Applique to provide a design on a fabric

Abstract

An appliqu of the invention comprises a disposable carrier film onto which a release layer and PU inks are printed using layering techniques. The ink layers can be multicolored and each color is applied sequentially using a conventional screen-printing method. A back-up, a lacquer layer, and an adhesive layer are printed in sequence over the ink layers. The ink includes reflective particles providing the optical effect of a 3-dimensional appliqu. The artwork is created by overlapping design layers to controlled specification sequences. The ink, because of the additives, creates a desired color tone, and this may be enhanced by layering of the ink in an overlapping region. Thus, there are three main regions, namely a central region with reflective ink, a shoulder region with overlapping matt and reflective inks and an outer region with only matt ink.

Claims

1. An appliqu for applying a design to a fabric, the appliqu comprising: at least one ink layer printed on a substrate; and an application adhesive suitable for adhering the appliqu to a fabric, wherein the appliqu is adapted to provide a three-dimensional visual effect.

2. An appliqu as claimed in claim 1, wherein at least one ink layer incorporates an additive to provide a three-dimensional visual effect in combination with other parts of the appliqu.

3. An appliqu as claimed in claim 2, wherein the additive comprises reflective particles.

4. An appliqu as claimed in claim 3, wherein the reflective particles are coated in an oxide.

5. An appliqu as claimed in claim 2, wherein the additive comprises an agent which expands, such as with application of heat.

6. An appliqu as claimed in any claim 5, wherein the agent is a blowing agent.

7. An appliqu as claimed in claim 4, wherein there are multiple layers of ink at least two of which only partly overlap.

8. An appliqu as claimed in claim 7, wherein a layer includes an additive comprising reflective particles.

9. An appliqu as claimed in claim 1, wherein the substrate is non-planar.

10. An appliqu as claimed in claim 1, further comprising an insert of a material configured to provide a surface profile.

11. An appliqu as claimed in claim 10, wherein the insert bridges stacks of layers including the ink and the substrate.

12. An appliqu as claimed in claim 11, wherein the stacks include an upper disposable carrier, a release adhesive layer, an ink layer, and an opaque backer layer which is bonded to a lacquer layer.

13. An appliqu as claimed in claim 11, wherein the insert is secured to the stack on each side by adhesive in a manner whereby it is free-floating within the appliqu.

14. An appliqu as claimed in claim 1, wherein an ink is printed alongside a flock on a substrate in a desired pattern.

15. An appliqu as claimed in claim 14, wherein the surfaces of the ink and of the flock are at different levels.

16. An appliqu as claimed in claim 14, wherein the flock fibres are reinforced with a permanent thermosetting adhesive layer.

17. A garment or piece of fabric comprising an appliqu of claim 1 adhered thereto.

18. An appliqu as in claim 12, where the carrier is of polyester material.

19. An appliqu as claimed in claim 4, wherein the oxide is a dioxide.

20. An appliqu as claimed in claim 4, wherein the oxide is a monoxide.

21. An appliqu as claimed in claim 4, wherein the oxide is iron oxide.

22. An appliqu as claimed in claim 10, wherein the insert spans a gap in the applique, the gap being a portion of the appliqu without an ink layer and without the substrate and bounded on opposite sides by the ink layer and the substrate.

23. An appliqu as claimed in claim 11, wherein the stacks include an upper disposable carrier, an ink layer, and an opaque backer layer which is bonded to a lacquer layer.

24. An appliqu as claimed in claim 11, wherein the stacks include an upper disposable carrier, a release adhesive layer, an ink layer, and an opaque backer layer which is bonded to an intermediate layer.

25. An appliqu as claimed in claim 12, wherein the lacquer layer allows the appliqu to stretch when the appliqu is applied to a fabric.

26. An appliqu as claimed in claim 1, further comprising an insert of a material comprising at least one of a fabric or a foil configured to provide a surface profile.

27. An appliqu as claimed in claim 26, wherein the insert spans a gap in the applique, the gap being a portion of the appliqu without an ink layer and without the substrate and bounded on opposite sides by the ink layer and the substrate.

28. An appliqu as claimed in claim 27, wherein sections of the appliqu bounding the gap include an upper disposable carrier, an ink layer, and an opaque backer layer which is bonded to an intermediate layer.

29. An appliqu as claimed in claim 27, wherein sections of the appliqu bounding the gap include an upper disposable carrier, an ink layer, and an opaque backer layer which is bonded to a lacquer layer.

30. An appliqu for applying a design to a fabric, the appliqu comprising: at least one ink layer printed on a substrate; and an application adhesive suitable for adhering the appliqu to a fabric, wherein the appliqu is adapted to provide a three-dimensional visual effect, wherein there are multiple layers of ink, and wherein at least one of: there are multiple layers of ink at least two of which only partly overlap; the appliqu comprises an upper disposable carrier; the at least one ink is a polyurethane ink; an intermediate layer is positioned between a backer layer and an adhesive layer; the appliqu comprises an adhesive layer comprising a hotmelt powder; or the appliqu comprises an adhesive layer comprising an activated permanent thermosetting compound.

31. An appliqu as claimed in claim 30, wherein the backer layer comprises a polyurethane-based ink.

32. An appliqu as claimed in claim 30, wherein the backer layer comprises a single polyurethane ink layer or multiple polyurethane ink layers.

33. An appliqu as claimed in claim 30, wherein: with respect to the multiple layers of ink, at least two of which only partly overlap.

34. An appliqu as claimed in claim 30, wherein: the appliqu comprises the upper disposable carrier.

35. An appliqu as claimed in claim 30, wherein: the at least one ink is a polyurethane ink.

36. An appliqu as claimed in claim 30, wherein: the intermediate layer is positioned between the backer layer and the adhesive layer.

37. An appliqu as claimed in claim 30, wherein: the appliqu comprises the adhesive layer comprising the hotmelt powder.

38. An appliqu as claimed in claim 30, wherein: the appliqu comprises the adhesive layer comprising the activated permanent thermosetting compound.

39. An appliqu as claimed in claim 30, wherein: the appliqu comprises the upper disposable carrier and a release adhesive layer.

40. An appliqu as claimed in claim 30, wherein: the intermediate layer is positioned between the backer layer and the adhesive layer; and the intermediate layer is a lacquer layer.

41. An appliqu as claimed in claim 30, wherein: the appliqu comprises an adhesive layer comprising a migration-resistant blocking agent.

42. An appliqu as claimed in claim 30, wherein a layer includes an additive comprising reflective particles and at least one other layer does not include an additive.

43. An appliqu as claimed in claim 30, wherein a layer includes an additive comprising reflective particles.

44. An appliqu as claimed in claim 30, wherein a layer includes an additive.

45. An appliqu as claimed in claim 30, wherein a layer includes an additive and at least one other layer does not include an additive.

Description

DETAILED DESCRIPTION OF THE INVENTION

(1) 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:

(2) FIG. 1 is a cross-sectional view of an appliqu of the invention for application of a design to a garment, FIG. 2 is a cross-sectional view of the appliqu after application onto textile fabric (F), and FIG. 3 is a plan view of the appliqu;

(3) FIGS. 4 and 5 are cross-sectional views of an appliqu before and after application to a fabric, the appliqu having a PU ink incorporating a blowing agent to give a 3D effect;

(4) FIGS. 6 and 7 are cross-sectional views of an appliqu before and after application to a fabric, the appliqu having PU ink raised in a screen-printed pattern to provide a 3D effect;

(5) FIGS. 8 and 9 are cross-sectional views of an appliqu before and after application to a fabric, the appliqu having a 3D textile insert; and

(6) FIGS. 10 and 11 are cross-sectional views of an appliqu before and after application to a fabric, the appliqu having flock alongside PU ink on a single substrate to provide a 3D effect.

(7) The invention provides an appliqu which gives a 3D visual effect. This is achieved by way of ink layering techniques and/or incorporation of additives such as reflective particles in an ink and/or non-planar configuration of a substrate and/or incorporation of a textile insert to provide physically different depths, and/or deposition of ink and flock of different or similar depths alongside each other in a pattern.

(8) Referring to FIGS. 1 to 3, an appliqu 9 of the invention comprises a disposable carrier film 7 onto which a release layer 6 and PU inks 5 and 4 are printed using layering techniques. The ink layers 4 and 5 can be multicoloured and each colour is applied sequentially using a conventional screen-printing method. A back-up 3, a lacquer layer 2, and an adhesive layer 1 are printed in sequence over the ink layers.

(9) The ink 4 includes additives, in this embodiment, reflective particles. These aspects provide the optical effect of a 3-dimensional appliqu. The artwork is created by overlapping design layers to controlled specification sequences. The ink 4, because of the additives, creates a desired colour tone, and this may be enhanced by layering of the inks as illustrated in the overlapping region 8. Thus, as viewed in FIG. 3, there are three main regions, namely: a central region with reflective ink 4, a shoulder region with overlapping matt and reflective inks 4 and 5, and an outer region with only matt ink 5.

(10) The ink 4, being blended with light reflecting particles, has a bright, sparkly shimmer, with a degree of light scattering behaviour. The light scattering ability of the additive is dependent directly on the concentration of additive blended into the ink Blends with higher amounts of the additive will scatter more light than those with lower amounts of additive. Polyurethane ink has a low light scattering ability. Therefore the ink 5 has a matt appearance and contrast between the matt ink 5 and the reflective ink 4 intensifies the optical 3-dimensional effect.

(11) The adhesive 1 comprises an adhesive system made from adhesive combined with hotmelt adhesive powder. The adhesive can include one or more of (but not limited to) acrylic; epoxide; polyamide; polyester; polyolefin; polyurethane; and polyurethane ester adhesives. For example, the adhesive TO485 polyurethane adhesive can be used.

(12) To apply a design to a textile, the appliqu 9 is simply placed on the textile with the disposable carrier face up 7, with the adhesive layer 1 in contact with the textile. Heat and pressure are applied so the adhesive 1 impregnates into the fabric (F) to seal the appliqu in place.

(13) The invention has the major advantage of optically creating a 3-dimensional effect even there is minimal impact on the manufacturing process. Also, the appliqu is very simple to apply with heat and pressure, in a conventional manner.

(14) Referring to FIG. 4 and FIG. 5, in another embodiment, an appliqu 10 has a physical 3-dimensional effect by printing PU inks 15 alongside inks 14 blended with additives which give varying heights to appliqu (best illustrated in FIG. 5). The additives in the ink 14 are chemically formulated blowing agents, and control of composition proportions allows excellent control of the ink thickness. The blowing agents are activated with heat upon application to expand from the depth shown in FIG. 4 to that shown in FIG. 5.

(15) Referring to FIG. 6 and FIG. 7, in another embodiment, an appliqu 20 provides a physical 3-dimensional effect by printing inks 24 and 25 of varying thicknesses onto a disposable carrier 27. Thus, there is flat polyurethane ink and raised inks. The invention has the major advantage of incorporating different depth of deposit, which is visually noticeable. The raised ink 24 is raised because of the use of thick stencil screen technology and PU ink of a higher viscosity to achieve the greater height. Also, the appliqu is easy to apply to fabric (F) using heat and pressure in a conventional manner. The surface of the appliqu can be textured. Again, the appliqu 20 has a backer layer 23, a lacquer layer 22, and an adhesive dispersion 21.

(16) Referring to FIG. 8 and FIG. 9, in another embodiment, an appliqu 30 provides a physical 3-dimensional effect by including in an appliqu a laser or die-cut motif, textile insert 34 between stacks of PU ink 35, backer 33, lacquer 32, and adhesive dispersion 31. The insert is applied so that the appliqu can be heat-applied in an easy one-step operation.

(17) The insert may alternatively be of foil, flock, natural or synthetic materials including textiles, film or hologram for example. The physical configuration is achieved by leaving an open area for the insert to show through. The insert is cut smaller than the total design area so that some adhesive remains outside the insert area for application.

(18) The adhesive 21 is a hot-melt adhesive comprises a thermoplastic film made from aromatic or aliphatic thermoplastic. The hot-melt film can include one or more of, (but not limited to) polyamide; polyester; polyolefin; polyurethane; and polyurethane ester. For example, the hot-melt film can be 76 m Bemis Polyester Hotmelt Film 5214.

(19) Referring to FIGS. 10 and 11, in another embodiment, in an appliqu 40 a physical 3-dimensional effect is achieved by printing multiple colours of flat PU inks 45 and multiple flocks 44 onto the same disposable carrier 47. The PU inks 45 and backer, lacquer, and adhesive layers 43, 42 and 41 are printed onto the disposable carrier 47 in the areas where PU ink is desired. Areas of the design where flock 44 is required are left void on the carrier during PU ink printing. These areas are then electrostatically flocked in the desired pattern and the flock adhesive 48 is printed last. The appliqu 40 is easy to apply to fabric (F) using heat and pressure. The surface of the appliqu has a visible height difference between the flat PU ink 45 and the raised flock fibres 44.

(20) This embodiment has the major advantage of creating a combination print where richly textured pile gives a plush hand feel alongside the smooth flat surface of polyurethane inks. Thus, the invention makes use of combining polymer appliqu technology with flock printing techniques. This combines, for example, the use of lightweight, sports-performance polyurethane appliqu materials with flock printing technology directly onto the carrier to create a polyurethane-flock combined appliqu. The flock can be any electro statically chargeable fibre, such as fibres made from rayon, nylon, cotton, acrylic and polyester.

(21) The Polyurethane adhesives 1, 11, 21, 31, and 41 referred to above are all of the cross-linking solvent-based polyurethane emulsion type or water-based polyurethane emulsion type, the particular cross-linking for each adhesive being chosen to suit the substrate. While alternatives are possible such as an acrylic-based adhesive for the release adhesive 46 (on disposable Polyester film 47), it is believed that polyurethane emulsions are more effective.

(22) The flock adhesive 48 referred to above is of the cross-linking water-based acrylic emulsion type, the particular cross-linking for each adhesive being chosen to suit the substrate. Alternatives are possible such as a polyurethane-based adhesive.

(23) The following summarizes advantageous features of the invention in various embodiments to achieve a 3-dimensional effect: Artwork layering techniques, ink formulations with additives such as light reflective particles, printing inks of varying thicknesses onto a carrier, and/or printing both flock alongside dink on the same carrier. A combination of a film-backed polyurethane heat transfer with a laser or die cut motif of fabric or other materials, where both are combined to allow them to be heat applied in an easy one step heat application operation. The combination of a PU appliqu with other materials creates a physical 3-dimensional effect. The ink incorporates blended mass-reducing particles, and/or fluorescent particles, and/or phosphorescent particles, and/or ultra violet particles or inks, and/or thermochromic particles, and/or photochromic particles, and/or electrochromic particles, and/or mirror particles, and/or porous particles, and/or metallic particles, and/or solar charged particles, and/or kinetic charged particles, and/or magnetic particles, and/or chemical agents which undergo changes to structure and thickness at defined temperatures Inks of different thicknesses are printed on the same carrier to achieve different heights. The ink has added colour pigment and/or dyes. The ink may be fully transparent, or translucent, or opaque. The ink may be ultra violet activated, have elastic stretch and recovery characteristics, be compression resistant, be malleable, and/or have compression and recovery characteristics. It may incorporate fabric material, which may be sublimated with a pre-printed pattern, or may be in its natural state. The fabric material may be pre-dyed and or coated. Dyed fabric can include but not exclusively standard textile dyes but this can also include metallic coatings, fluorescent coatings/dyes, heathers and other surface treatment. An insert may be included and this may be a fabric which is a woven fibre including, plain, twill, crow's feet, basket or satin weave. These fabrics can be made of: Natural Fabrics: linen, silk, satin, denim, canvas, jute, velvet, cotton, wool, organza, brocades, felt, natural recycled fabrics, organic fabrics, hemp. Synthetic Fabrics: polycotton, viscose, acetate, polyamide, organza, chiffon, sateen, lycra, spandex, lurex, taffeta, velour, polyester, acrylic, nylon, technical/composite fabrics, or recycled fabrics. The insert may be a flocked appliqu, or a film which can be coated and uncoated, or a metallic foil or an organometallic foil which can be coated and uncoated. The insert may be a motif, may have a holographic pattern, insert includes audio or visual digital components, include RF Id Tags components. Flock fibres, where included, can be pre dyed. The flock fibre can be any electro statically chargeable fibre, such as fibres made from rayon, cotton, nylon, acrylic and polyester. The flock fibres are of a high lustre type, and/or translucent, and/or of differing lengths, and/or of a pre-determined length, and/or contain an Ultra Violet coating Resin, where used, could encapsulate delicate fabrics or other materials. An application adhesive may be a polyurethane resin, or a hotmelt, or an acrylic co-polymer and a polyurethane resin.

(24) The following are examples of the inks, adhesives and additives, which can be used in various embodiments.

(25) Polyurethane Ink 4:

(26) Product: Nylotex NX Series

(27) Chemical Description: Polyurethane ink dispersion

(28) Polyurethane Ink 5:

(29) Product: Nylotex NX Series

(30) Chemical Description: Polyurethane ink dispersion

(31) Polyurethane Ink 14:

(32) Product: Nylotex NX Series

(33) Chemical Description: Polyurethane ink dispersion

(34) Polyurethane Ink 15:

(35) Product: Nylotex NX Series

(36) Chemical Description: Polyurethane ink dispersion

(37) Polyurethane Ink 24:

(38) Product: Nylotex NX Series

(39) Chemical Description: Polyurethane ink dispersion

(40) Polyurethane Ink 25:

(41) Product: Nylotex NX Series

(42) Chemical Description: Polyurethane ink dispersion

(43) Polyurethane Ink 35:

(44) Product: Nylotex NX Series

(45) Chemical Description: Polyurethane ink dispersion

(46) Polyurethane ink 45:

(47) Product: Nylotex NX Series

(48) Chemical Description: Polyurethane ink dispersion

(49) Backer 3:

(50) Product: Nylotex NX Series

(51) Chemical Description: Polyurethane ink dispersion

(52) Backer 13:

(53) Product: Nylotex NX Series

(54) Chemical Description: Polyurethane ink dispersion

(55) Backer 23:

(56) Product: Nylotex NX Series

(57) Chemical Description: Polyurethane ink dispersion

(58) Backer 33:

(59) Product: Nylotex NX Series

(60) Chemical Description: Polyurethane ink dispersion

(61) Backer 43:

(62) Product: Nylotex NX Series

(63) Chemical Description: Polyurethane ink dispersion

(64) Lacquer 2:

(65) Product: TO458

(66) Chemical Description: Polyurethane adhesive dispersion

(67) Lacquer 12:

(68) Product: TO458

(69) Chemical Description: Polyurethane adhesive dispersion

(70) Lacquer 22:

(71) Product: TO458

(72) Chemical Description: Polyurethane adhesive dispersion

(73) Lacquer 32:

(74) Product: TO458

(75) Chemical Description: Polyurethane adhesive dispersion

(76) Lacquer 42:

(77) Product: TO458

(78) Chemical Description: Polyurethane adhesive dispersion

(79) Adhesive 1:

(80) Product: D 1365 & TO458

(81) Chemical Description: Co-polyester hotmelt adhesive powder dispersed in a Polyurethane adhesive dispersion

(82) Adhesive 11:

(83) Product: D 1365 & TO458

(84) Chemical Description: Co-polyester hotmelt adhesive powder dispersed in a Polyurethane adhesive dispersion

(85) Adhesive 21:

(86) Product: D 1365 & TO458

(87) Chemical Description: Co-polyester hotmelt adhesive powder dispersed in a Polyurethane adhesive dispersion

(88) Adhesive 31:

(89) Product: D 1365 & TO458

(90) Chemical Description: Co-polyester hotmelt adhesive powder dispersed in a Polyurethane adhesive dispersion

(91) Adhesive 41:

(92) Product: D 1365 & TO458

(93) Chemical Description: Co-polyester hotmelt adhesive powder dispersed in a Polyurethane adhesive dispersion

(94) Adhesive 48:

(95) Product: TUBTRANS BOND-3,

(96) Chemical Description: Acrylic Co-Polymer in aqueous dispersion

(97) Additive in ink 4:

(98) Product: SIPI558 FM Pearl Glitter Specialty Effect,

(99) Chemical Description: Mica platelets coated with various thicknesses of titanium dioxide or iron oxide.

(100) Additive in ink 14:

(101) Product: NUPUFF 10250NPF,

(102) Chemical Description: Blowing agent dispersed in PU ink.

(103) Polyurethane Ink Product: Nylotex NX Series

(104) Supplier of above inks:

(105) Fujifilm Sericol Limited

(106) Pysons Road, Broadstairs, Kent. CT10 2LE, England.

(107) Polyurethane Ink Backer Product: Nylotex NX Series

(108) Supplier of above adhesives:

(109) Fujifilm Sericol Limited,

(110) Pysons Road, Broadstairs, Kent. CT10 2LE, England.

(111) Lacquer Product: TO458

(112) Supplier of above adhesives:

(113) Fujifilm Sericol Limited,

(114) Pysons Road, Broadstairs, Kent. CT10 2LE, England.

(115) Adhesive Product: TO458

(116) Supplier of above adhesives:

(117) Fujifilm Sericol Limited,

(118) Pysons Road, Broadstairs, Kent. CT10 2LE, England.

(119) Adhesive Product: Tubitrans Bond 3

(120) Supplier of above adhesives:

(121) CHT R. BEITLICH GMBH,

(122) Werk Oyten, Rudolf-Diesel-StraBe 19-21, D-28876 Oyten, Germany

(123) Hotmelt Product:

(124) Product: ADHESIVE HOTMELT NAME

(125) Chemical Description: EMS-Griltech Griltex D 1365E Copolyester Hotmelt Adhesive

(126) Supplier of above adhesives: EMS-CHEMIE AG

(127) Business Unit EMS-GRILTECH, Reichenauerstrasse, CH-7013 Domat, Switzerland.

(128) Additive to ink 4: Product: SIPI558 FM Pearl Glitter Speciality Effect, Supplier of above additive: Nazdar Ltd., Barton Road Heaton, Mersey, Stockport, England, SK4 3EG

(129) Additive Product to ink 14: NUPUFF 10250NPF,

(130) Supplier of above additive: Nazdar Ltd., Barton Road Heaton, Mersey, Stockport, England, SK4 3EG

(131) The invention is not limited to the embodiments described but may be varied in construction and detail. For example, the appliqu could be applied to a fabric other than that of a garment.