Flexible heat sealable decorative articles and method for making the same

Abstract

Various flexible heat sealable decorative articles and methods of making the same are described. The flexible heat sealable decorative articles are lightweight and can be combined with other decorative elements, such as metalized films. Various decorative are mixed or combined with one another to form highly attractive flexible heat sealable decorative articles.

Claims

1. A decorative article, comprising: an adhesive layer; and a metalized flexible polymeric layer, wherein the adhesive layer comprises polyurethane, wherein the adhesive layer has a color, wherein the adhesive layer is adhered to the metalized flexible polymeric layer, wherein the metalized flexible polymeric layer has one or more voids, wherein the metalized flexible polymeric layer is positioned on a decorative surface to be visible to a viewer; and a portion of the adhesive layer is visible, within the one or more voids, to the viewer.

2. The decorative article of claim 1, further comprising: an item of apparel, wherein the metalized flexible polymeric layer is adhered to the item of apparel by the adhesive layer.

3. The decorative article of claim 1, wherein the metalized flexible polymeric layer has one or more of the following properties: i) a density of no more than about 1.5 g/cm.sup.3; ii) a tensile strength of no more than about 10.sup.7 Pascals; and iii) a modulus of elasticity or flex strength of no more than about 10.sup.9 Pascals.

4. The decorative article of claim 1, wherein the metalized flexible polymeric layer comprises a metalized film having a metallic appearance.

5. The decorative article of claim 1, wherein the metalized flexible polymer layer comprises polyurethane.

6. The decorative article of claim 1, the one or more voids have substantially smooth and level void walls.

7. The decorative article of claim 1, wherein the metalized flexible polymeric layer comprises a high frequency molded polymeric material.

8. The decorative article of claim 1, wherein the adhesive layer is not visible through the metalized flexible polymeric layer.

9. The decorative article of claim 1, further comprising: an optically transmissive layer positioned between the metalized flexible polymeric layer and the adhesive layer.

10. The decorative article of claim 9, wherein the optically transmissive layer comprises a thermoplastic resin film.

11. The decorative article of claim 9, further comprising: a color-enhancing layer positioned between the optically transmissive layer and the adhesive layer, wherein the color-enhancing layer comprises a translucent color-containing ink layer.

12. The decorative article of claim 1, further comprising: an item of apparel, wherein the metalized flexible polymeric layer is adhered to the item of apparel by the adhesive layer.

13. A method, comprising: providing a decorative article intermediate comprising a flexible polyurethane layer having a metallic appearance; registering the flexible polyurethane layer with a laser etching system; and etching the flexible polyurethane layer by contacting the flexible polyurethane layer with a laser beam generated by the laser system, wherein the contacting of the laser beam with the flexible polyurethane layer forms one or more voids in the flexible polyurethane layer, wherein in one of (i) and (ii) is true: (i) wherein the decorative article intermediate comprises an adhesive layer adhered to the flexible polymeric polyurethane layer and wherein the adhesive layer is visible within the one or more voids; or (ii) further comprising: contacting the flexible polymeric polyurethane layer having one or more voids with an adhesive layer, wherein the adhesive layer is visible within the one or more voids.

14. The method of claim 13, wherein the registering comprises one of a mechanical registration, optical registration, electro-mechanical registration, computerized registration, or combination thereof.

15. The method of claim 13, wherein the contacting of a laser beam with the flexible polyurethane layer removes at least some of the flexible polyurethane layer.

16. The method of claim 15, wherein the contacting of the laser bean with the flexible polyurethane layer comprises a sequential contacting of the laser beam with the flexible polyurethane layer.

17. The method of claim 16, wherein each sequential contacting of the laser beam with the flexible polyurethane layer removes at least some of the flexible polyurethane layer contained in the one or more voids.

18. The method of claim 17, wherein (i) is true and wherein the laser etching comprises sufficient laser beam energy and sufficient sequential passes of the laser beam to remove at least most, if not all, of the flexible polyurethane layer contained in the one or more voids but little, if any, of the adhesive layer material.

19. A decorative article, comprising: an adhesive layer; and a flexible metalized polyurethane layer, wherein the adhesive layer is adhered to the flexible metalized polyurethane layer having one or more voids, wherein the flexible metalized polyurethane layer is positioned on a decorative surface to be visible to a viewer, and wherein a portion of the adhesive within the one or more voids is visible to a viewer.

20. The decorative article of claim 19, the one or more voids have substantially smooth and level void walls.

21. The decorative article of claim 19, wherein the adhesive layer is not visible through the flexible metalized polyurethane layer.

22. The decorative article of claim 19, further comprising: an optically transmissive layer positioned between the flexible metalized polyurethane layer and the adhesive layer, wherein the adhesive layer is adhered to the flexible metalized polyurethane layer, wherein the flexible metalized polyurethane layer has one or more voids, wherein the flexible metalized polyurethane is positioned on a decorative surface to be visible to a viewer, and wherein a portion of the adhesive layer within the one or more voids is visible to the viewer.

23. The decorative article of claim 22, wherein the optically transmissive layer comprises a thermoplastic resin film.

24. The decorative article of claim 23, further comprising: a color enhancing layer positioned between the optically transmissive layer and the adhesive layer, and wherein the color-enhancing layer comprises a translucent color-containing layer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The accompanying drawings are incorporated into and form a part of the specification to illustrate several examples of the present disclosure. These drawings, together with the description, explain the principles of the disclosure. The drawings simply illustrate preferred and alternative examples of how the disclosure can be made and used and are not to be construed as limiting the disclosure to only the illustrated and described examples. Further features and advantages will become apparent from the following, more detailed, description of the various aspects, embodiments, and configurations of the disclosure, as illustrated by the drawings referenced below.

(2) FIG. 1 depicts a cross-sectional view of an article according to some aspects of the present disclosure;

(3) FIG. 2 depicts a cross-sectional view of an article according to some aspects of the present disclosure;

(4) FIG. 3A is an elevation plan view of an article according to some aspects of the present disclosure;

(5) FIG. 3B is a cross-sectional view of FIG. 3A;

(6) FIG. 4 depicts a process according to some aspects of the present disclosure;

(7) FIG. 5 depicts a cross-sectional view of a decorative element according to some aspects of the present disclosure;

(8) FIG. 6 depicts a cross-sectional view of a decorative article according to some aspects of the present disclosure;

(9) FIG. 7 is an elevation plan view of a decorative article according to some aspects of the present disclosure;

(10) FIG. 8 depicts a cross-sectional view of a decorative article according to some aspects of the present disclosure;

(11) FIG. 9 depicts a cross-sectional view of a decorative article according to some aspects of the present disclosure; and

(12) FIG. 10 is an elevation plan view of a decorative article according to some aspects of the present disclosure.

DETAILED DESCRIPTION

(13) FIG. 1 depicts a cross-sectional view of a decorative article 100 according to various embodiments. The decorative article 100 includes a first layer 101 adhered a second layer 102. The first 101 and second 102 layers may be directly adhered to one another or may be adhered to one another by an adhesive (not depicted).

(14) FIGS. 2, 3A and 3B depict decorative articles 100 having one or more voids 105 in the first layer 101. In some configurations, a first portion of the second layer surface 104 is visible, to a person viewing the decorative article 100, within the one or more voids 105. The one or more voids 105 can be in the form of apertures having a depth “D” (FIGS. 2 and 3B). Typically, the one or more voids 105 are in the form of alphanumeric characters, graphic design images, or combination thereof. For example, the alphanumeric characters can in the form of letters and/or numbers and the graphic design images can be form of a mascot, company logo, geographic area, or professional insignia to name a few. FIG. 3A depicts an elevation plane view of decorative article 100 having the one or more voids 105 in form of alphanumeric characters, and FIG. 3B depicts a cross-sectional view of FIG. 3A along line 3B-3B. More specifically, FIGS. 3A and 3B depict configurations having the second layer surface 104 visible within the one or more voids 105 to person viewing upper surface 199 of the decorative article 100.

(15) Generally, laser engraving and/or cutting forms the one or more voids 105. That is, the first layer 101 can be etched and/or cut with a laser to form the one or more voids 105. The one or more voids 105 have void walls 188. Commonly, the first layer 101 has a sufficiently high melt and/or softening temperature so that when the first layer 101 is laser etched and/or cut the void walls 188 are formed with a substantially smooth and level wall surface. That is, the void walls 188 are substantially devoid of waves or sags in the wall surface. While not wanting to be limited by theory, it is believed that having a first layer 101 with a sufficiently high melt and/or softening temperatures the void walls 188 do not substantially sag during and/or after the laser etching and/or cutting. Furthermore, the sufficiently high melt and/or softening temperatures provide for substantially sharply delineated void walls 188. Moreover, the void walls 188 are substantially free of char after being formed by the laser cutting and/or etching process. It can be appreciated that in some embodiments, the first layer 101 can be one or more of molded with the one or more voids 105 or die-cut to form the one or more voids.

(16) FIG. 4 depicts process 200 for making decorative article 100.

(17) In step 210, a decorative article intermediate is provided for one or both of laser etching and/or laser cutting. The decorative article intermediate can be a first layer 101 adhered to a second layer 102 (FIG. 1) or the first layer 101 alone (that is, with a second layer 102 not adhered to the first layer 101). The decorative article intermediate provided on step 210 can be free of voids 105 or can have voids 105 formed by methods other than laser etching and/or cutting, such as by molding and/or die-cutting.

(18) In step 220, the decorative article intermediate is registered with a laser etching and/or cutting system. The registration can be a mechanical registration, optical registration, electro-mechanical registration, computerized registration, or a combination thereof. The decorative article intermediate is generally to liner base sheet having a low surface energy. The liner base sheet can comprise silicone and TEFLON™. The liner base sheet substantially acts as “release” sheet for holding the decorative article intermediate in place of steps 220 and 230. More specifically, the liner base sheet adheres the decorative article intermediate in position with light handling and easily and cleanly releases the decorative article intermediate when pulled apart.

(19) In step 230, the decorative article intermediate is sequentially etched and/or cut by the laser system. Some of the material comprising the decorative article intermediate is removed by the sequential etching and/or cutting of decorative article intermediate. A laser beam is generated by the laser system. The laser beam is contacted in registration with the decorative article intermediate. The contacting of a laser beam with the decorative article intermediate removes at least some of the material comprising the decorative article intermediate. The contacting of the laser beam sequentially with the decorative article intermediate removes some of material contained in the one or more voids 105 to be formed. The sequential process of contacting the laser beam with decorative article intermediate is continued until substantially all of the decorative article material contained within the one or more voids 105 is removed by the laser etching and/or cutting process. Typically, the contacting of the laser beam with the decorative article intermediate vaporizes at least some of the material contained in the one or more voids 105. When the decorative article intermediate comprises a first layer 101 adhered to a second layer 102, the decorative article 100 is formed by the sequential contacting of the laser beam with the decorative intermediate to create the one or more voids 105.

(20) Typically, one or more sequential passes of the laser beam forms the one or more voids 105. It can be appreciated that a single pass of the laser bean can include one or more laser pulses. It can be appreciated that each sequential pass of the laser beam comprises contacting of the laser beam with the decorative article intermediate.

(21) Generally, each pass of the laser beam in the sequential laser etching and/or cutting process removes more than about 0.5% of the decorative article intermediate material contained in the one or more voids 105. More generally, the each pass of the laser beam removes from about 0.5 to about 1% of the material contained the one or more voids 105. Even more generally, each pass of the laser bean removes from about 1% to about 5%, yet even more generally from about 5 to about 10%, still yet even more generally from about 10% to about 20%, still yet even more generally from about 15 to about 30%, still yet even more generally from about 25 to 40%, still yet even more generally from about 30 to about 50%, or yet still from about 45 to about 100% of the decorative article intermediate material contained in the one or more voids 105.

(22) Typically, the sequential etching and/or cutting of decorative article intermediate comprises no more than twelve sequential passes of the laser beam. However, in some embodiments the sequential etching and/or cutting of the decorative article intermediate comprises more than twelve sequential passes of the laser beam.

(23) The laser etching and/or laser cutting comprises a sufficient laser beam energy level and a sufficient number of passes of laser beam to remove the decorative article intermediate material contained in the one or more voids 105, but little, if any, of the second layer material 102, when the second layer 102 is present during the laser etching and/or laser cutting process.

(24) Regarding optional step 240, this step is included when the decorative article intermediate comprises the first layer 101 without a second layered adhered thereto, the optional step 204 comprises adhering the second layer 101 to the laser etched and/or cut first layer 101.

(25) The first layer 101 may or may not have a metallic appearance. The first layer 101 can be opaque. Typically, the second layer 102 is visible within the one or more voids 105, but not visible through an opaque first layer 101. It can be appreciated that in some embodiments the first layer 101 can have some level of transparency. In such embodiments, the second layer 102 may or may not be visible through the transparent first layer 101. Moreover, the appearance of the second layer 102 in the one or more voids 105 may or may not differ from the appearance of the second layer 102 through the transparent first layer 101. For example, the transparent first layer 101 can have a color or metallic appearance that affects the appearance of the second layer 102 when viewed through the transparent first layer 101. While not wanting to be bound by theory, the second layer 102 may have a yellow color and the transparent first layer 101 a blue color. In such an instance, the second layer 102 in the one or more voids 105 would appear to a viewer to be yellow, but the blue first layer 101 would appear green due to underlying yellow second layer 102.

(26) Typically, the first layer 101 has a metallic appearance. In some embodiments, one or both of the first 101 and second 102 layers have a substantial metallic appearance. The first layer 101 has opposing upper 199 and lower 198 surfaces. The lower surface 198 is, when the first 101 and second 102 layers are stacked, positioned adjacent to the second layer 102. In some embodiments, the upper surface 199 can have a substantially, smooth flat surface. Furthermore, the upper surface 199 can be a dimensionalized surface having three-dimensional profile.

(27) The decorative article 100 can be substantially flexible. That is, the decorative article 100 when adhered to an item of apparel (such as a shirt, jacket, jersey, leggings, pants, or such) can substantially bend and/or flex with the item of apparel during normal activity.

(28) The decorative article 100 can be substantially light-weight and flexible. Metals typically have a density of about 2 g/cm.sup.3 or more. Generally, the decorative article of 100 has a metallic appearance and a density of no more than about 1.5 g/cm.sup.3, more generally a density of no more than about 1.3 g/cm.sup.3, even more generally a density of no more than about 1.2 g/cm.sup.3, yet even more generally a density of no more than about 1.1 g/cm.sup.3, still yet even more generally a density of no more than about 1.0 g/cm.sup.3, more generally, or yet still even more generally a density of no more than about 0.9 g/cm.sup.3.

(29) Metals generally have a tensile strength of greater than about 10.sup.8 Pascals. Typically, the decorative article 100 has the appearance of a metal and a tensile strength of no more than about 10.sup.7 Pascals, more generally no more than about 10.sup.6 Pascals or even more generally no more than about 10.sup.5 Pascals.

(30) Metals commonly have a modulus of elasticity or flex strength greater than about 10.sup.10 Pascals. Typically, the decorative article 100 has the appearance of a metal and a modulus of elasticity or a flex strength of no more than about 10.sup.9 Pascals, more generally no more than about 10.sup.8 Pascals, even more generally no more than about 10.sup.7 Pascals, or yet even more generally no more than about 10.sup.6 Pascals.

(31) The first layer 101 can be a decorative metalized film. While not wanting to be limited by example, the decorative metalized film can be a molded metalized film. In one configuration, the decorative metalized film comprises a metal-interposed multi-layer thermoplastic synthetic resin film as described in one or more of U.S. Pat. Nos. 8,110,059; 5,589,022; 5,677,037; 5,599,416; 5,520,988; and 5,143,672, each of which is incorporated in its entirety herein by this reference. It can be appreciated that, the first layer 101 can be one or more of a metal film, a metal film adhered to polymeric film, a polymeric film having a metal distributed throughout the polymeric material, a bi-component film having a polymeric film substantially devoid of metal adhered to polymeric film having a metal distributed throughout the polymeric film, a polymeric film material having three or films adhered together and one of the three is one of a metal film or a polymeric film having a metal distributed throughout the polymeric film, or a combination thereof. In some embodiments, the first layer can be an intermetallic alloy or enamel.

(32) It some configurations, the first layer 101 can comprise one or more metalized layers stacked one on top of another. Moreover, the second layer 102 can be adhered to the first layer 101 having one or more metalized layers stacked one on top of another. The first layer 101 can have a texturized surface. The texturized surface can vary in pattern and/or form over the surface of the first layer 101.

(33) In some embodiments, the first layer 101 can comprise an organic polymeric composition. The organic polymeric composition may or may not contain a metallic material or a material that imparts a metallic appearance to the organic polymeric composition. The organic polymeric composition can be one of polyurethane, polyester and combination thereof.

(34) The organic polymeric composition can comprise a sublimation printable polymeric composition. The sublimation printable polymeric composition can be an organic polymeric sheet material capable of accepting sublimation dyes. While not wanting to be limited by example, the sublimation printable polymeric composition can comprise a polyester, polyester copolymer, polyester polymer alloy, polyester polymer blend or a combination thereof.

(35) Generally, the sublimation printable polymeric composition is substantially free of one or both of poly(cyclohexylene-dimethylene terephthalate) and poly(1,4-cyclohexylene-dimethylene terephthalate). More generally, the sublimation printable polymeric composition contains no more than about 1 wt %, even more generally no more than about 0.5 wt %, or yet even more generally no more than about 0.1 wt % of one or both of poly(cyclohexylene-dimethylene terephthalate) and poly(1,4-cyclohexylene-dimethylene terephthalate). Typically, the sublimation printable polymeric composition is substantially devoid of poly(cyclohexylene-dimethylene terephthalate) and poly(1,4-cyclohexylene-dimethylene terephthalate).

(36) The sublimation printable polymeric composition can be one of a rigid or semi-rigid polymeric sheet material. The sublimation printable sheet can be a rigid or semi-rigid, white polymeric material. The sublimation printable sheet material can comprise a first polymer and a second polymer. In accordance with some configurations, one or both of the first and second polymers can comprise polyester. According some embodiments, the first and second polymers, respectively, have first and second softening temperatures and first and second melt temperatures. The second softening temperature is greater than the first softening temperature and the second melt temperature is greater than the first melt temperature. Commonly, the second softening temperature is more than 50 degrees Fahrenheit greater than the first softening temperature, more commonly more than 100 degrees Fahrenheit greater than the first softening temperature, even more commonly more than 150 degrees Fahrenheit greater than the first softening temperature, or yet even more commonly more than about 200 degrees Fahrenheit greater than the first softening temperature. Typically, the second softening temperature is more than 50 degrees Fahrenheit greater than the first melting temperature, more typically more than 100 degrees Fahrenheit greater than the first melting temperature, even more typically more than 150 degrees Fahrenheit greater than the first melting temperature, or yet even more typically more than about 200 degrees Fahrenheit greater than the first melting temperature. While not wanting to be limited by theory, at least one of first or second polymers generally has a melt or softening temperature of more than about 350 degrees Fahrenheit, more generally a melt or softening temperature of more than about 375 degrees Fahrenheit, even more generally a melt or softening temperature of more than about 400 degrees Fahrenheit, yet even more generally a melt or softening temperature of more than about 425 degrees Fahrenheit, or still yet even more generally a melt or softening temperature of more than about 450 degrees Fahrenheit.

(37) Generally, the first and second polymers are substantially free of one or both of poly(cyclohexylene-dimethylene terephthalate) and poly(1,4-cyclohexylene-dimethylene terephthalate). More generally, the individually or together the first and second polymers contain no more than about 1 wt %, even more generally no more than about 0.5 wt %, or yet even more generally no more than about 0.1 wt % of one or both of poly(cyclohexylene-dimethylene terephthalate) and poly(1,4-cyclohexylene-dimethylene terephthalate). Typically, the first and second polymers are substantially devoid of poly(cyclohexylene-dimethylene terephthalate) and poly(1,4-cyclohexylene-dimethylene terephthalate).

(38) It is believed that having a sublimation printable polymeric composition comprising a polymer having a softening temperature of more than about 350 degrees Fahrenheit can substantially improve the sublimation printed image quality. For example, the sharper images and/or finer, sharper lines can be sublimated printed on polymeric compositions and/or polymeric sheet materials having a softening temperature more than about 350 degrees Fahrenheit compared to polymeric sheet materials substantially lacking a polymer having a softening temperature of more than about 350 degrees Fahrenheit.

(39) The organic polymeric composition can be in the form of a sublimation printable polymeric coating. A glossy clear film can be applied to the sublimation printable polymeric coating. Furthermore, the glossy clear film can be positioned on the printable polymeric coating surface.

(40) The organic polymeric composition can contain a sublimation printed image. Typically, the sublimation printed image quality of the organic polymeric composition is substantially superior to the sublimation dye print quality on textiles, flock, or other free standing polymeric films. The sublimation dye printed image on the organic polymeric composition is one or more of substantially sharper, clearer, and cleaner with more true and vibrant color then sublimation dyed printed images on textiles or other polymeric films.

(41) FIG. 5 depicts a first layer 101 having one of metalized film, an organic polymeric composition, a sublimation printable polymeric composition, or combination thereof layer 166 interposed between upper 161 and lower 162 optically transmissive layers. At least most of the visible light portion of the electromagnetic spectrum can be passed by the upper 161 and lower 162 optically transmissive layers. Typically, the upper 161 and lower 162 optically transmissive layers comprise thermoplastic synthetic resin films. A color-enhancing layer 165 can be positioned between the upper 161 and lower 162 optically transmissive layers. The color-enhancing layer 165 can be, for example, a translucent color-containing ink layer. Moreover, the color-enhancing layer 165 can contain one or more additional coats of a clear optically transmissive ink. A non-limiting example of a color-enhancing layer 165 is a translucent colored-ink printed over a metalized base film, such as silver metalized base film. It can be appreciated that the perceived value of the decorative article 100 is substantially enhanced when the color reflected back to a viewer is enriched by the of brilliance of the reflected metallized color. Furthermore, one or both of the upper optically transmissive layer 161 and one or more additional coats of the clear optically transmissive ink on the color-enhancing layer protect the color components of the first layer 101 from damage and/or degradation.

(42) It can be appreciated that in some embodiments, the one of metalized film, an organic polymeric composition, a sublimation printable polymeric composition, or combination thereof layer 166 is positioned between upper optically transmissive layer 161 and the color-enhancing layer 165, and the color-enhancing layer 165 is positioned between the lower optically transmissive layer 162 and the one of metalized film, an organic polymeric composition, a sublimation printable polymeric composition, or combination thereof layer 166. Furthermore, in some embodiments, the color-enhancing layer 165 is positioned between upper optically transmissive layer 161 and the one of metalized film, an organic polymeric composition, a sublimation printable polymeric composition, or combination thereof layer 166, and the one of metalized film, an organic polymeric composition, a sublimation printable polymeric composition, or combination thereof layer 166 is positioned between the lower optically transmissive layer 162 and the color-enhancing layer 165.

(43) The second layer 102 can comprise one of an adhesive layer, a woven textile, a knitted textile, or a polymeric layer. The polymeric layer can be one or more of a metal layer, a metal layer adhered to polymeric layer, a polymeric layer having a metal distributed throughout the polymeric layer, a two-layer film having a polymeric layer substantially lacking a metal adhered to a polymeric layer having a metal distributed throughout the polymeric layer, a layered-material having three or more layers adhered together and at least one of the layers is one of a metal layer or a polymeric layer having a metal distributed throughout the polymeric layer, intermetallic alloy, enamel, or a combination thereof.

(44) The second layer 102 can comprise one of a thermoplastic adhesive layer, a thermosetting adhesive layer, or an adhesive layer having thermoplastic and thermosetting adhesive properties. The thermosetting adhesive layer can be one of an A-stage thermosetting adhesive layer, a B-stage thermosetting adhesive layer or a C-staged thermosetting adhesive layer. The adhesive layer can be a hot melt adhesive. The adhesive layer can comprise in the form of single adhesive layer, a bi-layered adhesive or a tri-layered adhesive. The bi-layered adhesive can comprise a first adhesive stacked on a second adhesive. The tri-layered adhesive can comprise a metal or polymeric sheet positioned between first and second adhesive layers. The first and second adhesive layers in the bi-layered adhesive and tri-layered adhesive can differ in chemical and/or physical properties or can have substantially similar chemical and/or physical properties.

(45) The adhesive composition comprising the adhesive layer can have at one or both of its softening and melt temperatures a substantially high viscosity. In the absence of shear force, the adhesive composition at one or both of its softening and melt temperatures can have substantially little, if any, flow.

(46) The second layer 102 can comprise a polyester composition. Furthermore, the second layer 102 can comprise a polyester material containing one or more dyes, pigments, or combinations thereof. The one or more dyes, pigments, or combination thereof can impart a color to the polyester composition. The second layer 102 can have a color and/or color value that differs from the color and/or color value of the first layer 101. More specifically, the color and/or color value of the second layer 102 can differ from the color and/or color value of the first layer 101. Even more specifically, the color and/or color value of the first layer 101 can contrast with the color and/or color value of the second layer 102.

(47) The second layer 102 can comprise a polyurethane composition. Furthermore, the second layer 102 can comprise a polyurethane material containing one or more dyes, pigments, or combinations thereof. The one or more dyes, pigments, or combination thereof can impart a color to the polyurethane composition. The second layer 102 can have a color and/or color value that differs from the color and/or color value of the first layer 101. More specifically, the color and/or color value of the second layer 102 can differ from the color and/or color value of the first layer 101. Even more specifically, the color and/or color value of the first layer 101 can contrast with the color and/or color value of the second layer 102.

(48) FIG. 6 depicts decorative article 100 having a second layer 102 further comprising an optically transmissive layer 167. The transmissive layer 167 positioned adjacent to the first 101 layer. At least most of the visible light portion of the electromagnetic spectrum can be passed by the optically transmissive layer 167. Typically, the optically transmissive layer 167 comprises a thermoplastic synthetic resin film. Furthermore, the optically transmissive layer 167 can include a color-enhancing layer 168 positioned between the optically transmissive layer 167 and second layer 102. The color-enhancing layer 168 can be, for example, a translucent color-containing ink layer. Moreover, the color-enhancing layer 168 may contain one or more additional coats of a clear optically transmissive ink. A non-limiting example of a color-enhancing layer 168 is a translucent colored-ink printed over a metalized base film, such as silver metalized base film. It can be appreciated that the perceived value of the decorative article 100 is substantially when the enhanced when the color reflected back to a viewer is enriched by the brilliance of the reflected metallized color. Furthermore, one or both of the optically transmissive layer 167 and one or more additional coats of the clear optically transmissive ink protects the color-enhancing layer 168 from damage and/or degradation. It can be appreciated that in some embodiments, the optically transmissive layer 167 positioned between upper layer 101 and the color-enhancing layer 168, and the color-enhancing layer 168 is positioned between the second layer 102 and the optically transmissive layer 167. Furthermore, in some embodiments, the color-enhancing layer 168 is positioned between upper layer 101 and the optically transmissive layer 167, and the optically transmissive layer 167 is positioned between the color enhancing layer 168 and the second layer 102.

(49) It can be appreciated that one or both of the optically transmissive layer 167 and the color enhancing layer 168 may or may not have adhesive properties. In some embodiments, the optically transmissive layer 167 has adhesive properties. In some embodiments, the color enhancing layer 168 has adhesive properties. Moreover, the optically transmissive layer 167 can be heat sealed and/or laminated to the color enhancing layer 168 and one of the first 101 and second 102 layers. In some embodiments an adhesive is printed on the optically transmissive layer 167, in the zones where laser etching is not to preformed, to adhere to the color enhancing layer 168 and one of the first 101 and second 102 layers. Furthermore, the color enhancing layer 168 can be heat sealed and/or laminated to the optically transmissive layer 167 and one of the first 101 and second 102 layers. In some embodiments an adhesive is printed on the color enhancing layer 168, in the zones where laser etching is not to preformed, to adhere to the optically transmissive layer 167 and one of the first 101 and second 102 layers.

(50) The decorative article 100 can be heat sealed to a substrate. After the heat sealing of the decorative article 100 to the substrate, the substrate is substantially permanently adhered to the decorative article 100. The substrate can include any item of commerce. Suitable substrates include without limitation apparel, automotive components and elements, electronic components and devices, household items, electrical devices and components, luggage, personal devices and accessories (such as purses, wallets, and such), to name a few. Items of apparel can be hats, gloves, shoes, stockings, pants, jackets, jersey, shirts, blouses, coats, neckties, skirts, vests, and so forth. The decorative element 100 heat sealed to substrate is substantially wash resistant. That is, decorative article 100 remains substantially adhered to the substrate after about 100 standard wash cycles.

(51) The one or more voids 105 can be in the form of apertures having a depth “D” (FIGS. 2, 3B, 7, and 8) and/or in the form of one or more raised borders 107 having a height of “H” (FIGS. 7 and 9). The raised borders 107 can define one or more voids 105.

(52) The one or more raised borders 107 can comprise part of the first layer 101. The one or more raised borders 107 can define a perimeter 106 of one or more voids 105. To a person viewing the decorative article 100, a first portion of the second layer surface 104 may or may not be visible within the void 105. In some configurations, a portion of the first layer surface is visible within the one or more voids 105 to person viewing the decorative article 100. Outside of the perimeter 106 is viewable surface 103. The viewable surface 103 may comprise one of a second portion of the second layer surface, a portion of the first layer surface, a substrate surface (not depicted), or a combination thereof.

(53) An insert 108 can be positioned in some or all of the one or more voids 105 define by one or both of the apertures and raised borders 107. Referring to FIGS. 8 and 9, the decorative article 100 can have the insert 108 positioned in a void 105. In FIG. 9, the insert 108 is adhered by adhesive layer 123 to the raised borders 107 and one of the first 101 and second 102 layers. The raised border 107 substantially surrounds the insert 108 to hide the adhesive layer 123 and edge of the insert 108 from view. Furthermore, the adhesive layer 123 and insert 108 are substantially protected from wear or damage by the raised border 107. Accordingly, the raised border 107 can protect the insert 108 from delimitation. The height “H” of the raised border 107 above the surrounding surface 103 of one of the first 101 and second 102 layers is generally at least as high as the collective thickness of the insert 108 and adhesive layer 123. In FIG. 8, the insert 108 is adhered by adhesive layer 123 to the first layer 101 containing the void 105 and to one of the first 101 and second 102 layers. The first layer 101 substantially surrounds the insert 108 to hide the adhesive layer 123 and edge of the insert 108 from view. Furthermore, the adhesive layer 123 and insert 108 are substantially protected from wear or damage by the first layer 101 that surrounds the adhesive layer 123 and insert 108. Accordingly, the first layer 101 can protect the insert 108 from delimitation. The depth “D” of the void in the first layer 101 is generally at least as high as the collective thickness of the insert 108 and adhesive layer 123.

(54) The insert 108 visible to a viewer can be positioned within the one or more voids with the top surface 122 of insert 108 is substantially flush with the top surface 121 of the first layer 101 and/or the one or more raised borders 107 (FIGS. 8 and 9). In such configurations, the insert 108 can be adhered to one of the first 101 and second 102 layers by an adhesive 123.

(55) The decorative article 100 can be adhered to an optional backing adhesive (not depicted). The decorative article 100 can be adhered to a substrate (not depicted) by the backing adhesive.

(56) It can be appreciated that in construction of decorative articles, limitations are imposed by the need to have borders around each color to contain the color and thereby avoid colors flowing into one another. The various decorative articles 100 of FIGS. 1, 2, 3A, 3B and 5-9 can avoid this problem by using one or more multi-colored decorative elements as inserts within one or more voids. The decorative element can be formed into a three dimensional design, such as by thermoforming or etching, thereby providing the decorative element with the desired three-dimensional relief. This can obviate the need to have complex and expensive dies for construction of the decorative element. In other words, a blank could be formed as a planar object, with the three-dimensional relief being provided by the decorative element(s).

(57) The insert 108 and/or first portion of the second layer surface 104 visible within the one or more voids 105 can be framed by the first layer 101 surrounding the one more voids 105. In some configurations, the insert 108 and/or first portion of the second layer surface 104 is positioned within the one or more voids 105 and recessed below top surface 121 of the first layer 101 and/or the one or more raised borders 107. The top surface 121 and the insert 108 and/or first portion of the second layer surface 104 being visible to the viewer of the decorative article 100.

(58) The insert 108 and/or a first portion of the second layer surface 104 can comprise a polymerically coated aluminum metal element. Preferably, the polymerically coated aluminum metal element. The polymerically coated aluminum metal element can comprise a sublimation dye printable polymeric coating position on and/or adjacent to an aluminum metal substrate. The sublimation printable polymeric material is cured and substantially permanently adhered to the aluminum metal substrate. Commonly, an insert 108 comprising the polymerically coated aluminum metal element contains a sublimation printed image.

(59) An exemplary polymerically coated aluminum metal element is sold under the tradename UNISUB® (a registered mark of Universal Woods, Inc.). It is believed that UNISUB® is polymeric laminate comprises aluminum metal coated with a polymeric material. The polymeric laminate includes sublimation dyeable polymeric coating and a white-colored polymeric coating. The sublimination dyeable polymeric coating is typically positioned on at least one surface of the polymerically coated aluminum metal element. More commonly, the sublimination dyeable polymeric coating is typically positioned on opposing surfaces of the polymerically coated aluminum metal element, even more commonly all surfaces of the polymerically coated aluminum metal element are coated with the sublimination dyeable polymeric coating. The white-colored polymeric coating is positioned between the aluminum metal and the sublimation dyeable polymeric coating. A glossy clear film can be applied to the sublimation dyeable polymeric coating. Furthermore, the clear glossy clear film can be positioned on the dyeable polymeric coating surface opposing the dyeable polymeric coating surface in contact with the white-colored coating. Moreover, the polymeric coated aluminum metal can be laser cut to any desired shape.

(60) Commonly, the polymerically coated aluminum metal element has a thickness of no more than about 10 mm. More commonly, the polymerically coated aluminum metal element has a thickness of no more than about 9 mm, even more commonly of more than about 8 mm, yet even more commonly of no more than about 7 mm, still yet even more commonly of no more than about 6 mm, still yet even more commonly of no more than about 5 mm, still yet even more commonly of no more than about 4 mm, still yet even more commonly of no more than about 3 mm, still yet even more commonly of no more than about 2 mm, still yet even more commonly of no more than about 1 mm, still yet even more commonly of no more than about 0.5 mm, still yet even more commonly of no more than about 0.25 mm, still yet even more commonly of no more than about 0.1 mm, or yet still even more commonly of no more than about 0.05 mm. In some configurations, the polymerically coated aluminum element typically has a thickness of more than about 10 mm.

(61) The polymerically coated aluminum metal element is normally dimensionally stable. That is, the thickness of the polymerically coated aluminum metal element is substantially sufficient for the aluminum metal element to lie flat, and stay substantially flat during use of the decorative article 100.

(62) The polymerically coated aluminum metal element is preferably wash resistant. That is, the sublimation dye printed image contained in polymerically coated aluminum metal element is substantially maintained after about 100 standard laundry washings. Furthermore, when the polymerically coated aluminum metal element is adhered to a hybrid article, the polymerically coated aluminum metal element remains adhered to decorative article 100 after about more than 100 standard laundry washings.

(63) Typically, the sublimation dye print quality of the polymerically coated aluminum element is substantially superior to the sublimation dye print quality on textiles, flock, or free standing polymeric films. Sublimination dye printed images on the polymerically coated aluminum metal element are one or more of substantially sharper, clearer, and cleaner with more true and vibrant color then sublimination dyed printed images on textiles. Moreover, the sublimation dye printed polymerically coated aluminum metal element is substantially more durable than sublimation dye printed textiles and flock. That is, the sublimation dye printed image contained in polymerically coated aluminum metal element is substantially maintained after about 100 standard laundry washings. Furthermore, when the polymerically coated aluminum metal element is adhered to a hybrid article, the polymerically coated aluminum metal element remains adhered to decorative article 100 after about more than 100 standard laundry washings.

(64) The insert 108 can comprise a polymeric material containing a hologram. The hologram-containing insert 108 can provide a level of authentication of the decorative article 100. While not wanting to be limited by example, a decorative article 100 in the form of a security badge having a hologram-containing insert 108 can be easily authenticated and difficult to reproduce.

(65) The insert 108 can be a sublimation printable sheet material. The sublimation printable sheet material can be a polymeric sheet material capable of accepting sublimation dyes. The sublimation printable sheet material can be one of a rigid or semi-rigid polymeric material. More specifically, the sublimation printable sheet material can be one of a rigid or semi-rigid, white polymeric material.

(66) In some configurations, the sublimation printable sheet material comprises a first polymer and a second polymer. While not wanting to be limited by example, the sublimation printable sheet material can comprise a polyester, polyester copolymer, polyester polymer alloy, polyester polymer blend or a combination thereof. That is, in accordance with some configurations, one or both of the first and second polymers comprise polyester.

(67) The first and second polymers, respectively, have first and second softening temperatures and first and second melt temperatures. The second softening temperature is greater than the first softening temperature and the second melt temperature is greater than the first melt temperature. Commonly, the second softening temperature is more than 50 degrees Fahrenheit greater than the first softening temperature, more commonly more than 100 degrees Fahrenheit greater than the first softening temperature, even more commonly more than 150 degrees Fahrenheit greater than the first softening temperature, or yet even more commonly more than about 200 degrees Fahrenheit greater than the first softening temperature. Typically, the second softening temperature is more than 50 degrees Fahrenheit greater than the first melting temperature, more typically more than 100 degrees Fahrenheit greater than the first melting temperature, even more typically more than 150 degrees Fahrenheit greater than the first melting temperature, or yet even more typically more than about 200 degrees Fahrenheit greater than the first melting temperature.

(68) While not wanting to be limited by theory, at least one of first or second polymers generally has a melt or softening temperature of more than about 350 degrees Fahrenheit, more generally a melt or softening temperature of more than about 375 degrees Fahrenheit, even more generally a melt or softening temperature of more than about 400 degrees Fahrenheit, yet even more generally a melt or softening temperature of more than about 425 degrees Fahrenheit, or still yet even more generally a melt or softening temperature of more than about 450 degrees Fahrenheit. It is believed that having a sublimation printable sheet material comprising a polymer having a softening temperature of more than about 350 degrees Fahrenheit can substantially improve the sublimation printed image quality. For example, the sharper images and/or finer, sharper lines can be sublimated printed on sheet material comprising a polymer having a softening temperature more than about 350 degrees Fahrenheit compared to a sheet material substantially lacking a polymer having a softening temperature of more than about 350 degrees Fahrenheit.

(69) The insert 108 can be according to some configurations a metalized polymeric material. The metalized polymeric material of insert 108 commonly has one or both of a different metallic color and a texturized surface than one of the first 101 and second 102 layers.

(70) The insert 108 can be according to some configurations a knitted or woven textile. The woven and/or knitted material can contain a sublimation printed image.

(71) According to some configurations the insert 108 can include a polymeric fill material. The polymeric fill material can comprise any polymeric material. Typically, the polymeric fill material is positioned in the one or more of the voids 105 in the form of a liquid and/or paste material. The polymeric fill material, after positioning the polymeric fill material in the one or more voids, is solidified and/or cured.

(72) While not wanting to be limited by theory, the polymeric fill material can be thermoplastic polymeric fill material. The thermoplastic polymeric fill material can be positioned in the one or more voids 105 while the thermoplastic polymeric fill material is substantially at or above its melt temperature. The thermoplastic polymeric fill material, after being positioned in the one or more voids 105, can be cooled to solidify the thermoplastic polymeric fill material within the one or more voids 105.

(73) The polymeric fill material can be a thermosetting-polymeric fill material. The thermosetting-polymeric fill material can be positioned in the one or more voids 105 while substantially in one of A- or B-stage. The thermosetting-polymeric fill material after being positioned in the one or more voids 105 can be one of cured or cooled to solidify the thermosetting-polymeric fill material within the one or more voids 105. For example, the thermosetting-polymeric material contained with the one or more voids 105 can be solidified within the one or more voids 105 by substantially curing and/or C-staging the thermosetting polymeric fill material.

(74) The polymeric fill material can have a colored and/or metallic like appearance. It can be appreciated that can one of partially or substantially completely fill the one or more voids 105.

(75) The first 101 and second 102 layers can be positioned side-by-side or stacked one on top of the other as further described herein and/or in U.S. patent application Ser. No. 13/625,797, filed Sep. 24, 2012, which is incorporated fully herein by this reference. A thermosetting or thermoplastic adhesive can adhesively join the first 101 and second 102 layers. The adhesive can be in the form of an adhesive layer positioned between the first 101 and second 102 layers. The metalized film of one or both of the first 101 and second 102 layers can have a texturized surface. The pattern and/or form of the texturized surface can vary over one or both of the first 101 and second 102 layers.

(76) In another configuration, an intermediate layered structure, such as a metalized film and flock and/or a textile (in a stacked or side-by-side configuration), is thermoformed in a, typically closed metal, die and optionally one or more of the decorative elements are dimensionalized to provide a highly attractive decorative article. In one application, flock is adhered, by one or both of a thermoplastic adhesive and an A-, B- or C-staged thermosetting adhesive to a surface of the metalized film, which assembly is placed in a metal die and thermoformed. Not only is the flock more tightly adhered to the metalized film by the process but also the assembly can be formed into a nonplanar, three-dimensional article through thermoforming. An added benefit is that the flock and/or metalized film is/are precisely cut by the die during thermoforming. The flock can also be dimensionalized by and during thermoforming.

(77) FIG. 10 depicts a decorative article 100 according to an aspect of the present disclosure. The hybrid article comprises a metalized material 1310 and dyed layer film 1320. The metalized material 1310 has a texturized surface 1315 containing one or more voids 105. Positioned in the one or more voids 105 is an insert exposed surface 104 of the color-enhancing layer 168. It can be appreciated that has a plurality of texturized surfaces having differing attractive patterns 1315a, 1315b, etc. The decorative article 100 further includes a wall 107 containing an insert 108.

(78) An example of a decorative article 100 is a pin-backed badge. The decorative article 100 can be used as patch to be sewn on to substrate. Moreover, the decorative article 100 can be backed with a pressure sensitive adhesive for use as a stick-on patch or backed with a heat sealed adhesive film for heat application to a desired substrate.

(79) In some configurations, taking the shape of the substrate is desirable, but taking the shape of an underlying seam or contour is not. In such configurations, the metalized film can include a thin spacer having substantially sufficient flexibility to conform to the general shape of the substrate but substantially sufficient rigidity to not substantially conform to substrate irregularities, such as seams, channels and/or grooves. Non-limiting examples of such a thin spacer are thin mylar films and silicon foam pads. In some configurations, the thin spacer has a sufficiently high softening temperature so as to substantially conform to substrate irregularities during lamination. While not wanting to be bound by theory, it is believed that the high softening temperature of the thin spacer prevents the thin spacer from softening during lamination and conforming to the substrate irregularities when one or both of heat and pressure are applied during lamination. Similarly, lesser amounts of heat and/or pressure can be applied to the spacer and/or metalized film positioned about the substrate irregularities to decrease and/or eliminate the confirming of the metalized film to substrate irregularities.

(80) The thin spacer many be applied to some or all of the metalized film. In some configurations, the tin spacer may be applied to a portion of metalized film in contact with the substrate irregularities. Furthermore, in some configurations, the thin spacer is positioned between the metalized film and the substrate. A first spacer surface of the thin spacer is adhesively bond to the metalized film by a first spacer adhesive. The thin spacer has a second spacer surface in an opposing relationship to the first spacer surface. The second spacer surface may or may not have a second space adhesive positioned on it. In some configurations, the second surface of the thin spacer (that is, the thin spacer surface positioned nearest the substrate) is substantially free of adhesive about the portion of the thin spacer positioned above the substrate irregularities. However, the second surface of thin spacer not positioned about the substrate irregularities may include a second spacer adhesive. The thin spacer and metalized film are adhered to the substrate by the second spacer adhesive. It can be appreciated, that the thin spacer and metalized film are not adhered to the substrate irregularity. As such, the thin spacer and metalized film do not substantially conform with the surface irregularity. Furthermore, it is believed that the thin spacer and metalized film can move substantially freely about the substrate irregularity.

(81) A number of variations and modifications of the disclosure can be used. It would be possible to provide for some features of the disclosure without providing others.

(82) The present disclosure, in various aspects, embodiments, and configurations, includes components, methods, processes, systems and/or apparatus substantially as depicted and described herein, including various aspects, embodiments, configurations, subcombinations, and subsets thereof. Those of skill in the art will understand how to make and use the various aspects, aspects, embodiments, and configurations, after understanding the present disclosure. The present disclosure, in various aspects, embodiments, and configurations, includes providing devices and processes in the absence of items not depicted and/or described herein or in various aspects, embodiments, and configurations hereof, including in the absence of such items as may have been used in previous devices or processes, e.g., for improving performance, achieving ease and\or reducing cost of implementation.

(83) The foregoing discussion of the disclosure has been presented for purposes of illustration and description. The foregoing is not intended to limit the disclosure to the form or forms disclosed herein. In the foregoing Detailed Description for example, various features of the disclosure are grouped together in one or more, aspects, embodiments, and configurations for the purpose of streamlining the disclosure. The features of the aspects, embodiments, and configurations of the disclosure may be combined in alternate aspects, embodiments, and configurations other than those discussed above. This method of disclosure is not to be interpreted as reflecting an intention that the claimed disclosure requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed aspects, embodiments, and configurations. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate preferred embodiment of the disclosure.

(84) Moreover, though the description of the disclosure has included description of one or more aspects, embodiments, or configurations and certain variations and modifications, other variations, combinations, and modifications are within the scope of the disclosure, e.g., as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights which include alternative aspects, embodiments, and configurations to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those claimed, whether or not such alternate, interchangeable and/or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter.