WO2020264538A2 - Film de décoration conforme multicouches - Google Patents

Film de décoration conforme multicouches Download PDF

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Publication number
WO2020264538A2
WO2020264538A2 PCT/US2020/047559 US2020047559W WO2020264538A2 WO 2020264538 A2 WO2020264538 A2 WO 2020264538A2 US 2020047559 W US2020047559 W US 2020047559W WO 2020264538 A2 WO2020264538 A2 WO 2020264538A2
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WO
WIPO (PCT)
Prior art keywords
layer
conformal
coat layer
decoration film
image
Prior art date
Application number
PCT/US2020/047559
Other languages
English (en)
Other versions
WO2020264538A3 (fr
Inventor
Robert J. MABBOTT
Original Assignee
Mabbott Robert J
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 Mabbott Robert J filed Critical Mabbott Robert J
Publication of WO2020264538A2 publication Critical patent/WO2020264538A2/fr
Publication of WO2020264538A3 publication Critical patent/WO2020264538A3/fr

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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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/02—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations

Definitions

  • Some implementations of the present invention generally relate to a method of making printed multi-layer decoration films and applying them to the form and texture of multi-material surfaces, such as the surface of a shoe, using one or more types of novel image windows.
  • US 6,802,140 B2 discloses a shoe and methods of shoe decoration, using several layers of an acrylic polymer emulsion gel, to affix various sizes and types of paper to a finished shoe after having been immersed in a liquid polymer gel, but does not attest to any real commercial applicability.
  • Direct inkjet printing provides yet another form of shoe decoration, but is limited to printing the single components of a shoe with a flat-bed inkjet printer, and although the process is repeatable for certain types of canvas sneakers, it does not work well on other types of footwear material, especially natural materials like leather.
  • US 7,699,458 B2 discloses a method of transfer printing, applying an image sheet comprised a flexible layer of a Shape Memory Polymer, an image bonded to said layer by means of an image key coat.
  • the image sheet is bonded to the surface by means of an adhesive, and a process which involves heating of the Shape Memory Polymer to a temperature above its Glass Transition Temperature.
  • Mabbott ‘458 further discloses methods for applying images to, shoes such as fashion shoes and recreational shoes (e.g, sports and walking shoes) From this disclosure, it should be readily understood that Mabbott‘458 is disclosing an alternative method of footwear decoration, featuring the use of a flexible layer of Shape Memory Polymer.
  • Mabbott‘458 further discloses by reference to US 7,025,451 B2 ( Mabbott‘451) a method for transferring an image onto a non- planer surface in which an image transfer sheet comprising a shape memory polymer or like substance is used to transfer said image to a target substrate.
  • Footwear surface decoration methods exist, but none of the afore mentioned methods or referenced disclosures, deliver a footwear surface decoration method that comes anywhere close to mirroring the form and texture of the materials that are used in the manufacturing of finished footwear like the present invention does nor are they designed to meet the footwear customers increasing demand for a more individualized footwear offering, which delivers the value, physical performance, haptic feel, and longevity that a customer has come to expect from a factory-made pair of shoes like the present invention is.
  • An object of the present invention is to provide a multi-layer conformal decoration film with an image receiving layer, the surface of which can be digitally printed using different commercially available digital printing technologies.
  • Another object of the present invention is to provide a multi-layer conformal decoration film which once printed uses one or more novel image windows in the application process.
  • a novel image window in the spirit of the current invention is designed to facilitate the removal of the multi-layer conformal decoration film from the release surface and transport it, with a right reading image to the point of application, thereafter for use re-use or to be discarded.
  • Another object of the present invention is to provide a printed multi-layer conformal decoration film where the image window can be applied by hand to the form and texture of the material surface of a finished shoe, thereafter being permanently bonded to said materials using directional heated forced air, like that of a heat gun.
  • Another object of the present invention is to provide different types of novel image windows to be used in the process of removing the printed multi-layer conformal decoration film from the release surface and transporting it to the point of application.
  • Another object of the present invention is to provide for a thermoplastic sheet to be attached to the upper most surface of a novel image window, thereafter heated, softened and vacuumed to the form and texture of a shoe component, several adjoined components or alternatively to the material surface of a finished shoe.
  • Another object of the present invention is to provide for a thermoplastic sheet assembly to be attached to the upper most surface of a novel image window, thereafter using directional high velocity heated air to soften the thermoplastic sheet and force it to conform to the form and texture of the material surface of a shoe component, several adjoined components or the alternatively to the material surface of a finished shoe.
  • Another object of the present invention is to provide a for a thermoplastic sheet assembly to be attached to the upper most surface of a novel image window whereby the thermoplastic sheet assembly can be precisely controlled, and the printed image mapped with pixel to pixel conformal accuracy to the target surface to which it has been applied.
  • Another object of the present invention is to provide a multi-layer conformal decoration film that enables sub-surface decorative elements to be embedded into its surface, using different layer constructions, thus enabling a myriad of different special effects to be achieved, including but not limited to, glow-in-the-dark, holographic effects, security indicia and micro-electronics.
  • a printed multi-layer conformal decoration film is constructed to comprise the following: a releasable carrier, designed to enable a first key coat adhesion layer, with the most desirable bond and release properties; a second image layer, providing a right reading digital image, printed onto the first key coat adhesion layer, designed to enable the most desirable ink adhesion and print quality; a third key coat layer, coated onto the second image layer, designed to enable the most desirable surface uniformity, a fourth top coat layer, coated onto a third key coat layer, designed to enable the most desirable surface finish.
  • a method of preparing the image target surface or surfaces of a shoe which comprise the following: removing any impurities from the surface of the shoe, by using an appropriate cleaning agent, thereby making it fit for purpose; applying a material key coat to the receiving surface or surfaces of a shoe, of the type, compatible with a first key coat layer of the completed printed multi-layer conformal decoration film.
  • a method of applying a completed printed multi-layer conformal decoration film construction to the surface of a shoe using one or a number of novel image windows, which may or may not be of different types, but nonetheless comprise the following steps: constructing an image window around the printed image, so as, to have it secured against the upper top coat surface of the completed printed multi- layer conformal decoration film, applying a pressure sensitive adhesive to the contacting side of the novel image window; using the image window to lift the completed multi-layer printed conformal decoration film up and away from the releasable carrier, placing the completed printed multi-layer conformal decoration film against the target surface or surfaces of a shoe; applying localized force to the upper top coat surface or surfaces of the printed multi-layer conformal decoration film, which may or may not be by direct contact using a low energy heated air source to create a conformal surface between the printed multi-layer film construction and the surface of the shoe, thereby creating a temporary bond between the printed multi-layer conformal decoration film and the surface of the shoe, where
  • the method used to apply the printed multi- layer conformal decoration film to the surface of a shoe may be by hand using the action of pressure applied with friction or maybe that of a non-contact heated forced air, which may include the use of vacuum or heat assisted vacuum.
  • novel image windows assemblies that enable the application of printed multi-layer conformal decoration films to a material surface which may include a component, several adjoined components or the material surface of the finished shoe.
  • a novel image window that is constructed to affect the easy removal of the printed multi-layer conformal decoration film from the release layer which may be of a rigid kind so as to enable the conformal decoration of the material surface of shoe components, which novel image window may or may not be contoured around the shape or shapes of the shoe components.
  • the novel image window may be flexible so as to be easily bent around curved or contoured surfaces, for example the toe section of a lasted shoe, alternatively the novel image window may be made out of a memory plastic or metal material, which once bent will maintain its shape or even change its shape given certain stimuli.
  • a novel image window may also be stretchable, so as to eliminate any creasing of the multi-layer conformal decoration films during the application process.
  • FIG 1 is a cross section of the basic layer construction of a printed multi-layer conformal decoration film, with the addition of a releasable carrier;
  • FIG 2 is a cross section similar in construction to that of FIG 1 with the addition of a color coat layer
  • FIG 3 is a cross section similar in construction to that of FIG 1 with the addition of a second key coat layer and a foil coat layer;
  • FIG 4 is a cross section similar in construction to that of FIG 1 with the addition of a color coat layer; but with the removal of the image layer;
  • FIG 5 is a cross section similar in construction to that of FIG 1 with the addition of a foil coat layer; but with the removal of the image layer,
  • FIG 6 is a cross section, the same in construction as FIG 1 depicting the completed printed multi-layer conformal decoration film with image window layer affixed to the top coat layer, thereafter removing and discarding the releasable carrier;
  • FIG 7 is a cross section, the same in construction as FIG 1 depicting the conformal application of the printed multi-layer conformal decoration film construction, affixed to the image window being applied to a target material surface;
  • FIG 8 is a cross section, the same in construction as FIG 1 depicting a novel image window being removed from the upper top coat layer of the printed conformal decoration film;
  • FIG 9 is a perspective view of an image window depicting a rigid frame affixed to and surrounding a printed multi-layer conformal decoration film being applied to a single shoe component;
  • FIG 10 is a perspective view of a novel image window depicting a rigid frame affixed to and surrounding a printed multi-layer conformal decoration film being applied to several adjoined shoe components.
  • FIG 1. there is a drawing of a cross section exemplifying a multi-layer conformal decoration film that is constructed to comprise the following: a releasable carrier 10 designed to enable a first key coat layer 12 with the most desirable bond and release properties; an image layer 14 providing a right reading digital image printed onto the first key coat layer 12 designed to enable the most desirable ink adhesion and print quality, a second key coat layer 16 coated onto the image layer 12 designed to enable the most desirable surface uniformity, a top coat layer 18 coated onto the second key coat layer 16 designed to enable the desired surface finish, haptic characteristics and physical performance of the completed multi-layer printed conformal decoration film.
  • a releasable carrier 10 designed to enable a first key coat layer 12 with the most desirable bond and release properties
  • an image layer 14 providing a right reading digital image printed onto the first key coat layer 12 designed to enable the most desirable ink adhesion and print quality
  • a second key coat layer 16 coated onto the image layer 12 designed to enable the most desirable surface uniformity
  • the releasable carrier 10 may comprise a raw based paper with a weight of 175 gsm and a thickness between 200 and 240 microns, which may be laminated on one or both sides with a thin gauged polypropylene film.
  • Polypropylene in this embodiment may exhibit surface energy of between 34 and 38 dynes sq cm deemed necessary to affect the bond to and release from the first key coat layer 12. It is important to note that someone with ordinary skill in the art would be able to select different release papers and or films to achieve the same desired result given a basic understanding of surface energy and bond and release principles.
  • the first key coat layer 12 is then coated onto the releasable carrier 10 using conventional coating technology, which may be any coating method that is able to deliver an aqueous liquid resin coating of a thickness preferably between 9-25 microns to the surface of the releasable carrier.
  • aqueous liquid resin will be of a permanent tacky highly flexible nature, exhibiting dry characteristics of elongation at break of at least and be applied as a non- continuous coating
  • the coating material should be that of a material that has good adhesion to natural and manmade leather textile and synthetic materials and various different plastics as well as combination acrylics and polyurethane dispersions.
  • the image layer 14 in the preferred embodiment is comprised of an ink that is deposited onto the first key coat layer 12 using a digital inkjet printer.
  • a digital inkjet printer There are different types of digital printers and inkjet technologies in the commercial market place and it is a feature of the present invention for the first key coat layer to accept primarily non-absorbing inks, including but not limited to UV, solvent and latex.
  • the first key coat layer it is desirable but with some inks it may not be necessary to coat a second key coat layer 16 onto the image layer 14 however the use of a second key coat layer is described here as part of the preferred embodiment.
  • the second key coat layer 16 when deemed necessary is coated onto the image layer 14 which in turn is combined with the first key coat layer 12 to enable the most desirable surface uniformity and bonding characteristics to both the combination layers 12 and 14 and to the final finish topcoat layer 18
  • the second key coat layer 16 which is also an aqueous liquid resin coating differs from the first key coat layer 12 in that it may comprise a highly compatible acrylic polyurethane dispersion coated to a thickness generally between 30 and 50 microns which when dry produces a uniform film layer
  • a preferred material for the final finished topcoat layer 18 may that of an aqueous liquid resin film forming coating comprised of an aliphatic polyurethane dispersion for example of the type commercially available as PUR-MATT 300 VP (ex-Alberdingk Boley) coated generally to a dry weight thickness of between 25 and 60 microns onto its predecessor layer which maybe any layer or combination layer herein described in the preferred embodiment or alternatively described and depicted in the embodiments hereinafter.
  • the final finished topcoat 18 which when coated and dried generally to a dry weight thickness of between 25 and 60 microns should become a soft feel, flexible inherent matt high scuff abrasion chemical and UV resistant film of which formula can be customized further to suit the surface haptic and performance
  • FIGS 2 -6 similar in construction to FIG 1 but with the inclusion or omission of layers that define the different embodiments.
  • FIG 2 is the same in construction as FIG 1 but with the inclusion of a color coat layer 20 which in this embodiment refers to a pigmented white polyurethane dispersion which may be of the base material type used for the second key coat layer 16 which pigment may be provided as a by weight titanium dioxide.
  • the function of color coat layer 20 is to add white opacity to any part of the image or non-image area where white inks from the printer are not available.
  • FIG 3 is the same in construction as FIG 1 but with the inclusion of an encapsulated special effects layer 22 which may be created in the nature of a foil layer which may include special colors, metallic, holograms and glow-in-the-dark.
  • FIG 4 and FIG 5 are the same construction as FIG 1 but each with the omission of the image layer 14.
  • the novel image window is an exemplary example of the material and methodology the current invention uses to deliver a multi-layer conformal decoration film to the material surface of a shoe component, several adjoined shoe components or to an already finished shoe.
  • the focal point of a novel image window has been on a rigid frame construction, there are other novel image window frame embodiments that have relevance to the present invention.
  • the frame 32 may be of a fixed shape, not necessarily rectangle, and may be a continuous shape without angles like that of a circle or the outer frame may be rectangular but the window itself may comprise one or a number of windows cut out from its solid center; the frames may also be flexible which bend easily around curved or contoured surfaces, for example the toe section of a lasted shoe. Flexible frames may be made out of different plastics and metals that are able to be bent into and then maintain their shape until put into another shape; or the shape of the frame may be pre-molded to accommodate a repeatable application; frames of this nature may be most applicable to the hand application of multi-layer conformal decoration films to finished footwear, especially when tension is required to eliminate any air entrapment or creasing in the surface of multi-layer conformal decoration film.
  • FIG 6 is a cross section, the same in construction as FIG 1, depicting the completed printed multi-layer conformal decoration film with the novel image window 26 affixed to the top coat layer 18.
  • the novel image window 26 in the referenced drawing can be made from any material that allows it to be temporarily affixed, bonded, adhered, glued or stuck to the printed multi-layer conformal decoration film, as an example the novel image window layer 26 may have an adhesive coated to its surface which may be pressure sensitive which may also be delivered as a pressure sensitive tape where such exposed adhesive is then pressed onto the upper surface top coat layer 18 of the multi-layer conformal decoration film.
  • the adhesive characteristics should be compatible with the top coat layer 18 which surface depending on its final finish may require different adhesion values to affect the required bond and release characteristics.
  • the requirement is for the strength of adhesion of the novel image window 26 to the top coat layer to be stronger than that of the releasable carrier 10 so that the releasable carrier 10 can be easily and completely be removed from the first key coat layer 12 thereafter which may or not be discarded.
  • FIG 7 is a cross section of the multi-layer conformal decoration film affixed to a novel image window 26 being applied to a material key coat layer 28 after being coated onto a target material layer 30 which may be a shoe component, several adjoined shoe components or the material surface of a finished shoe.
  • FIG 8 is a cross section of a novel image window 26 being removed from the top coat layer 18 of the printed conformal decoration film after it has been affixed to the material key coat layer 28 previously coated to the target material 30 which may be an individual component several adjoined components or it may be the material surface of the finished shoe itself. It is a feature of the present invention to be able to apply the multi-layer conformal decoration film to individual and adjoined components using high speed application equipment in a manufacturing
  • FIG 8 illustrates a multi-layer conformal decoration film to be applied to the surface of a shoe component, several adjoined components or the material surface of a finished shoe.
  • the word‘Conformal’ is described as“mapping to a surface or region upon another surface so that all angles between intersecting curves remain unchanged.” This description applies amply to the present inventions disclosed ability to conformally wrap around edges, across stitching and to conform to a textured or raised surface of a component or several adjoined components it also provides for the disclosure regarding the conformal wrapping of objects in a 3D state for example the multi-layer conformal decoration of a finished shoe wherein such wrapping and application method may include a novel image window applied to a multi-layer conformal decoration film whereby the multi-layer conformal decoration film may be made by digital spray deposition of a kind that enables the precise control of material film states across any and all of the surface of the multi-layer conformal decoration film, thus enabling the recordation and transmittal of printed multi-layer conformal decoration film to be precisely and accurately mapped with pixel to pixel accuracy to the material surface of a finished shoe with all angles between intersecting curves remaining unchanged.
  • FIG 9 is a perspective view of a novel image window 26 depicting a rigid frame 32 affixed to and surrounding a printed multi-layer conformal decoration film being applied to a single shoe component 34.
  • FIG 10 is a perspective view of a novel image window 26 depicting a rigid frame 32 affixed to and surrounding a printed multi-layer conformal decoration film being applied to several adjoined shoe components.

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  • Footwear And Its Accessory, Manufacturing Method And Apparatuses (AREA)

Abstract

L'invention concerne un procédé de fabrication de films de décoration conformes multicouches imprimés et d'application de ceux-ci à la forme et à la texture des surfaces à matériaux multiples, telles que la surface d'une chaussure, à l'aide d'un ou de plusieurs types de fenêtres d'image.
PCT/US2020/047559 2019-06-28 2020-08-23 Film de décoration conforme multicouches WO2020264538A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201916456223A 2019-06-28 2019-06-28
US16/456,223 2019-06-28

Publications (2)

Publication Number Publication Date
WO2020264538A2 true WO2020264538A2 (fr) 2020-12-30
WO2020264538A3 WO2020264538A3 (fr) 2021-03-04

Family

ID=74060674

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Application Number Title Priority Date Filing Date
PCT/US2020/047559 WO2020264538A2 (fr) 2019-06-28 2020-08-23 Film de décoration conforme multicouches

Country Status (1)

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WO (1) WO2020264538A2 (fr)

Family Cites Families (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2969143A (en) * 1956-05-17 1961-01-24 Phillips Petroleum Co Pressure-sensitive adhesive tape
US4662966A (en) * 1984-09-26 1987-05-05 Nissha Printing Co. Ltd. Apparatus for transfer printing
GB0301091D0 (en) * 2003-01-17 2003-02-19 Mabbott Robert J Provision of images on surfaces
US8709141B2 (en) * 2007-03-02 2014-04-29 Ppg Industries Ohio, Inc. Heat releasable composite coatings and related methods
US7818217B2 (en) * 2007-07-20 2010-10-19 Nike, Inc. Method of customizing an article
US20100252187A1 (en) * 2009-04-02 2010-10-07 Jonathan Javier Calderas Methods of Making Customized Articles for Applying Color on Surfaces

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WO2020264538A3 (fr) 2021-03-04

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