturing a printed article having a primary layer and a b er backing layer, in which the primary layer is bonded to the backing layer under he4t, nd pressure and a printed image is transferred under heat and pressure onto the pr'n 'y layer from a transfer sheet carrying an image printed on the transfer sheet in subli 'ic dye, said bonding process and said image transfer process being carried,' fut simultaneously by pressing the primary layer, the rubber backing layer and the tra'X'1-19 kr sheet together in a heated press.
  2. 2. A process according to claim 1, in which the primary layer is a fabric layer.
  3. 3. A process according to claim 2, in which the fabric layer is a tufted fabric.
  4. 4. A process according to claim 2, in which the fabric layer is a felt fabric.
  5. 5. A process according to claim 2, in which the fabric layer is a non woven spun bond ed fabric.
  6. 6. A process according to claim 2, in which the fabric layer is a woven fabric.
  7. 7. A process according to any one of claims 2 to 6, in which the fabric layer inOic s polyester fibres or a blend of polyester and other fibres.
  8. 8. A process according to any one of claims 2 to 6, in which the fabric layer includes n 'n fibres or a blend of nylon and other fibres.
  9. 9. A process according to claim 1, in which the primary layer is a PVC/Nitrile ri ibl er blend.
  10. 10. A process according to any one of the preceding claims, in which the transfer sh(,ol is a digitally printed transfer sheet.
  11. 11. A process according to any one of the preceding claims, in the heated press is heOt d to a temperature of approximately 160C to 170C.
    9
  12. 12. A process according to any one of the preceding claims, in which the primary layer, the rubber backing layer and the transfer sheet are pressed in the heated press for a time of approximately 20 minutes.
  13. 13. A process according to any one of the preceding claims, in which a frame member is used to form the edge of the rubber backing layer during the pressing process.
  14. 14. A process according to claim 13, in which the transfer sheet is aligned with the frame member, prior to being placed the heated press.
  15. 15. A process according to any one of the preceding claims, wherein the rubber backing layer extends beyond the primary layer on at least one side of the article to provide an extended border section, onto which a printed image is transferred from a transfer sheet carrying an image in sublimatic dye.
  16. 16. A process according to claim 15, in which a sheet of ink-receptive fabric is bonded to the upper surface of the extended border section.
  17. 17. A process according to claim 15 or claim 16, in which the extended border section is removable by cutting the rubber backing layer adjacent an edge of the primary layer.
  18. 18. A process according to any one of the preceding claims, wherein the printed article is cut into a plurality of tiles.
  19. 19. A process according to claim 18, in which each tile has a printed border.
  20. 20. A process according to any one of the preceding claims, wherein the printed article is a mat.
  21. 21. A process for manufacturing a printed article, the process being substantially as described herein with reference to and as illustrated by Fig. 1, or Fig. 2, or Figs. 3 and 4 of the accompanying drawing.
  22. 22. A printed article having a parimary layer printed with an image and a rubber backing layer bonded to the primary layer, said article having been manufactured by a process according to any one of the preceding claims.
  23. 23. An article according to claim 22, wherein said article includes an extended bord ir section that carries a printed image.
  24. An article according to claim 22, wherein said article is divided into a plurality of tll( s, 1 each tile having a printed border.
  25. 25. An article according to any one of claims 22 to 24, said article being a mat.
  26. 26. An article according to any one of claims 22 to 25, wherein said primary layel is fabric layer of polyester tufted fabric.
  27. 27. A printed article substantially as described herein with reference to and as illustrated y Fig. 1, or Fig. 2, or Figs. 3 and 4 of the accompanying drawing.
GB9927067A 1999-10-07 1999-11-16 Manufacturing and printing process Withdrawn GB2358371A (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
AU75353/00A AU7535300A (en) 1999-10-07 2000-09-28 Manufacturing and printing process
PCT/GB2000/003708 WO2001025524A1 (en) 1999-10-07 2000-09-28 Manufacturing and printing process

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB9923772A GB2357261A (en) 1999-10-07 1999-10-07 Manufacturing and printing process

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GB9927067D0 GB9927067D0 (en) 2000-01-12
GB2358371A true GB2358371A (en) 2001-07-25

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GB9927067A Withdrawn GB2358371A (en) 1999-10-07 1999-11-16 Manufacturing and printing process

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6393988B1 (en) * 1998-08-01 2002-05-28 Max Imaging Systems Limited Process for transfer printing on flat articles
CN105411328A (en) * 2015-11-18 2016-03-23 张继金 Method for manufacturing cup mat by virtue of waste clothes

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB0100158D0 (en) * 2001-01-04 2001-02-14 Bateman Roger Christopher Improved advertising apparatus and method
GB0126700D0 (en) * 2001-11-06 2002-01-02 Walk Of Mats Ltd Mat and method of manufacturing a mat
DE102012002805A1 (en) * 2012-02-15 2013-08-22 Carl Freudenberg Kg Composite of textile fabric and outer fabric

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2213099A (en) * 1987-12-07 1989-08-09 Walk Off Mats Ltd Method of marking rubber goods
WO1997009159A1 (en) * 1995-09-01 1997-03-13 Walk Off Mats Limited Mat manufacture

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2213099A (en) * 1987-12-07 1989-08-09 Walk Off Mats Ltd Method of marking rubber goods
WO1997009159A1 (en) * 1995-09-01 1997-03-13 Walk Off Mats Limited Mat manufacture

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6393988B1 (en) * 1998-08-01 2002-05-28 Max Imaging Systems Limited Process for transfer printing on flat articles
CN105411328A (en) * 2015-11-18 2016-03-23 张继金 Method for manufacturing cup mat by virtue of waste clothes
CN105411328B (en) * 2015-11-18 2017-06-06 张继金 The method that plate mat is made using waste and old clothing

Also Published As

Publication number Publication date
GB9927067D0 (en) 2000-01-12
GB9923772D0 (en) 1999-12-08
GB2357261A (en) 2001-06-20

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