Patent Publication Number: US-2010112244-A1

Title: Printed Emblems

Description:
FIELD 
     The present invention relates to the field of emblems and emblem production. 
     SUMMARY 
     In one aspect, the invention provides a method of manufacturing an emblem. The method includes the steps of providing a fabric layer having first and second surfaces, disposing a thermoplastic adhesive layer on the first surface of the fabric layer, and disposing an ink layer on the second surface of the fabric layer. In some embodiments, the ink layer may include a nylon ink. In some embodiments, the fabric layer may be a polyester fabric, such as a 2 oz. polyester fabric. In some embodiments, the thermoplastic adhesive layer may be a polyurethane, such as a 3 mil clear polyurethane. In various embodiments, the thermoplastic adhesive may be disposed on the first surface of the fabric layer by heat sealing. In various embodiments, the ink may be disposed on the second surface of the fabric layer by screen printing. 
     In some embodiments, the method may include the step of printing a design on the ink layer. The design may be printed on the ink layer using, for example, a screen printer, an inkjet printer, a digital printer, a laser printer, a ribbon printer, and combinations thereof. The design may be printed using, for example, ultraviolet ink, inkjet ink, laser ink, ribbon ink, and combinations thereof. 
     In another aspect, the invention provides a method of printing an emblem. The method includes the steps of providing a fabric layer having first and second surfaces, disposing a thermoplastic adhesive layer on the first surface of the fabric layer, disposing an ink layer on the second surface of the fabric layer, and printing a first design on the ink layer. In some embodiments, the ink layer may include a nylon ink. The design may be printed on the ink layer using, for example, a screen printer, an inkjet printer, a digital printer, a laser printer, a ribbon printer, and combinations thereof. The design may be printed using, for example, ultraviolet ink, inkjet ink, laser ink, ribbon ink, and combinations thereof. In some embodiments, the method may include the step of embroidering a second design over the first design. 
     In another aspect, the invention provides a multilayer emblem that includes a fabric layer having a first surface and a second surface, a thermoplastic adhesive layer, and an ink layer. The thermoplastic adhesive layer is disposed on the first surface of the fabric layer, and the ink layer is disposed on the second surface of the fabric layer. In some embodiments, the fabric layer may be a polyester fabric, such as a 2 oz. polyester fabric. In some embodiments, the thermoplastic adhesive layer may be a polyurethane, such as a 3 mil clear polyurethane. In some embodiments, the ink layer may include a nylon ink. In some embodiments, the ink may be white. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       The foregoing and other objects, aspects, features, and advantages of the invention will become more apparent and may be better understood by referring to the following description taken in conjunction with the accompanying drawings, in which: 
         FIG. 1  depicts a cross sectional view of an exemplary emblem in accordance with an illustrative embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to  FIG. 1 , in one embodiment, an emblem  10  includes three layers, namely a fabric layer  20 , a thermoplastic adhesive layer  30 , and an ink layer  40 . The fabric layer  20  has at least a first surface and a second surface (i.e., a first side and a second side). The fabric layer  20  provides a support surface for the thermoplastic adhesive layer  30  and the ink layer  40  and also provides body to the emblem  10 . The fabric layer  20  can be any suitable thickness, such as, for example, about 1 oz., about 2 oz., about 3 oz., about 4 oz., about 5 oz., about 6 oz., about 7 oz., about 8 oz., about 9 oz., or about 10 oz. In some embodiments, the fabric layer  20  can be a polyester fabric and, preferably, can be a polyester non-woven fabric such as Pelon. In a preferred embodiment, the fabric layer  20  is a 2 oz. polyester fabric. 
     With continued reference to  FIG. 1 , a thermoplastic adhesive layer  30  is disposed on a first surface of the fabric layer  20 . The thermoplastic adhesive layer  30  can be any suitable adhesive which allows the emblem  10  to be heat sealed onto a substrate, such as a garment or another layer of material. In some embodiments, the thermoplastic adhesive layer  30  includes a urethane, such as a polyurethane. The thermoplastic adhesive layer  30  can be any suitable thickness, such as, for example, about 1 mil, about 2 mil, about 3 mil, about 4 mil, about 5 mil, about 6 mil, about 7 mil, about 8 mil, about 9 mil, or about 10 mil. In a preferred embodiment, the thermoplastic adhesive layer is a 3 mil clear polyurethane. The thermoplastic adhesive layer  30  can be disposed over substantially the entire first surface of the fabric layer  20 , or the thermoplastic adhesive layer  30  can be disposed over a portion of the first surface of the fabric layer  20 . 
     The fabric layer  20  and the thermoplastic adhesive layer  30  may be bonded together by heat sealing, preferably at a temperature of about 350 to 450 degrees Fahrenheit (° F.), and more preferably at about 400° F. In an embodiment, the heating is performed under conditions of about 20 to about 70 pounds per square inch (“psi”) of pressure, preferably about  60  psi, for about from 4 to 18 seconds. 
     With continued reference to  FIG. 1 , an ink layer  40  is disposed on a second surface of the fabric layer  20 . In some embodiments, the ink layer  40  provides a background onto which one or more designs can be printed and/or embroidered. As used herein, the term “design” includes any marking, such as, for example, one or more letters, words, logos, drawings, pictures, insignias, trademarks, and combinations thereof. The ink can be any suitable color. In a preferred embodiment, the ink is white. In some embodiments, the ink is a nylon ink or includes a nylon ink. The ink layer  40  can be deposited on the second surface of the fabric layer  20  using screen printing or any other suitable method. The ink layer  40  can be disposed over substantially the entire second surface of the fabric layer  20 , or the ink layer  40  can be disposed over a portion of the second surface of the fabric layer  20 . 
     One or more designs can be printed on the ink layer  40 . Any suitable printing method can be used to print a design on the ink layer  40 . For example, a design can be printed on the ink layer  40  using screen printing, digital printing, inkjet printing, and combinations thereof. In addition, any suitable ink can be used to print the design on the ink layer  40 , such as for example, ultraviolet ink, inkjet ink, laser ink, ribbon ink, and combinations thereof. In some embodiments, a second design is embroidered over a first printed design. 
     The emblem  10  as described herein may be used in a variety of different manners. In some embodiments, the emblem  10  may be used in connection with embroidered emblems. In some embodiments, the emblem  1 O may be used in connection with screen printing of emblems. In still other embodiments, the emblem  10  may be used in connection with sublimation processes used to construct emblems. 
     The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.