APPLIQUE AND METHOD FOR ITS MANUFACTURE

Abstract: A method of manufacturing an appliqué uses a laminate of a first layer of a thermoplastics material on which a layer of flock is adhered, and a second layer of a substrate material for supporting the thermoplastics material. The substrate material restricts distortion of the thermoplastics material during printing. A preselected design is then printed on the flok on the first layer. Prior to the step of printing the preselected design the laminate is passed through a blind printing cycle which is a printing cycle in which no ink is used. This has the effect of preparing and stabilising the thermoplastics material layer with the result that when a design is subsequently printed on the laminate a lower distortion of the design occurs and, when two or more colour impressions are made, a much better registration of the coloured inks with one another is obtained.

Description: APPLIQUE AND METHOD FOR ITS MANUFACTURE The present invention relates to appliques. Known appliques generally comprise one or more layers of material, of which the uppermost layer of material is a thermoplastics material film on which a design is printed. Such appliques are intended for bonding to a substrate, normally an item of clothing, by heat and high frequency welding. Appliques are normally manufactured in sheet form with the applique printed design being repeated a dozen or more times on the sheet before the sheet is separated into individual appliques. One of the major problems associated with the use of thermoplastics material is that it has a low elasticity level and when stretched, although it will try and revert to its previous state, it does not entirely succeed and thus becomes distorted after stretching. This results in distortion of the printed design. During multicoloured printing of a sheet of appliques, the thermoplastics material moves or stretches slightly when each colour impression is made, as a result of which it is impossible to print large sheets with the colours exactly in register over the whole sheet. In addition, the inks used in printing normally need to be cured at 160°C or higher. However, the thermoplastics material used in the manufacture of appliques has a melting point of typically between 180°C and 200°C and begins to distort at 150°C, causing distortion of the applique after printing. The present invention seeks to provide an improved applique and method of manufacture. Accordingly, the present invention provides a method of manufacturing an applique comprising: providing a laminate of a first layer comprising a thermoplastics material, and a second layer of a substrate material for supporting said thermoplastics material; and printing a preselected design on an upper surface of said first layer; wherein prior to the step of printing said preselected design said laminate is passed through a blind printing cycle as herein defined. The phrase "blind printing cycle" as used herein refers to a printing cycle for the laminate in which no printing ink is used and no design is therefore printed on the laminate. This has the effect of preparing and stabilising the thermoplastics material layer with the result that when a design is subsequently printed on the laminate a lower distortion of the design occurs and, when two or more colour impressions are made, a much better registration of the coloured inks with one another is obtained. The present invention also provides an applique comprising a laminate having: a first layer comprising a thermoplastics material; and a second layer of a substrate material serving to support said thermoplastics material and restrict distortion thereof during printing of a preselected design on said first layer. In a preferred form of the invention the substrate is a silicone material conveniently having a nominal weight of 180gsm. Advantageously, the substrate contains both polyester and polyamide fibres. Alternatively or additionally, the substrate may be a paper with a silicone coating or layer. The thermoplastics material is conveniently PVC and the substrate provides a stable base for the PVC, restricting movement of the PVC in varying ambient temperatures, varying states of "wetness" during printing and varying humidity conditions. The substrate also enables the PVC to retain its normal state at a temperature above 150°C during curing of the printing inks, when it would normally begin to distort. As a result, it provides a stable base for inks to be cured at a temperature of between 150°C and 200° and preferably between 165°C and 185°C. Example 1 In one example of applique according to the present invention, the thermoplastics material a thermoplastics material layers, 0.2mm thick is supported on a substrate 0.2mm thick and is coated with an adhesive layer to which flock is secured. The flock has a fibre content which is dispersed at a rate of lOOgm per m 2 , compared with a normal rate of 80gm per m 2 . The fibres are also cut at 0.5mιrt length with each fibre having a thickness of typically 1.7 desitex. The substrate has the following parameters which are average production values: Advantageously, the adhesive layer is 0.125mm thick to enable the root of each fibre to contact the thermoplastics material layer, leaving 0.375mm of each fibre exposed. The maximum thickness of the printed applique is about 1mm, preferably 0.9mm. The control of the flock enables the printing process to be much more exacting since the improved density and uniformity of height of the flock fibres more closely resembles a flat surface. The "blind printing cycle" also has the effect of removing rogue fibres i.e. extra long fibres protruding above the finished flock surface. During printing, the improved density and pressure equalisation created by the uniform height of the fibres reduces surface movement of the fibres when the weight and pressure of a printing screen is introduced onto the flock surface. The surface more closely resembles a flat stable surface producing a clear print. The ink used in printing the design on the thermoplastics material is a water-based ink which contains a thickening agent (typically Sericol ZE596) and a flock transfer catalyst (typically Sericol FT386), these preferably being added at 5% and 6% by weight, respectively. The thickener also enables ink to be deposited directly onto the flock itself without "bleeding" i.e. without the ink leaking away from the printed areas. The use of a catalyst and thickening agent improves the viscosity of the ink to aid deposit of the ink and render it less transparent. It also reduces the curing temperature of the ink and enables the ink to bond better to the flock. The ink curing process is effected using a dryer such as a gas dryer at a constant temperature of 165°C to 185°C for two to three minutes. Printing can be effected to a resolution equivalent to 300dpi . Each printing ink colour is left to dry after curing for between one and three hours in ambient temperature to avoid any unnecessary movement of the thermoplastics material layer and after the final printing the appliques are left to dry in atmosphere overnight. Alternatively, drying can be effected in wicket dryers at a suitable temperature above ambient, e.g. up to 40°C The percentage elongation of the finished product (substrate, PVC and flock) is compared below with the substrate itself, and with the PVC and flock layer without the substrate support. Wet Elongation % MD CD (a) Stable Substrate 0.15 0.30 (b) S.S./PVC/Flock 0.10 0.17 (finished product) (c) PVC & Flock 0.55 0.10 MD = Machine Direction CD = Cross Direction Finally, during welding of an applique according to the present invention to an item of clothing, an impervious film of acetate may be sandwiched between the applique and the article of clothing to prevent migration of ink between the two.

Claims: CLAIMS 1. A method of manufacturing an applique comprising: providing a laminate of a first layer comprising a thermoplastics material, and a second layer of a substrate material for supporting said thermoplastics material; and printing a preselected design on an upper surface of said first layer; wherein prior to the step of printing said preselected design said laminate is passed through a blind printing cycle as herein defined. 2. A method as claimed in claim 1 wherein said substrate serves for restricting distortion of said thermoplastics material during printing. 3. A method as claimed in claim 1 or 2 wherein said substrate comprises paper with a silicone layer thereon. 4. A method as claimed in claim 1 or 2 wherein said substrate comprises a silicone material. 5. A method as claimed in claim 3 or 4 wherein said substrate has a nominal weight of 180gsm. 6. A method as claimed in any of the preceding claims wherein said substrate contains polyester and polyamide fibres. 7. A method as claimed in any of the preceding claims wherein said thermoplastics material is PVC. 8. A method as claimed in any of the preceding claims wherein said thermoplastics material has a layer of flock adhered thereto to form said upper surface of said first layer. 9. A method as claimed in claim 8 wherein said flock has a density of lOOgm per m 2 . 10. A method as claimed in claim 8 or 9 wherein said flock is formed from fibres having a nominal length of 0.5mm. 11. A method as claimed in claim 8, 9 or 10 wherein said flock comprises fibres having a thickness of 1.7 desitex. 12. A method as claimed in any of the preceding claims wherein said substrate has a maximum elongation of 5% when tested according to DIN 53 112. 13. A method as claimed in any of the preceding claims wherein said preselected design is printed using a water-based ink. 14. A method as claimed in claim 13 wherein said ink contains a thickening agent and a flock transfer catalyst. 15. A method as claimed in claim 14 wherein said thickening agent is Sericol ZE596 and said transfer catalyst is Sericol FT386. 16. A method as claimed in claim 14 or 15 wherein said thickening agent forms approximately 5% by weight of said ink and said flocker transfer catalyst forms approximately 6% by weight of said ink. 17. A method as claimed in any of the preceding claims wherein the step of printing said preselected design comprises: a) printing a first coloured ink on said upper surface of said first layer; b) curing said ink at a temperature in the range 165° to 185° for a preselected time period; c) allowing said ink to dry in ambient temperature for a second preselected time period; and repeating steps (a) to (c) for each further coloured ink. 18. A method as claimed in claim 17 wherein said first preselected time period is in the range two to three minutes and said second preselected time period is in the range one to three hours. 19. A method of manufacturing an applique, substantially as hereinbefore described with reference to Example 1. 20. An applique comprising a laminate having: a first layer comprising a thermoplastics material; and a second layer of a substrate material serving to support said thermoplastics material and restrict distortion thereof during printing of a preselected design on said first layer. 21. An applique as claimed in claim 20 wherein said substrate comprises paper with a silicone layer thereon. 22. An applique as claimed in claim 20 wherein said substrate comprises a silicone material. 23. An applique as claimed in claim 21 or 22 wherein said substrate has a nominal weight of 180gsm. 24. An applique as claimed in any of the preceding claims wherein said substrate contains polyester and polyamide fibres . 25. An applique as claimed in any of the preceding claims wherein said thermoplastics material is PVC. 26. An applique as claimed in any of the preceding claims wherein said thermoplastics material has a layer of flock adhered thereto to form said upper surface of said first layer. 27. An applique as claimed in claim 26 wherein said flock has a density of lOOgm per m 2 . 28. An applique as claimed in claim 26 or 27 wherein said flock is formed from fibres having a nominal length of 0.5mm. 29. An applique as claimed in claim 26, 27 or 28 wherein said flock comprises fibres having a thickness of 1.7 desitex. 30. An applique as claimed in any of the preceding claims wherein said substrate has a maximum elongation of 5% when tested according to DIN 53 112. 31. An applique as claimed in any of the preceding claims wherein said preselected design is printed using a water-based ink. 32. An applique as claimed in claim 30 wherein said ink contains a thickening agent and a flock transfer catalyst. 33. An applique as claimed in claim 31 wherein said thickening agent is Sericol ZE596 and said transfer catalyst is Sericol FT386. 34. An applique as claimed in claim 31 or 32 wherein said thickening agent forms approximately 5% by weight of said ink and said flocker transfer catalyst forms approximately 6% by weight of said ink. 35. An applique substantially as hereinbefore described with reference to Example 1.

Inventors: ENGLAND DOUGLAS ROY, ENGLAND, DOUGLAS, ROY
Applicants: ENGLAND DOUGLAS ROY, FABREX LTD, FABREX LIMITED
Application year: 1993
Main classification: B44C1
IPC codes: B44C1, D06P5, D06Q1