Pad printed apparel

Abstract

A tagless article of apparel formed from a knitted fabric having a selected thickness, the article of apparel having inner and outer surfaces, and a product label pad printed directly on the inner surface from a clich with an ink composition comprising an ink, a solvent, and a hardener, the clich having a depth sufficient to cause the ink composition to penetrate the inner surface of the fabric to a depth less than the thickness of the fabric.

Claims

1. A method for pad printing a pattern comprising product label information on a textile substrate with a pad printing machine having a clich, at least one printing pad, and at least one printing area, to form a tagless product label, the method comprising the steps of: positioning a textile substrate on the printing area of the pad printing machine, the textile substrate having a selected thickness and inner and outer surfaces; transferring a pattern comprising product label information from the clich to the at least one printing pad, the pattern having a depth less than the thickness of the textile substrate and formed from a composition including an ink, a solvent, and a hardener, such that the composition dries without penetrating the entire thickness of the textile substrate; and transferring the pattern comprising the product label information from the at least one printing pad to one of the inner surface or the outer surface of the textile substrate, the transferred pattern being printed on the textile substrate such that the pattern is readable following at least fifty launderings.

2. The method of claim 1, wherein the textile substrate comprises a knitted textile substrate.

3. The method of claim 1, wherein the textile substrate comprises an article of apparel.

4. The method of claim 3, wherein the article of apparel is underwear.

5. The method of claim 3, wherein the article of apparel is outerwear.

6. The method of claim 3, wherein the article of apparel is activewear.

7. The method of claim 3, wherein the article of apparel is intimate apparel.

8. The method of claim 1, wherein the textile substrate is formed from materials selected from the group consisting of cotton, polyester, nylon, and elastomers.

9. The method of claim 1, wherein the textile substrate has a thickness of at least about 40 microns.

10. The method of claim 1, wherein the ink is acrylic-based.

11. The method of claim 1, wherein the cliche has a depth of between about 40 microns and 100 microns.

12. The method of claim 1, wherein the product label is comprised of a plurality of colors.

13. The method of claim 1, wherein the product label is an embellishment.

14. The method of claim 13, wherein the embellishment is comprised of a plurality of colors.

15. A method of printing a pattern on a textile substrate, the method comprising: positioning a textile substrate on a printing area of a pad printing machine, the textile substrate having an inner surface and an outer surface opposite the inner surface; transferring a pattern from a cliche of the pad printing machine to a printing pad of the pad printing machine, the pattern formed from a composition comprising an ink, a solvent, and a hardener, and the pattern having a depth less than a thickness of the textile substrate between the inner surface and the outer surface; and applying, with the printing pad, the pattern to one of the inner surface or the outer surface of the textile substrate positioned on the printing area, wherein the pattern comprising the composition penetrates the inner surface or the outer surface of the textile substrate to a depth less than the thickness of the textile substrate, wherein the pattern is substantially not visible from the other surface of the inner surface or the outer surface.

16. The method of claim 15, wherein the printing area comprises a flat surface, and wherein positioning the textile substrate on the printing area comprises laying the textile substrate flat on the flat surface of the printing area.

17. The method of claim 15, wherein the textile substrate comprises a knitted substrate.

18. The method of claim 15, wherein the depth of the pattern is between 40 microns and 100 microns.

19. The method of claim 15, wherein the thickness of the textile substrate is greater than 50 microns.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a flow diagram of the pad printing process of the present invention;

(2) FIG. 2 illustrates the prior art process of attaching labels or patterns to articles of apparel;

(3) FIG. 3 is a sectional view taken along Line 3-3 of FIG. 2;

(4) FIG. 4 illustrates the process of pad printing patterns according to the present invention;

(5) FIG. 5 is a sectional view taken along Line 5-5 of FIG. 4; and

(6) FIGS. 6 through 8 are exemplary embodiments of apparel having patterns pad printed thereon.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(7) The present invention is directed to a method of pad printing a pattern on a textile substrate, a fabric that is pad printed with a pattern thereon, and a tagless article of apparel formed from the fabric. As it is conventionally defined in the art, pad printing refers to the transfer of an image from an etched plate, or clich, onto an object to be printed via a printing pad.

(8) As shown in FIG. 1, one aspect of the present invention is directed to the method for pad printing a pattern on a textile substrate with a pad printing machine. Pad printing machines are well known in the art and the types and features of such machines and their operational parameters are well known. Typically, however, a pad printing machine comprises a printing bed, or printing area, at least one clich, and at least one printing pad. Since such machines are known to those skilled in the art, a description of pad printing equipment is not necessary herein, except where specific features are needed to practice the present invention. One suitable pad printing machine, however, is the Inkprint 60LPE2C, available from Comec of Milan, Italy. This pad printing machine is electro-pneumatically operated and controlled by a micro-processor. The machine can print in two colors, and can print two objects simultaneously. While this particular machine has been found quite suitable, the invention is not limited to this machine or to two color printing.

(9) Unlike conventional pad printed objects, the material to be pad printed in the present invention is a substantially flat textile substrate, i.e., fabric. It has been found that the printing pads conventionally used to print indicia on solid shaped objects, such as golf balls and coffee mugs, may also be used to print patterns on substantially flat textile substrates. By the phrase substantially flat, we mean that the substrate may be pad printed while positioned in a relatively flat, or planar position (Step 110). As those skilled in the art will appreciate, textile substrates, fabrics, and apparel formed therefrom, are pliable and may be easily manipulated into numerous orientations for printing. Thus, the invention is not limited to printing on textile substrates in a particular orientation.

(10) As used herein, the textile substrate may be a knitted, woven, or non-woven fabric. The fabric may be formed from any of the conventionally known materials such as cotton, polyester, nylon, lycra, and spandex, or combinations and intimate blends thereof; however, the fabric is not limited to those materials. For example, while not an exhaustive list, the fabric may be formed from 100 percent cotton, 100 percent nylon, cotton/polyester, cotton/spandex, nylon/spandex, and polyester/cotton/spandex. As those skilled in the art will also appreciate, a wide range of fabric constructions are possible and may be pad printed according to the present invention.

(11) It has also been found that the fabric forming the textile substrate is desirably at least about 40 microns in thickness, as will be explained in greater detail below. For example, pantyhose may have a thickness of about 50 microns (0.002 inches). Other fabric constructions, such as a knitted fleece, may be over 3,000 microns (0.13 inches) in thickness.

(12) Once the textile substrate has been positioned on the printing area or bed of the pad printing machine, the pattern is transferred from the etched clich to the printing pad (Step 120). Conventionally, the patterns to be pad printed on non-textile, solid objects, are etched in the clich to a depth of between about 20 microns and 40 microns. It has been found, however, that the etched pattern of the present invention should have a depth of between about 40 microns and 100 microns. It has been found that a deeper pattern is needed to achieve the depth and penetration needed for a clear, dense printed pattern. As will be understood, however, the depth of the pattern will depend on the thickness of the textile substrate. Specifically, the depth of the etched pattern is less than the thickness of the fabric so that the printed pattern has sufficient penetration, without completely penetrating the textile substrate.

(13) While there are numerous inks that are used in pad printing applications, it has been found that an acrylic-based ink provides the most suitable image. One such ink, available from Comec, is Ink No. PLT6. As with other pad print inks, the PLT6 ink uses a quick drying solvent and will dry at room temperature in approximately 2-3 minutes. It will completely harden after about 24 hours. A hardener is also mixed with the PLT6 ink in a ratio of between about to 1 part hardener to 10 parts ink. As will be further described below, it has also been found that the hardener enhances the durability of the ink on the printed textile substrate.

(14) One pad selected for the present invention is a rectangular, silicone rubber pad. As those skilled in the art know, the choice of pads depends on a number of factors, including the dimensions of the print area, the shape of the surface to be printed, and the texture of the surface to the printed. One particular pad selected for printing rectangular patterns, such as product labels, is Model No. 267 BJB, available from Comec.

(15) After the pattern has been transferred from the clich to the pad, the pad is manipulated into position to transfer the inked image to the textile substrate (Step 130).

(16) Another aspect of the present invention is a pad printed fabric, and tagless apparel formed therefrom. By tagless apparel, it is meant apparel having product labels or other embellishments that are not comprised of traditional sewn-in product tags or embroidered patterns. By embellishment, we mean decorative or fanciful images or patterns, ornamentation, etc. Referring now to FIG. 2, an exemplary article of prior art apparel is illustrated. Specifically shown is the manner in which product labels, such as label 220, have been conventionally attached to the apparel. Label 220 is shown here sewn into the neck 210 of a shirt 200. As better seen in FIG. 3, the product label or tag 220 is shown in a sectional view as sewn to the shirt 200 along at least one stitch line 222. Further, other patterns or indicia 230, such as corporate names and logos, for example, are either sewn or embroidered to the garment 200. As described hereinabove, the steps of attaching separate labels involve additional manufacturing costs, including additional material and labor costs.

(17) Turning now to FIG. 4, the fabric and apparel 400 formed therefrom are shown with patterns 420 and 430 pad printed thereon in accordance with the present invention. Pattern 420 is exemplary of a product label, having at least one form of indicia 424 printed inside the neck band of shirt 400. Similarly, pattern 430 is shown pad printed on shirt 400 in accordance with the present invention.

(18) FIG. 5 better illustrates how a pattern, such as a product label, is formed according to the pad printing process of the present invention. As shown in FIG. 5, and as described hereinabove, the pattern transferred from the clich and printed on the article of apparel has a depth, d, that is less than the thickness, t, of the fabric to be printed. This permits the pattern to penetrate the fabric substrate, forming a deep, clear image, without completely penetrating or bleeding through the fabric. As those in the textile and apparel arts will appreciate, this results in a printed product label or other embellishment that appears substantially identical to the sewn tag 222 of the prior art garment 200. The printed image, however, is not substantially visible from the outside (back) of the garment.

(19) As further shown in FIGS. 6 through 8, the method of the present invention may be used to pad print labels, logos, or other embellishments on a wide spectrum of apparel types. Shirt 600 is exemplary of a T-shirt, underwear, outerwear, intimate apparel, or activewear with a product label 620 and a logo 630. By activewear, we mean athletic apparel, sportswear, casualwear, etc. By intimate apparel, we mean brassieres, panties, night wear, etc. Either label 620 or logo 630 may be pad printed in a single color, or multiple colors, such as portions 632 and 634 on logo 630. As shown in FIG. 7, briefs 700 are exemplary of underwear and are also shown with a printed product label 720 on waistband 710. As shown in FIG. 8, bra 800 is exemplary of intimate apparel and is shown with a printed product label 820 on strap 810.

(20) In addition to the advantages and unexpected results of the present invention, already described above, it has been found that a product label or other embellishment that is pad printed in accordance with this method has a high durability to repeated launderings. A product label or indicia printed with the ink and hardener described above will readily withstand more than 50 home launderings without any appreciable fading.

(21) Although the present invention has been described with a preferred embodiment, it is to be understood that modifications and variations may be utilized without departing from the spirit and scope of the invention, as those skilled in the art will readily understand. Such modifications and variations are considered to be within the purview and scope of the appended claims and their equivalents.