PROCESS FOR CREATING A SUBLIMATED PRINTED HEAT-SEALABLE APPLIQUE

Abstract

A process for producing a colorfast thermal applique using a polyester fabric blank, dye-sublimation printing a graphic image on the fabric blank, and calendar or heat-press laminating a multi-layer composite consisting of two opposing outer layer polyurethane adhesive sides with a middle layer or layers of die impeding and absorbing polymers adhered onto the unprinted side of the printed fabric blank. The multi-zone composite comprises a first layer of clear or pigmented polyurethane adhesive followed by a pigmented disperse die impeding and absorbing polymer layer or layers and a third clear layer of polyurethane adhesive. The first layer of the triple-layer adhesive is fused under combined temperature and pressure to the polyester blank until said first layers impregnates into said fabric blank. The fabric blank is then cut into a discrete finished applique which, upon application to a fabric substrate, does not substantially change the physical and visual characteristics of that substrate, including performance fabric substrates to which the applique is applied.

Claims

1. A heat-sealable applique, comprising: a base fabric printed on one side with a dye; and a thermal adhesive laminated to an opposing side of said base fabric, said thermal adhesive comprising a multi-layer composite, including, a first layer of polyurethane adhesive having a melting temperature within a range of between 100-140 deg. C, a third layer of polyurethane adhesive having a melting temperature within a range of between 100-140 deg. C, and a second polymer barrier layer between said first layer and third layer, said second polymer barrier layer configured for preventing dye migration there through and having a melting temperature lower than said first layer and third layer and within a range of between 150-210 deg. C, whereby said first layer is fused directly into the unprinted opposing side of said base fabric and separates said second layer and third layer from said base fabric, and said second layer prevents dye migration from said base fabric layer to said third layer and vice versa.

2. The heat-sealable applique according to claim 1, wherein the second polymer barrier layer comprises any one or more from among a group consisting of polyurethane, polyester, polyolefin and polyaramid.

3. The heat-sealable applique according to claim 1, wherein the second polymer barrier layer comprises a dye absorbing material.

4. The heat-sealable applique according to claim 3, wherein the second polymer barrier layer comprises activated carbon.

5. The heat-sealable applique according to claim 1, wherein the second polymer barrier layer comprises an opaque pigment.

6. The heat-sealable applique according to claim 5, wherein the opaque pigment comprises any one or more from among the group consisting of titanium dioxide, antimony oxide, zinc oxide, magnesium silicate, calcium sulfite, barium sulfate, zinc borate, anhydrous sodium potassium alumina silicate, calcium carbonate, and carbon black.

7. The heat-sealable applique according to claim 6, wherein the opaque pigment comprises particles suspended in polymer.

8. The heat-sealable applique according to claim 7, wherein the opaque pigment comprises white-pigmented particles and black-pigmented particles.

9. A heat-sealable applique, comprising: a base fabric printed on one side with a dye; and a thermal adhesive laminated to an opposing side of said base fabric, said thermal adhesive comprising a multi-layer composite, including, a first layer of polyurethane adhesive having a melting temperature within a range of between 110-135 deg. C, a second layer of polyurethane adhesive having a melting temperature within a range of between 110-135 deg. C, a white-pigmented polymer barrier layer between said first layer and second layer, and a black-pigmented polymer barrier layer between said first layer and second layer, said white-pigmented polymer barrier layer and said black-pigmented polymer barrier layer having a melting temperature lower than said first layer and second layer and within a range of between 155-210 deg. C, whereby said first layer is fused directly into the unprinted opposing side of said base fabric and separates said white-pigmented polymer barrier layer, said black-pigmented polymer barrier layer, and said second layer from said base fabric, and said white-pigmented polymer barrier layer and said black-pigmented polymer barrier layer prevent dye migration from said base fabric layer to said second layer and vice versa.

10. The heat-sealable applique according to claim 10, wherein the white-pigmented polymer barrier layer and said black-pigmented polymer barrier layer both comprise any one or more from among a group consisting of polyurethane, polyester, polyolefin and polyaramid.

11. The heat-sealable applique according to claim 10, wherein the black-pigmented polymer barrier layer comprises a dye absorbing material.

12. The heat-sealable applique according to claim 11, wherein the dye absorbing material comprises activated carbon.

13. The heat-sealable applique according to claim 10, wherein the white-pigmented polymer barrier layer comprises titanium dioxide particles suspended in polymer.

14. A process for making a heat-sealable applique, comprising the steps of: printing a base fabric on one side with a graphic by dye sublimation printing; obtaining a multi-layer composite adhesive film having a first layer of polyurethane adhesive with a melting temperature within a range of between 100-140 deg. C, a second layer of polyurethane adhesive having a melting temperature within a range of between 100-140 deg. C, and a polymer barrier between said first layer and second layer, said polymer barrier configured for preventing dye migration there through and having a melting temperature lower than said first layer and second layer and within a range of between 150-210 deg. C; fusing the first layer of said multi-layer composite adhesive film directly into the unprinted opposing side of said base fabric, leaving said polymer barrier layer and second layer separated from the base fabric; whereby said polymer barrier layer prevents dye migration from said base fabric layer to said second layer and vice versa.

15. The process for making a heat-sealable applique according to claim 14, wherein said step of obtaining said multi-layer composite adhesive film further comprises a multi-layer polymer barrier layer having a white-pigmented layer and a black-pigmented layer.

16. The process for making a heat-sealable applique according to claim 15, wherein said white-pigmented layer comprises titanium-dioxide particles suspended in polymer and said black-pigmented layer comprises carbon black particles suspended in polymer.

17. The process for making a heat-sealable applique according to claim 14, wherein said step of fusing the first layer of said multi-layer composite adhesive film directly into the unprinted opposing side of said base fabric comprises applying pressure.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Other objects, features, and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiment and certain modifications thereof when taken together with the accompanying drawings in which:

[0020] FIG. 1 is a top view of an applique emblem 10 according to the present invention as applied to apparel.

[0021] FIG. 2 is a cross-sectional view of an embodiment of the present invention taken at line x-x of FIG. 1.

[0022] FIG. 3 is a process diagram of the process for creating the applique 10 of FIGS. 1-2.

[0023] FIG. 4 is a cross-sectional view of an alternate embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0024] The present invention is a process for producing a heat-activated applique that retains graphical integrity by preventing migration of dye from the transfer or through the transfer from the garment fabric below. The opaque layered-adhesive composite also prevents show through of the garment fabric whilst providing minimal visual opaque adhesive at the edge of the applique. A preferred embodiment of the heat-activated applique comprises a graphic printed onto an applique base fabric, and then laminated with a three-layer heat-activated adhesive.

[0025] With combined reference to FIGS. 1 and 2, the heat-activated applique 10 of the present invention includes a base fabric layer 14 printed on one side, and laminated on the other side to a three-layer thermal adhesive composite comprising two heat-activated adhesive layers 11, 13 sandwiching a dye migration barrier layer 12. The lower heat-activated adhesive layer 11 bonds the applique 10 to a substrate 15, which may be any fabric or leather or textile substrate. A graphic image 9 is printed atop the applique base fabric layer 14. The graphic 9 may be any decorative image or shape including alpha-numeric characters, logos or images. The graphic 9 can be printed atop the applique base fabric layer 14 by sublimation printing in which a dye is heat transferred into the surface of the fabric layer. The three composite thermal adhesive layers 11, 12, 13 collectively block migration of disperse dyes to the substrate 15 or from the substrate 15 to printed applique layer 14.

[0026] In a preferred embodiment the middle layer 12 comprises a layer of white-pigmented polyurethane blended with one or more dye-absorbing materials, preferably aluminum silicate, and having a melting point higher than upper and lower layers 11, 13 and within the range between 150-210 degrees C. The preferred white pigment in middle adhesive layer 12 is titanium dioxide (TiO2). Lower adhesive layer 11 comprises a clear layer of polyurethane with a melting point within the range between 100-140 degrees C. The lower adhesive layer 11 is used as the adhesive for securing the applique 10 to substrate 15 (apparel or other products), while the upper adhesive layer 13 comprises a clear polyurethane layer with a melting point with the range of 110-140 degrees C. reserved for securing the printed applique to base fabric layer 14. The middle polymer layer 12 serves to provide an opaque or semi-opaque layer, the white pigment serving as light reflecting suspended insoluble particles with no migration tendency themselves. The thermoplastic in this middle layer 12 has good dye migration resistance by barrier and/or absorption, and high temperature and UV resistance. All three layers 11, 12, 13 when combined provide a robust migration barrier that inhibits migration of ink or dyes to the substrate 15, or vice versa.

[0027] The applique 10 is well-suited for application to any fabric or leather substrate, including coarser non-woven fabrics such as felt and fleece (substrate being herein defined as any leather or fabric, whether woven fabric or non-woven fabric, or any other flexible material used for apparel, signage, banners, pennants or similar, and non-woven being herein defined as any fabric substrate produced by processes other than weaving).

[0028] FIG. 3 is a process diagram of the process for creating the applique 10 of FIGS. 1-2. The process begins by obtaining the components thereof.

[0029] Specifically, at step 100 a polyester fabric blank is acquired.

[0030] At step 110 a three-layer polymer thermal adhesive composite is acquired with adhesive laminate layers (combined layers 11, 12, 13). The triple-layer composite laminate 11, 12, 13 is preferably created in advance for ready-made application to the applique fabric base layer 14. One skilled in the art will readily understand that the separate layers 11, 12, 13 may be individually-applied to applique base fabric layer 14 or substrate 15 with the same result, but it is more efficient and economical to pre-produce the triple-layer composite laminate in advance for ready-made application to the applique base fabric layer 14. Pre-production of triple-layer composite laminate layer (combined layers 11, 12, 13) is accomplished as follows:

[0031] At step 120 a lower adhesive layer 11 of clear or pigmented ink resistant polyurethane is laminated to the white middle polymer layer 12 at a first temperature preferably within a range of from 100 degrees C. to 140 degrees C., and at step 122 (which is preferably but not necessarily performed simultaneous to 120) an upper adhesive layer 13 of clear polyurethane is laminated to middle adhesive layer 12 at said first temperature. The lower adhesive layer 11 has a melting range of 100-140 degrees C., and the upper adhesive layer 13 has a melt range of 110-140 degrees C. The first temperature is sufficient to melt the lower and upper adhesive layers 11, 13. This will fuse the lower and upper adhesive layers 11, 13 to the middle polymer layer 12, but the first temperature is below the melting range of the white middle layer 12. This lower adhesive layer 11 is used as the adhesive for securing the applique 10 to substrate 15 or other products, while the upper adhesive layer 13 is reserved for securement to applique base fabric layer 14. This step 120 effectively forms the composite triple-layer polyurethane adhesive laminate, that it may be sandwiched between sheets of release paper for later use. Upon cooling the result of step 120 is a triple-layer polymer composite laminate layer comprising combined layers 11, 12 and 13.

[0032] Referring back to the applique base fabric layer 14, at step 130 a graphic 9 is printed onto one side of the base fabric layer 14.

[0033] At step 140 the triple-layer composite adhesive laminate produced in step 120 including layers of adhesive 11, 13, and polymer disperse dye impeding and absorbing layer 12 are fused to the printed fabric applique layer 14. Upper layer 13 is fused directly to the non-printed side of the base fabric layer 14 under a combined temperature and pressure condition sufficient to activate and flow the clear upper layer of adhesive 13 into the base fabric layer 14. Typically, an appropriate heat-sealing condition uses a temperature is 10 degrees C. higher than the melting point of the adhesive layers and a pressure of 30-80 psi.

[0034] At step 150 the now-printed and laminated base fabric layer 14 is cut through using lasers or other mechanical cutting means into a discrete applique 10. The applique 10 can then be utilized to decorate, apparel or other products, by adhering the applique 10 using the clear adhesive layer 11 which is activated at a lower heat and pressure than required to melt flow the middle white layer polymer 12.

[0035] The result is a decorated applique 10 utilizing a base fabric layer 14 with a printed graphic 9. The choice of at least two dissimilar polymers including at least one adhesive arranged in three layers 11, 12, 13, two such layers 11, 13 being clear adhesive and one 11 being reserved for the purpose of heat-sealing to the apparel substrate 15, plus one pigmented layer 12 there between helps maintain the integrity of the printed graphs by blocking migration of disperse dyes in either direction. The decorated applique 10 may be processed under conditions appropriate to its use and function. The migration resistance of the combined triple-layer composite 11, 12, 13 was measured in both wet and dry conditions as per American Association of Textile Chemists and Colorists (AATCC) 163 (Colorfastness-Die transfer in storage) and provided a E<0.5 on average across the range of sublimation 20 colors red, orange, yellow, green, blue, indigo, and violet (ROYGBIV). E is a spectroscopic colorfastness standard measurement of variation. E of <0.5 is almost imperceptible to the average person, and prior adhesives used for similar purposes could not achieve better than E<0.7. This new adhesive formulation also provides a means of application with reduced visual adhesive edge, whilst still providing the required opacity to prevent garment color show through. The adhesive edge was measured on average to be <0.2 mm. Adhesives with required opacity used prior to this development could have an adhesive edge as high as 0.4 mm.

[0036] It should now be apparent that the foregoing results in a color-printed and/highlighted applique 10 as in FIGS. 1-2 30 that gives an aesthetically-pleasing embossed or otherwise color-contrasted appearance in a form that is easily applied to a garment or other textile.

[0037] In an alternate embodiment as shown in FIG. 4 the composite adhesive laminate is comprised of four layers 11, 12, 13 and 16, with a clear first adhesive layer 11 reserved for adhering to the unprinted face of the base fabric layer 14 with a melting point of 110-135 degrees C. The first layer 11 is laminated to a white pigmented second layer 12 having a melting point of 155-210 degrees C., which is in turn laminated to a black or darkly pigmented third barrier layer 16 of polyurethane having a melting point of 155-210 C. The third layer 16 is laminated to a clear adhesive layer 13 having a melting point of 110-135 degrees C., and reserved for adhering to a garment or other textile. In this embodiment the pigmented polymeric layers 12, 16 do not melt when heat-sealed to the fabric applique layer 14 or the garment or textile, as the clear adhesive layers 11, 13 melt at much lower temperatures and are reserved for adhesion. Because the pigmented layers 12, 16 do not flow during application, visual adhesive edges around the applique are prevented. Additionally, the black or darkly pigmented layer performs the double function of preventing dyes from entering the pigmented white layer as well blocking any color non uniformities in the garment, for instance if it were patterned. The pigmented white layer thus stays completely uniform regardless of the garment patterning or migration and serves to brighten the appearance of the applique relative to using only a single black or darkly colored pigmented layer. The preferred white pigment in this embodiment is titanium dioxide and the preferred black pigment is active carbon. The result is a heat-sealable fabric applique well suited for patterned garments and textiles or those garments and textiles that are prone to significant migration.

[0038] Having now fully set forth the preferred embodiments and certain modifications of the concept underlying the present invention, various other embodiments as well as certain variations and modifications thereto may obviously occur to those skilled in the art upon becoming familiar with the underlying concept. It is to be understood, therefore, that the invention may be practiced otherwise than as specifically set forth herein.

STATEMENT OF INDUSTRIAL APPLICABILITY

[0039] Hot-pressing a thermal applique onto an underlying substrate that was pre-colored using dye sublimation can release the dye, causing migration into the applique and discoloration. In addition, thermal appliques can produce an undesirable opaque adhesive edge along the edge of the decoration. It is another object to provide an improved production process by which said appliques can be manufactured cost effectively.