U.S. patent application number 13/820900 was filed with the patent office on 2013-06-27 for application of designs to garments.
This patent application is currently assigned to ITW IRELAND. The applicant listed for this patent is Celine Cremin. Invention is credited to Celine Cremin.
Application Number | 20130160193 13/820900 |
Document ID | / |
Family ID | 44903294 |
Filed Date | 2013-06-27 |
United States Patent
Application |
20130160193 |
Kind Code |
A1 |
Cremin; Celine |
June 27, 2013 |
APPLICATION OF DESIGNS TO GARMENTS
Abstract
An applique includes a substrate or carrier, flock derived from
recycled material, ink in the flock, and an adhesive for adhering
the applique to a fabric.
Inventors: |
Cremin; Celine; (Kinsale,
IE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Cremin; Celine |
Kinsale |
|
IE |
|
|
Assignee: |
ITW IRELAND
Kinsale, County Cork
IE
|
Family ID: |
44903294 |
Appl. No.: |
13/820900 |
Filed: |
September 14, 2011 |
PCT Filed: |
September 14, 2011 |
PCT NO: |
PCT/IB11/54026 |
371 Date: |
March 5, 2013 |
Current U.S.
Class: |
2/244 |
Current CPC
Class: |
D06Q 1/12 20130101; A41D
27/08 20130101; D06P 5/004 20130101; D06Q 1/14 20130101 |
Class at
Publication: |
2/244 |
International
Class: |
A41D 27/08 20060101
A41D027/08 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 15, 2010 |
IE |
2010/0578 |
Claims
1. 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.
2. (canceled)
3. An applique as claimed in claim 1, wherein the flock fibre
length is in the range of 0.1 mm to 1.2 mm
4. An applique as claimed in claim 1, wherein fibres are arranged
in predefined areas extending uniformly across the carrier or
substrate.
5. An applique as claimed in claim 1, wherein 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.
6. An applique as claimed in claim 1, wherein the flock is printed
with ink according to a design.
7. An applique as claimed in claim 1, wherein the applique
comprises at least two adhesive layers.
8. An applique as claimed in claim 1, wherein a recycled flock
applique is inserted into a flock print, to create a combination of
surface textures.
9. An applique as claimed in claim 1, wherein a recycled flock
applique is inserted into a recycled flock print, to create a
combination of surface textures.
10. An applique as claimed in claim 1, comprising flock fibres of a
plurality of colours and/or various recycled flock materials.
11. An applique as claimed in any preceding claim, further
comprising a recycled flock applique insert.
12. An applique as claimed in claim 1, wherein the flock is over a
textile substrate whereby textile creates structure for the
print.
13. An applique as claimed in claim 1, wherein the flock is over
sublimated textile.
14. An applique as claimed in claim 1, wherein the flock is over a
foil, metal or foil film.
15. An applique as claimed in claims 14, wherein the foil comprises
a holographic pattern.
16. An applique as claimed in claim 1, wherein the flock is over a
migration-resistant barrier or migration-resistant barrier
composite.
17. A method of manufacturing an applique of claim 1, comprising
the steps of depositing the flock onto a carrier or substrate and
applying an ink to the flock.
18. A method as claimed in claim 17, wherein the carrier or
substrate is a disposable carrier.
19. A method as claimed in claim 17, wherein the flock is deposited
onto a release adhesive.
20. A method as claimed in claim 17, comprising forming a printed
single colour or multicoloured recycled flocked surface using
recycled flock fibres.
21. A method as claimed in claim 20, wherein the flock is applied
by electrostatic flocking machine and flock fibres are flocked onto
the release adhesive which is still wet.
22. An method as claimed in claim 17, wherein 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.degree. to 120.degree..
23. A method as claimed in claim 17, comprising the step of drying
in an oven and removing any surplus and loose excess flock.
Description
[0001] The invention relates to application of designs to garments
and other fabrics.
[0002] Conventional appliques or transfers comprise man-made fibres
that do not decompose and therefore are not susceptible to
recycling.
[0003] The invention is directed towards achieving more
environmentally-friendly fabrics.
SUMMARY OF THE INVENTION
[0004] According to the invention, there is provided an applique
comprising: [0005] a substrate or carrier, [0006] flock derived
from recycled material, [0007] ink in the flock, and [0008] an
adhesive for adhering the applique to a fabric.
[0009] In one embodiment, the flock comprises fibres of random
length.
[0010] In another embodiment, the flock fibre length is in the
range of 0.1 mm to 1.2 mm
[0011] In a further embodiment, fibres are arranged in predefined
areas extending uniformly across the carrier or substrate.
[0012] 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.
[0013] In another embodiment, the flock is printed with ink
according to a design.
[0014] In a further embodiment, the applique comprises at least two
adhesive layers.
[0015] In one embodiment, a recycled flock applique is inserted
into a flock print, to create a combination of surface
textures.
[0016] In another embodiment, a recycled flock applique is inserted
into a recycled flock print, to create a combination of surface
textures.
[0017] In a further embodiment, the applique comprises flock fibres
of a plurality of colours and/or various recycled flock
materials.
[0018] In one embodiment, the applique further comprises a recycled
flock applique insert.
[0019] In another embodiment, the flock is over a textile substrate
whereby textile creates structure for the print.
[0020] In a further embodiment, the flock is over sublimated
textile.
[0021] In one embodiment, the flock is over a foil, metal or foil
film.
[0022] In another embodiment, the foil comprises a holographic
pattern.
[0023] In a further embodiment, the flock is over a
migration-resistant barrier or migration-resistant barrier
composite.
[0024] 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.
[0025] In one embodiment, the carrier or substrate is a disposable
carrier.
[0026] In another embodiment, the flock is deposited onto a release
adhesive.
[0027] In a further embodiment the method comprises forming a
printed single colour or multicoloured recycled flocked surface
using recycled flock fibres.
[0028] In one embodiment, the flock is applied by electrostatic
flocking machine and flock fibres are flocked onto the release
adhesive which is still wet.
[0029] 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.degree. to 120.degree..
[0030] In a further embodiment, the method comprises the step of
drying in an oven and removing any surplus and loose excess
flock.
DETAILED DESCRIPTION OF THE INVENTION
[0031] 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:
[0032] FIGS. 1(a) to (e) are a series of cross-sectional diagrams
showing stages of manufacturing of an applique of the invention, in
which FIG. 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, and FIG. 1(d) shows the
stage after adhesive has been bonded to the flock fibres to
complete the applique; and FIG. 1.(e) is a view after heat
application bonding to fabric;
[0033] FIG. 2 is a view after removal of the disposable
carrier;
[0034] FIGS. 3 to 10 are diagrammatic cross-sectional views showing
appliques of various embodiments, in which:
[0035] FIG. 3 shows use of an eco flock encapsulated by a flock
print,
[0036] FIG. 4 shows an eco flock encapsulated by a recycled flock
transfer,
[0037] FIGS. 5(a), (b), and (c) show stages of manufacture of an
applique with a mixed fibre eco flock transfer,
[0038] FIG. 6 shows flocking directly onto an adhesive layer,
[0039] FIG. 7 shows flocking directly onto a satin or textile
material,
[0040] FIG. 8 shows flocking directly onto a sublimated satin
textile mat,
[0041] FIG. 9 shows flocking directly onto a metal foil or
holographic foil film, and
[0042] FIG. 10 shows flocking directly onto a migration resistant
barrier.
DESCRIPTION OF THE EMBODIMENTS
[0043] 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.
[0044] 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.
[0045] A method of manufacturing a recycled flock applique includes
the steps of: [0046] (i) providing a substrate or carrier
comprising of recycled flock fibres and a flock adhesive, [0047]
(ii) providing a substrate or carrier comprising of skeleton flock
fibres and a flock adhesive, [0048] (ii) providing a coloured image
in the design, and [0049] (iii) providing a permanent adhesive
layer to bind recycled flock fibres.
[0050] 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.
[0051] 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.
[0052] 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.degree. 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.
[0053] 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.
[0054] The recycled textile materials are ground and sieved to
textile length, typically 0.1 mm to 1.2 mm These fibres, unlike
conventional fibres, can be of random shape. The non-recycled
material content averages 10%-75% of the weight of the
transfer.
[0055] 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.
[0056] 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.
[0057] 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
[0058] 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.
[0059] 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.
[0060] 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.
[0061] A starch-based adhesive may be employed, so that it may be
recycled.
[0062] 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
[0063] 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.
[0064] 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 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.
Alternatively, applications can be carried out using high frequency
welding or ultrasonic bonding.
[0065] The applique is applied by pressing under heat, in this
example 160.degree. C. and 2 Bar for 20 seconds, allowed to cool,
and the disposable carrier is peeled from the applique.
[0066] 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.
[0067] 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.
[0068] 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.
[0069] 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).
[0070] 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. In this embodiment, the various layers are
applied as follows: [0071] A release adhesive 21 is printed onto
the carrier 25 and flock 20 is deposited onto the release adhesive,
and a permanent 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 in FIG. 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.
[0072] 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. In this embodiment, the layers are
applied as follows: [0073] A release adhesive is printed onto a
carrier 35 and flock 30 is deposited onto the release adhesive, and
a permanent 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 in FIG. 7 is
bonded onto the graphic through heat application, to create a
multilayer graphic.
[0074] An advantage of this system is that it is possible to create
a multiple-layer recycled flock graphic.
[0075] 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 advantage of this
configuration is that infinite textile patterns can be created
through the use of different colours/types of flock fibres in
combination with printing graphics.
[0076] 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. In this embodiment, the various layers are
applied as follows: [0077] A release adhesive is printed onto a
carrier 48 and flock 41, 42 is deposited onto the release adhesive,
and a 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 in FIG. 7 is
bonded onto the graphic through heat application, to create a
multilayer graphic.
[0078] An advantage of this system is that it is possible to create
a multiple layer recycled flock graphic.
[0079] 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. In this
embodiment, the various layers are applied as follows: [0080] A
release adhesive is printed onto a carrier 48 and flock 41, 42 is
deposited onto the release adhesive, and a permanent adhesive 40 is
screen-printed onto back of the flock in areas where graphic is
required. A pre-manufactured recycled fabric composite 49 is bonded
onto the graphic through heat application, to create a multilayer
recycled applique.
[0081] An advantage of this system is that it is possible to create
a multiple layer recycled flock graphic incorporating recycled
fabric.
[0082] Referring to FIG. 6 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.
[0083] 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.
[0084] 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.
[0085] 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. 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.
[0086] 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.
[0087] 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.
[0088] In an arrangement shown in FIG. 10 foil, 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.
[0089] 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.
[0090] 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.
[0091] 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.
[0092] 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.
[0093] The invention is not limited to the embodiments described
but may be varied in construction and detail.
* * * * *