Patent Abstract:
The present invention relates generally to a multi-colored two-part decorative flocked article and to a method making and process of using the same.

Full Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present application claims the benefit of U.S. Provisional Application Nos. 61/105,725, filed on Oct. 15, 2008, 61/198,142, filed on Nov. 3, 2008, and 61/120,237 filed on Dec. 5, 2008, each of which is incorporated in their entirety herein by this reference. 
     
    
     FIELD OF INVENTION 
       [0002]    This invention is directed generally to a two-part decorative flocked article and specifically to a method of making the multi-colored two-part decorative flocked article and a process of using the same. 
       BACKGROUND 
       [0003]    The following text should not be construed as an admission of knowledge in the prior art. 
         [0004]    U.S. Pat. No. 4,810,549 to Abrams et al. discloses a method of creating of a multi-colored flocked transfer comprising a plurality of multi-colored flocked fibers positioned between an adhesive layer and a carrier sheet, the multi-colored flock fibers being adhered to the carrier sheet by a release adhesive. The multi-colored flocked transfer can be adhered a substrate by contacting the adhesive layer with the substrate and applying heat. 
         [0005]    Another method for creating a multi-colored flocked transfer is a direct flocking process. The direct flocking process typically comprises applying flock to an adhesive previously applied to the substrate. A multi-colored flock transfer is formed by applying each color of the multi-color image in a separate direct flocking process. In the direct flocking process, each color is separately contacted with the previously applied adhesive, one color after another, until all the colors comprising the multi-color transfer have been applied. 
         [0006]    Yet another method of creating a multi-colored flocked transfer on a substrate is applying a multi-colored flocked sticker to the substrate. The flock sticker typically comprises a plurality of multi-colored flock fibers, a liner paper, and a pressure-sensitive adhesive. The multi-colored flocked transfer is adhered to the substrate by the pressure sensitive adhesive. 
         [0007]    For some multi-colored flocked designs the above methods do not produce satisfactory multi-colored flocked transfers. The direct flocking method is rife with problems. Basically, the direct flocking method is an inexact flocking method that results in fibers being located at many different angles and depths in the adhesive. Direct flocking typically produces flock transfers which “shed” fibers. 
         [0008]    The level of detail achievable in a die-cut process limits the level of detail that can be achieved in the flock sticker method. More specifically, the level of detail is limited by the ability to remove or “weed” portions of the die-cut image that are to be discarded and not included in the final flocked image. 
       SUMMARY OF THE INVENTION 
       [0009]    An embodiment of the present invention is a process for making a flock transfer comprising positioning a release adhesive on a release sheet, contacting a plurality of flock fibers with the release adhesive to form a flock transfer; and indicating on the release sheet one or more registrable positions. The plurality of flock fibers has opposing first and second ends. The first ends are in contact with the release. The second ends of the flock fibers are fee of a permanent adhesive. 
         [0010]    The plurality of flock fibers comprises two or more differing colors of flock fibers. The plurality of flock fibers forms one or more flock image shapes. Preferably, the one or more flocked images substantially resemble a desired flocked image. In a preferred embodiment, the one or more flocked images comprise sufficient flock to form the desired flocked image. 
         [0011]    In another embodiment, the method for making the flock transfer further comprises indicating on the release sheet one or more registrable positions. In one configuration, the one or more registrable positions are determined relative to and after the printing the release adhesive. In another configuration, the one or more registrable positions are determined prior to and/or simultaneously with the printing of the release adhesive. In some instances, when the one or more registrable positions are determined prior to the printing of the release adhesive, the release adhesive is positioned on the release sheet relative to the one or more registrable positions. 
         [0012]    Another embodiment of the present invention is a flock transfer made by one of the above described methods for making the same. 
         [0013]    A preferred embodiment of the present invention is a method for making a flocked article, comprising receiving a flocked transfer sheet having one or more transfer sheet registrable positions indicated on the flocked transfer sheet, the flocked transfer sheet comprising a release adhesive positioned between flock fibers and a release sheet, and thereafter: indicating one or more substrate registrable positions on a substrate; positioning an adhesive on the substrate; registering at least one of the one or more flock transfer registrable positions with at least one of the one or more substrate registrable positions; and contacting the plurality of flock fibers with the adhesive, the flock fibers and the adhesive being in registrable. 
         [0014]    Preferably, the plurality of flock fibers comprises two or more differing colors of flock fibers. 
         [0015]    In a preferred embodiment, the adhesive is positioned on the substrate by a screen-printing process. In a more preferred embodiment, the adhesive is positioned in a form of one or more adhesive images. The flock fibers on the flock transfer form one or more flock images. In a preferred embodiment, the one or more flock images are contacted with the one or more adhesive images. Preferably, the one or more flock images have substantially enough flock to form a flock surface covering most, if not all, of the one or more adhesive images. 
         [0016]    In another preferred embodiment, the adhesive is printed with a line width resolution of at least about 0.5 mills. In a more preferred embodiment, the adhesive is printed with a line width resolution of at least about 0.3 mils 
         [0017]    The registering is selected from the group of registering methods consisting of mechanical registering methods, optical registering methods, and combinations thereof. In some embodiments, the indicating of the one or more substrate registrable positions on the substrate is conducted after and the positioning of the adhesive on the substrate and wherein the one or more substrate registrable positions are indicated on the substrate relative to the adhesive. In other embodiments, the positioning of the adhesive on the substrate is conducted after the indicating of the one or more substrate registrable positions on the substrate, preferably the adhesive is positioned on the substrate relative to the one or more substrate registrable positions. 
         [0018]    In a preferred embodiment, the adhesive comprises a paste adhesive. Preferably, the paste adhesive comprises a water-based paste adhesive. That is, the water-based paste adhesive comprises water and at least one of a thermosetting adhesive, a thermoplastic adhesive, and/or a combination of thermosetting and thermoplastic adhesives. Preferably, after positioning the adhesive on the substrate, but before the contacting the flock fibers with the adhesive, the printed paste adhesive is modified by one or more of: i) removing at least some of the liquid from the paste adhesive; ii) heating the paste adhesive; iii) curing at least some of the paste adhesive; iv) thickening the paste adhesive; v) glazing the paste adhesive; and vi) contacting a viscosity modifier with the paste adhesive. In some embodiments, the adhesive is positioned on the substrate by a screen-printing process. It is preferred, but not required, that the adhesive positioned on substrate be maintained in a substantially dimensionally stable position for at least some of the period from the screen-printing process until adhering the textile element to the substrate. 
         [0019]    In a preferred embodiment, the method further comprises after the contacting the flock fibers with the adhesive, adhering the flock fibers to the substrate. One or both of the contacting and adhering of the textile flock fibers to the substrate further comprises one or both of applying pressure and heat. During one or both of contacting and adhering steps, the flock fibers are at least partially embedded in the adhesive. 
         [0020]    In another embodiment, the method for making a flocked article further comprises receiving an insert, registering at least one of the one or more insert registrable positions with at least one of the one or more substrate registrable positions, and positioning an insert surface adjacent to the substrate, the insert and the substrate being in registration. Preferably, the insert is positioned on the substrate prior to the contacting of the flock fibers with the adhesive. In one configuration, the flock fibers at least partially surround the perimeter of the insert. 
         [0021]    The insert comprises one or more of: a woven textile material, a non-woven material, a metallic material, a polymeric material, a polyester material, and a satin material. In one embodiment, the insert further comprises an insert adhesive positioned on the insert surface positioned adjacent to the substrate. In one configuration, the insert is adhered to substrate by the insert adhesive. In another configuration, the insert is adhered to the substrate by the adhesive. 
         [0022]    Another embodiment of the present invention is an article made by one of the above described methods for making the same. 
         [0023]    Additional advantages of the present invention will become readily apparent from the following discussion, particularly when taken together with the accompanying drawings. 
         [0024]    As used herein, “at least one”, “one or more”, and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together. 
         [0025]    It is to be noted that the term “a” or “an” entity refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. It is also to be noted that the terms “comprising”, “including”, and “having” can be used interchangeably. 
         [0026]    The above-described embodiments and configurations are neither complete nor exhaustive. As will be appreciated, other embodiments of the invention are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0027]      FIG. 1  depicts a process for making a flock transfer according to an embodiment of the present invention; 
           [0028]      FIG. 2  depicts a process for making a flocked article according to an embodiment of the present invention; 
           [0029]      FIG. 3  depicts a cross-sectional view of a flock transfer according to an embodiment of the present invention; 
           [0030]      FIG. 4  depicts a top elevation view of the flock transfer of  FIG. 3 ; 
           [0031]      FIG. 5  depicts a top elevation view of a flocked article according to an embodiment of the present invention; 
           [0032]      FIG. 6  depicts a cross-sectional view of the flocked article of  FIG. 5 ; 
           [0033]      FIG. 7A  depicts a flocked article make according to another embodiment of the present invention; 
           [0034]      FIG. 7B  depicts a flocked article made according to yet another embodiment of the present invention; 
           [0035]      FIG. 8  depicts a top elevation view of a flocked article according to yet another embodiment of the present invention; and 
           [0036]      FIG. 9  depicts a cross-sectional view of the flocked article of  FIG. 8 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0037]    Process  100  for making a flock transfer  300  is depicted in  FIG. 1 . The flock transfer  300  comprises a release adhesive  320  positioned between a plurality of flock fibers  330  and a release sheet  310 , as depicted in  FIGS. 3 and 4 . In one preferred embodiment, the flock fibers form a flock image  335  positioned on the release sheet  310 , the flock image  335  is positioned relative to one or more flock transfer registrable positions  340 . 
         [0038]    The flock fibers can be any natural or synthetic material. The synthetic material can include vinyl, rayons, nylons, polyamides, polyesters, polyester terephthalates, polyethylene terephthalates), poly(cyclohexylene-dimethylene terephthalates), acrylic, and natural materials (such as cotton and wool), Preferably, the flock fibers comprise one of rayon, nylon, polyamides, polyester, polyethylene terephthalate) and poly(cyclohexylene-dimethylene terephthalate). In some instances, a conductive coating or finish can be applied continuously or discontinuously over the exterior surface of the flock fibers  330  to permit the flock fibers  330  to hold an electrical charge. 
         [0039]    The flock fibers can be colored. The colored flock fibers can be pre-colored or sublimation printed. Sublimation printing involves vapor phase transportation a dye into the flock fibers, preferably along the entire length of the flock fibers. In a preferred embodiment, the plurality of flock fibers  330  can comprise a plurality of differing colored flock fibers. In a preferred embodiment, the plurality of flock fibers  330  comprises two or more differing colors of flock fibers. 
         [0040]    The release sheet  310  can be any substrate that is dimensionally stable under the conditions of temperature and pressure encountered during the process. The release sheet  310  can be any low-cost, dimensionally stable substrate, such as paper, plastic film, a porous film, and the like in the form of a discontinuous sheet or a running web line material. Preferably, the release sheet is in a discontinuous form and/or a porous film. A preferred porous film is further discussed in U.S. Pat. No. 6,025,068 to Pekala, which is incorporated in its entirety hereby by this reference. A particularly preferred porous film is sold by PPG Industries Inc. under the trade name TESLIN™. In some instances, battery separator membranes can also be used as the release sheet  310 . Examples of suitable battery separator membranes include without limitation battery separator membranes sold by Celgard or by Daramic, Inc., as for example, battery separator membranes sold under the tradenames or Daramic Industrial CL™ and Artisyn™. Artisyn™ is an uncoated, nono-layer, highly filled polyolefin sheet. 
         [0041]    The release adhesive  320  can be any adhesive that adheres more strongly to the release sheet than the flock fibers, but adheres to both enough to hold them together. The release adhesive can be in the form of one of a paste, a liquid, an emulsion, and/or dispersion. For example, the release adhesive  320  can be any temporary adhesive, such as a resin or a copolymer, e.g., a polyvinyl acetate, polyvinyl alcohol, polyvinyl chloride, polyvinyl butyral, acrylic resin, polyurethane, polyester, polyamides, cellulose derivatives, rubber derivatives, starch, casein, dextrin, gum arabic, carboxymethyl cellulose, rosin, silicone, or compositions containing two or more of these ingredients. 
         [0042]    In step  120 , the release adhesive  320  is applied to the release sheet  310  prior to and/or after registering (step  110 ) the one or more flock transfer registrable positions  340  on the release sheet  310 . The release adhesive  320  can be applied to the release sheet  310  by a printing process, such as, but not limited to printing (such as, screen-printing, pad printing, flexographic, lithographic, and gravure), spray and/or roller processes. In a preferred embodiment, the release adhesive  320  is screen-printed on the release sheet  310 . The release adhesive  320  can be applied to release sheet  310  in the form of a solution or emulsion. The release adhesive  320  may be applied on the release sheet  310  in the shape of the desired design or without regard to the overall design desired. In one preferred embodiment, the release adhesive  320  is printed on the release sheet  310  to substantially represent a desired final flock image in size, shape and color scheme. Preferably, the desired final flock image can be a graphical design image having a desired graphical image color scheme. In some configurations, the desired final flock image can be a graphical design image having a desired graphical image color scheme that includes one or more random sub-graphical images which can include one or more substantially and/or partially random color schemes. 
         [0043]    In one embodiment, the registering of the one or more flock transfer registrable positions  340  on the flocked transfer  300  is conducted prior to, during and/or substantially simultaneous with the applying release adhesive  320  to the release sheet  310 . In such an instance, the registration is substantially precise and/or accurate to precisely and/or accurately position the release adhesive  320  on the release sheet  310  relative to the one or more flock transfer registrable positions  340 . 
         [0044]    In another embodiment, the release adhesive  320  is applied to the release sheet  310  prior to the registering the one or more flock transfer registrable positions  340  on the flocked transfer  300 . That is, the one or more flock transfer registrable positions  340  are registered on the flocked transfer  300  (such as, but not limited to on the release sheet  310 ) after applying the release adhesive  320  to the release sheet  310 . That is, the registering of the one or more registration flock transfer registrable positions  340  (step  110 ) can be before, during and/or after the printing the release adhesive  320 . In some instances, the registering of the one or more registrable positions  340  (step  110 ) can be after contacting the plurality of flock fibers  330  with the release adhesive  320 . Preferably, step  110  is preformed once during process  100 . More preferably, step  110  is performed once before one of the following: before step  120 , after step  120  but before step  130 , and/or after step  130 . 
         [0045]    The one or more flock transfer registrable positions  340  registered in step  110  can be permanent, semi-permanent, or virtual designations on the flock transfer  300 . Non-limiting examples of registrable position designators are: symbols printed on the release sheet  310 , symbols embossed (including voids and/or cut-outs) on the release sheet  310 , and/or positions calculated with respect to the release sheet  310  (such as, triangulated relative to release sheet  310 ) and/or the plurality of flock fibers  330  and/or release adhesive  320  positioned on the release sheet  300 . 
         [0046]    The release sheet can be supplied with the one or more flock transfer registrable positions  340  designated on the release sheet  310  and/or the one or more flock transfer registrable positions  340  can be designated during the step  110 . 
         [0047]    When the registering process is conducted after the printing of the release adhesive in step  120 , the one or more flock transfer registrable positions  340  can be registered relative to the position of one or both of the release adhesive  320  and/or the plurality of flock fibers  330 . 
         [0048]    The one or more flock transfer registrable positions  340  can be determined in step  110  by mechanical and/or optical methods. One non-limiting example of a mechanical registration method is a mechanical jig with one or more stops. Non-limiting examples of optical registration methods are laser light positioning and optical identification, preferably controlled by a computer. A non-limiting example of an optical/mechanical method is a machine vision device controlled and/or operated by a computer. 
         [0049]    Changes in temperature and/or humidity can affect the registration process and positioning of release adhesive  320  on the release sheet  310 . For this reason, the release sheet  310  and/or release adhesive  320  should preferably be substantially dimensionally stable under operational conditions, such as, but not limited to operational temperatures and/or humidities. 
         [0050]    In step  130 , the plurality of flock fibers  330  are contacted with the release adhesive  320  to form the flock transfer  300 . In some instances, one color of the differing flock fibers colors after another are contacted with the release adhesive  320 , until all of the differing colored flock fibers are contacted with the release adhesive  320 . The plurality of flock fibers  330  are contacted with the release adhesive  320  using known techniques, such as, electrostatic and gravity flocking techniques. It is desired that at least most of the plurality of flock fibers  330  are orthogonal or perpendicular to the release sheet  310 . The contacting of the plurality of flock fibers  330  with the release adhesive  310  further discussed in U.S. Pat. Nos. 7,344,769, 7,364,782, 7,402,222, 7,381,284, and 7,390,552 all to Abrams, each of which is incorporated in its entirety wherewith by this reference. 
         [0051]    In step  150 , the flock transfer  300  is supplied to process  200 .  FIG. 2  depicts a process for making a flocked article  350  after receiving the flock transfer  300 .  FIG. 5  depicts a top elevation view of a flocked article according to one embodiment, and  FIG. 6  depicts a cross-sectional view of the flocked article of  FIG. 5 . 
         [0052]    In step  220 , the flock transfer  300  is received. The flock transfer  300  can be received sequentially from step  130 , optionally from step  140  or the flock transfer  300  can be received from another source (such as, but not limited to a supplier or vendor of flock transfers). 
         [0053]    In step  210 , an adhesive  380  is applied to the substrate  370 . As in the case of applying the release adhesive  320  to the release sheet  310 , the adhesive  380  can be applied to the substrate prior to, during, and/or after registering one or more substrate registrable positions  390  on substrate  370  (step  205 ). 
         [0054]    In one embodiment, the registering of the one or more substrate registrable positions  390  on the substrate  370  (that is, step  205 ) is conducted prior to and/or substantially simultaneous with the applying the adhesive  380  to the substrate  370 . In such an instance, the registration is substantially precise and/or accurate to precisely and/or accurately apply the adhesive  380  to the substrate  370  relative to the one or more substrate registrable positions  390 . In one embodiment, the precision and/or accuracy of the registration method substantially aids in accurately and/or precisely applying freestanding fine lines of the adhesive  380  on the substrate  370 . 
         [0055]    In step  205 , one or more substrate registrable positions  380  are registered on substrate  370 . The one or more substrate registrable positions  380  can be permanent, semi-permanent, or virtual designations on the substrate  370 . The registrable position designators on the substrate  370  can be: symbols printed on the substrate  370 , elements of substrate  370  (such as, but not limited to profile or structural elements), elements permanently or reversibly attached to the substrate  370 , and/or positions calculated with respect to the substrate  370  (such as, triangulated relative to substrate  370 ) and/or with respect to the adhesive  380  applied to the substrate  370  and/or combinations thereof. The substrate  370  can be supplied with the one or more substrate registrable positions  390  designated on the substrate  370  and/or the one or more substrate registrable positions  390  can be designated on the substrate  370  during the registration process. 
         [0056]    Preferably, step  205  is preformed once during process  200 . More preferably, step  205  is performed once before one of the following: before step  210 , after step  210  but before step  255 , and/or after step  210  but before step  230 . 
         [0057]    The substrate  370  can be any material, such as, without limitation: polymeric; metallic; textile (woven or non-woven); paper; plastic; organic (wooden, cellulosic, leather, fibrous, etc.); polymeric (including homopolymers, heteropolymers, polymeric blends and alloys, and mixtures thereof); paper; paperboard, cardboard, ceramic; and inorganic (glass, mineral, etc.). Preferred substrates  370  are textile, plastic, polymeric, and organic materials. 
         [0058]    When the adhesive  380  is positioned on the substrate  370  prior to the registering of the one or more substrate registrable positions  390  on the substrate  370 , the one or more substrate registrable positions  390  are registered on the substrate  370  after the positioning of the adhesive  380  on the substrate  370 . In such an instance, the one or more substrate registrable positions  390  can be registered relative to the position of the adhesive  380  positioned on substrate  370 . 
         [0059]    The registering of the one or more substrate registrable positions  390  is conducted similarly to the registering of the one or more flock transfer registrable positions  340 . That is, the methods for registering the one or more substrate registrable positions  390  are substantially similar to the methods for registering the one or more flock transfer registrable positions  340 . Similarly the one or more substrate registrable positions  390  can be permanent, semi-permanent, or virtual designations on the substrate  370 . It can be appreciated that, registrable position designations the release sheet  310  and the substrate  370  means any thing, respectively, position on and/or within the release sheet  310  and/or substrate  370 . 
         [0060]    Returning to the adhesive  380 , the adhesive  380  can be applied to the substrate  370  by any printing process, such as, but not limited to printing (such as, screen-printing, pad printing, flexographic, lithographic, and gravure), spray and/or roller processes. Preferably, the adhesive  380  is applied to the substrate  370  in a printing process. More preferably, the adhesive  380  is applied to the substrate  370  in screen-printing process. The adhesive  380  is printed to form one or more adhesive images  385 . Preferably, the one or more adhesive images substantially resemble the desired, final flocked image on the flocked product  360 . The desired, final flock image can comprise one or flocked images. 
         [0061]    Non-limiting examples of suitable adhesives  380  are: pressure sensitive adhesives, hot-melt thermoplastic adhesives, A- and/or B-staged thermosetting adhesives, solvent based adhesive mixtures (including organic and non-organic solvents, and water), adhesive slurries, dispersed liquid adhesives, dispersed solid adhesives, adhesive particles, or combinations thereof. In a preferred embodiment, the adhesive  380  is a heat sensitive adhesive comprising fine adhesive particles. 
         [0062]    The adhesive  380  can be a water-based and/or solvent-based adhesive. Furthermore, the adhesive  380  can be in the form of a liquid, solid, powder and/or paste. The adhesive  380  can comprise without limitation one or more of: epoxies, phenoformaldehydes, polyvinyl butyrals, cyanoacrylates, polyethylenes, isobutylenes, rubber-based adhesives (styrene copolymers, including without limitation styrene-isoprene-styrene, styrene-butadiene-styrene, and copolymers thereof), silicones, non-crosslinked rubber based latexes, acrylics (acrylics, methacrylates, ethylene ethyl acrylates, ethylene methyl acrylates, and co-polymers thereof), polyurethane, polyamides, polyvinyl acetates, latexes, chloroprenes, butyls, polybutadienes, isoprenes, neoprenes, and polyesters, and can exhibit thermoplastic and/or thermosetting behavior. 
         [0063]    The screen-printable adhesive can be a thermoplastic adhesive and/or a material that has thermoplastic properties after being heated, such as after being at least partially dried and/or heat cured. Preferably, one or both of heat and pressure activates the adhesive  380 . 
         [0064]    The adhesive  380  can be the form of a solution, an emulsion and/or a paste. In an embodiment, the adhesive  380  is a paste adhesive. In preferred embodiment, the adhesive  380  is a screen-printable paste adhesive. In a more preferred embodiment, the paste adhesive comprises a water-based paste adhesive. In an even more preferred embodiment, the water-based paste adhesive comprises water and at least one of a thermosetting adhesive, a thermoplastic adhesive, and/or a combination of thermosetting and thermoplastic adhesives. 
         [0065]    The adhesive  380  can be printed as freestanding, fine lines of the adhesive  380 . The freestanding, fine lines of the adhesive  380  can have a line width resolution of at least about 0.5 mils. In a more preferred embodiment, the adhesive  380  can be printed as freestanding fine lines having a line width resolution of at least about 0.3 mils. 
         [0066]    In an even more preferred embodiment, freestanding, fine lines of the adhesive  380  comprise the paste adhesive. The fine lines of the paste adhesive spread and/or broaden less, that is, have a greater line resolution than fine lines of printed liquid and/or adhesive emulsions of the prior art. While not wanting to bound by any theory, the liquid adhesives and/or adhesive emulsions of the prior art have at least one of a lower viscosity and/or a lower surface tension than the paste adhesive. Therefore, the liquid adhesives and/or adhesive emulsion spread and/or broaden after being printed. The paste adhesive can have at least a substantially greater viscosity than liquid adhesives and/or adhesive emulsions and, therefore, fine printed lines of the paste adhesive substantially spread and/or broaden less than fine printed lines of the liquid adhesives and/or adhesive emulsions. 
         [0067]    Furthermore, the printing of higher resolution fine lines of the adhesive  380  can be affected by the substrate  370 . While not wanting to be bound by any theory, finer lines and/or higher resolution can be obtained by printing the adhesive  380  on smoother and/or higher energy substrates. The printed fine lines of the adhesive  380  can have a lesser tendency to broaden and/or spread on smoother and/or higher energy surfaces. More specifically, the printed fines of the paste adhesive can have a lesser tendency to broaden and/or spread on smoother and/or higher energy surfaces than liquid adhesives and/or adhesive emulsions. 
         [0068]    The ability to print freestanding fines lines of the paste adhesive allows for flocked article design features previously unattainable by the prior art methods, such as, thin, narrow, delicate design features previously unattainable by the methods of the prior art flock transfer methods. While not wanting to be limited by example, freestanding fine lines of the paste adhesive allows for fine line designs, such as, but not limited to, the fine line design depicted in  FIG. 7A .  FIG. 7A  depicts a flocked design formed by printing freestanding, fine lines of the paste adhesive on a cardboard substrate and applying flock fibers to the printed paste adhesive, the resolution of the flocked fiber design lines  801  being about 0.2 to about 0.4 mils.  FIG. 7B  depicts the same flocked formed by printing an adhesive on a flocked surface of a flock transfer sheet. The flocks and substrates of  FIGS. 7A and 7B  are the same. Furthermore, the same printing screen was used to print the same paste adhesive. The difference between  FIGS. 7A and 7B  being the substrate onto which the paste adhesive is printed. In  FIG. 7A , the paste adhesive is printed on a (cardboard) substrate where the adhesive spreads and broadens little, if any. In  FIG. 7B , the paste adhesive is printed on a substrate (a flocked surface) where the adhesive can spread and broaden. The resolution of the flocked fiber web line  802  of  FIG. 7B  is form about 0.6 to about 0.8 mils. 
         [0069]    In some embodiments, the screen-printable paste adhesive  380  is printed on partially porous and/or roughened substrate, such as, a fabric, the paste adhesive is preferably at least partly pushed into the substrate  370 . While the adhesive  380  is at least partly pushing into the substrate  370 , it is preferred that at least some of the adhesive  380  extends upward from the substrate  370  surface. Preferably, the adhesive  380  positioned on the substrate  370  forms a relatively uniform profile of the adhesive  380  extending upward from the substrate  370  surface. More preferably, the adhesive  380  forms a relatively uniformly flat profile of the adhesive  380  extending upward from the substrate  370  surface. While not wanting to be bound by theory, the relatively uniform adhesive profile is preferred for subsequent contacting with the flock transfer  300 . 
         [0070]    The adhesive  380  can be printed on the substrate  370  in the form of an adhesive image  385  ( FIG. 7 ). Preferably, the adhesive image  385  is substantially about the same shape and size as the flock transfer image  335 . More preferably, the flock transfer image  335  is at least larger than the adhesive image  385 . The at least larger flock transfer image  335  substantially assures that at least all of the adhesive image  385  is contacted with flock. 
         [0071]    In one embodiment, the substrate  370  is maintained on the screen-printing machine pallet after applying the adhesive  380  to the substrate  370  in a substantially undisturbed condition to form a substantially dry adhesive. A substantially undisturbed condition means the screen-printed adhesive substantially maintains its position relative to the one or more substrate registrable positions  390  throughout the drying process. That is, the screen-printed image  385  is substantially about the same size, shape and position relative to the one or more substrate registrable positions  390  prior to and after the drying process. In one embodiment, when the substrate  370  is a deformable substrate (such as, a fabric), the substrate  370  is allowed to remain substantially undisturbed on the screen printing machine pallet during the drying process. 
         [0072]    While not wanting to be bound by theory, a higher viscosity adhesive can secure at least most of plurality of the flock fibers  3330  to the substrate  370  to a greater extent than a lower viscosity adhesive. The flock fibers in contact with the adhesive are less likely to move and/or to be dislodged from the high viscosity adhesive  380  than from the lower viscosity adhesive  380 . Additionally, the screen-printed higher viscosity adhesive  380  is less likely to change shape during one or more of drying, curing, and/or heat pressing compared to the lower viscosity adhesive  380 . 
         [0073]    In another embodiment, the viscosity of the adhesive  380  is increased by one or more of: a) the passage of time, wherein the adhesive  380  looses liquid and/or begins to dry; b) exposure to heat, wherein the rate of loss of water is accelerated; and/or c) chemical thickening of the adhesive  380 , such as, but not limited to gelling agents, skin forming agents, or such. Care must be taken when increasing the viscosity of adhesive  380  by exposure to heat to not trap water inside of the drying adhesive. The trapping of water within the drying adhesive  380  can degrade one or more of the adhesive performance and cure. 
         [0074]    In one embodiment, after applying the adhesive  380  to the substrate  370  the liquid in the adhesive  380  is ‘flashed’ off. The liquid can be ‘flashed off’ by a flash unit on the screen printing press. In some instances, the liquid is ‘flashed off’ by applying heat to the adhesive  380  after applying the adhesive  380  to the substrate  370 . 
         [0075]    In one embodiment, after printing the adhesive  380  on the substrate  370 , the substrate  370  with the adhesive  380  is moved from the printing machine to a drier. Preferably, the substrate  370  with the adhesive  380  is moved from the printing machine to the drier in time period of less than about 3 seconds to about 30 minutes. More preferably, for productivity sake, the substrate  370  with the adhesive  380  printed thereupon is moved from the printing machine to the drier immediately after the adhesive  380  in printed on the substrate  370 . The substrate  370  can be mounted on a flat surface (such as, but not limited to a board) to maintain dimensional stability during the manufacturing process from the contacting of the adhesive  380  with the substrate  370  to production of the final flocked article  360  in step  240 . Preferably, the time period for the drying process ranges from about 1 minute to about 180 minutes. More preferably, the drying period is from about 10 minutes to about 100 minutes. In a preferred embodiment, substantially enough of the liquid is removed during the drying process to form a substantially dry adhesive film on the substrate  370 . The dry adhesive film is substantially dry enough not to resist modification (that is, not be substantially removed and smudged) by routine handling. In a more preferred embodiment, the liquid being removed is the water contained with the water-based paste adhesive. 
         [0076]    In a preferred embodiment, the liquid is removed in an air-drying process. In a more preferred embodiment, the liquid water contained within the paste is removed in an air-drying process. After printing the paste adhesive on the substrate  370 , the screen-printed adhesive can air-dried at temperature from about ambient to about 175° F., preferably from about ambient to about 120° F. In another configuration, the paste adhesive can be dried using an air-exchange process. For example, in a room and/or cabinet, that removes the vaporized liquid water by the air exchange process. In more preferred configuration, the paste adhesive is air-dried at a temperature from about ambient to about 120° F. in combination with an air-exchange process. 
         [0077]    In another embodiment, substrate  370  with the adhesive  380  positioned thereupon is moved without substantial distortion to a drier belt for the optional drying step (not shown) after step  210 . Preferably, the adhesive  280  is stabilized and substantially dried (or ‘finished’) during the drying step. The stabilizing and drying (or finishing) of the adhesive  380  prepares the adhesive  380  for contacting the flock transfer  300 . After the drying the substrate  370  with the dried adhesive is moved without substantial distortion (that is, the dimensional stability of the substrate  370  and/or adhesive  380  are maintained during the move) to at least one of the contact  230  and adhering  240  steps. During the contacting step  230 , one or both of heat and/or pressure can be applied to embed the plurality of flock fibers  330  into the adhesive  380 . 
         [0078]    In another embodiment, the viscosity of the adhesive  380  is increased by printing a glazing on the adhesive  380 , a non-limiting example is described in U.S. application Ser. No. 11/413,797 with a filing date of Apr. 28, 2006, the entire contents of which is incorporated herein by this reference. 
         [0079]    In step  225 , the one or more flock transfer registrable positions  340  are determined. The one or more flock transfer registrable positions  340  and the one or more substrate registrable positions  390  are utilized to substantially align the flocked image  335  with the adhesive image  385 . 
         [0080]    In step  230 , the flocked image  335  and the adhesive image  385  are contacted substantially in registration. That is, the one or more flock transfer registrable positions  340  and the one or more substrate registrable positions  390  are utilized in contacting the flock transfer  300  in substantial registration with the printed adhesive image  385  (step  130 ). Registering the one or more flock transfer registrable positions  340  and the one or more substrate registrable positions  390 , one to the other, affords a higher quality artistic design manufacturing process than in the prior art manufacturing processes. 
         [0081]    The registering of the one or more flock transfer registrable positions  340  and/or the one or more substrate registrable positions  390  can be affected by changes in temperature and/or humidity. For these reasons, one or both of the substrate  370  and the flock transfer  300  should be substantially dimensionally stable under operational conditions. 
         [0082]    In step  230 , at least most, if not all, of the plurality of flock fibers  330  are contacted with the adhesive  380 . In a preferred embodiment, the flock transfer image  335  is at least lager than the adhesive image  385 , therefore, not all of the plurality of flock fibers  330  are contacted with the adhesive in  380 . 
         [0083]    In step  235 , at least most, if not all, of the flock fibers in contact with the adhesive  380  are adhered to the substrate  370  to form an article of manufacture  360 . The plurality of flock fibers  330  are substantially adhered to the substrate by the adhesive  380 . One or both of heat and pressure can be applied during one or both of the contacting and/or adhering of the flock transfer  300  to the substrate  370 . 
         [0084]    In a preferred embodiment, one or both of heat and pressure can be applied during the adhering step  235  to adhesively bind plurality of flock fibers  330  to the substrate  370 . The heat can soften and/or partially melt the adhesive  380 . The flock fibers ends in contact with the softened and/or partially melted adhesive  380  can be embedded in the softened and/or melted adhesive  380 . After setting the adhesive  380  (that is, solidifying and/or cross-linking) the embedded flock fibers are substantially permanently adhered by the adhesive  380  to the substrate  370 . 
         [0085]    Returning to the drying of the adhesive  380 , the substrate  370  can remain mounted on the flat, dimensionally stable surface during one or more of the contacting of the adhesive with the substrate (step  210 ), the registering of the one or more substrate registrable positions (step  210 ), the drying of the adhesive (not shown), the contacting (step  230 ), and adhering of the (step  235 ). In a preferred embodiment, the flat, dimensionally stable surface: a) supports the substrate  370  during the embedding of the flock fibers into the adhesive  380 ; and b) supports and/or restrains the substrate  370  in a dimensionally stable position during the adhesive registering of the one or more substrate registrable positions  390 . 
         [0086]    In another embodiment, the release sheet  310  along with the release adhesive  320  are removed after one of the adhering step  235 , preferably after adhesive  380  has set (that is, after adhesive  380  has cooled to ambient temperature and/or cross-linked). The flock fibers with ends substantially embedded in the adhesive  380  remain after the release sheet  310  is removed, while the flock fibers that do not have an end substantially embedded in the adhesive  380  remain attached to release sheet  310 . 
         [0087]    In optional embodiment, the flocked article  360  includes an insert  400  having one or more insert registrable positions, the insert  400  registrable positions being similar to the transfer and/or substrate one or more registrable positions. The insert  400  can have an insert adhesive applied to one surface of the insert. 
         [0088]      FIG. 8  depicts a top elevation view of a flocked article according to another embodiment, the flocked article having an insert, and  FIG. 9  depicts a cross-section view of the flocked article of  FIG. 8 . Preferably, the flock fibers  330  at least partially surround the perimeter of the insert  400 . In some embodiments, the perimeter of the insert  400  is not surrounded by the flock fibers  330 . The greater resolution achieved with the freestanding, fine line printing of the paste adhesive allows for a tighter fit, that less, less of gap between the insert  400  and the flock fibers  330 . 
         [0089]    The insert  400  can comprise any material. Non-limiting examples of preferred insert materials are: metallics, textiles (woven or non-woven), papers, plastics, organics (wooden, cellulosic, leather, fibrous, etc.), polymers (including homopolymers, heteropolymers, polymeric blends and alloys, and mixtures thereof), ceramics, and inorganics (glass, mineral, etc.). The insert  400  can comprise a mixture of insert materials. In other embodiments, the insert can have at least one of: a substantially flat planar shape; a beaded-shape; a two-dimensional graphic image, alphanumeric, and/or artistic shape; and/or a three-dimensional graphic image, alphanumeric, and/or artistic shape. 
         [0090]    In a preferred embodiment, the insert  400  comprises one of: a woven textile material, a non-woven material, a polymeric material, a polyester material, and a satin material. Exemplary woven textiles, including the woven inserts, include loosely or heavily woven polyesters with increased surface dimensionality or character, with or without an image, such as a sublimation dye printed image. In a preferred configuration the woven textile is a woven textile product sold under the trade name ObiTex™ by Fiberlok®, having an enhanced surface texture and luster that provides an embroidered or hand-stitched embroidered appearance. Preferably, the woven textile can contain an image on a first side of the woven textile. The image is typically comprises at least one of: a sublimation dye image; an embossed image; a woven image; or a combination thereof. A second adhesive can be positioned on a second side of the woven textile, the first and second sides being opposing sides. The second adhesive can be a hot-melt adhesive, preferably one of: a thermoplastic adhesive, a thermosetting adhesive, or a mixture thereof. The second adhesive can be activated by at least one of the heat and/or pressure. The activated second adhesive can adhere the woven insert to the substrate  270 . 
         [0091]    Preferably, the woven insert is pre-cut to the desired shape. More preferably, the woven insert is pre-cut, such as laser cut, to minimize fraying of the cut edges. 
         [0092]    The insert  400  is received in step  245 . In step  250 , the one or more insert registrable positions are determined. The one or more insert registrable positions and the one or more substrate registrable positions  390  are utilized to substantially align the insert with the substrate  370 . In step  255 , the insert  400  and the substrate  370  are contacted in substantially in registration. 
         [0093]    In a preferred embodiment, the insert adhesive is contacted with the substrate surface in step  255 , the insert adhesive substantially adhering the insert  400  to the substrate  370 . In another embodiment, the insert  400  can be contacted with at least some of the adhesive  380 , preferably prior to contacting the plurality of flock fibers with the adhesive  380 , the adhesive  380  substantially adhering the insert  400  and the plurality of flock fibers  330  to the substrate  310 . The insert  400  and the plurality of flock fibers  330  are adhered to the substrate  370  in step  235 . 
         [0094]    In another optional embodiment, the flock transfer  300  can comprise a woven textile and can lack any flock fibers. In such an instance, the woven textile is registered with the adhesive  380  and contacted with the adhesive in registration. After contacting the adhesive  380  the woven textile is adhered to the substrate  370  in step  235  to produce the article of manufacture  360  in step  240 . 
         [0095]    In one embodiment, the transfer  300  is manufactured by first party and received by a second, unrelated party. The second party receives the transfer having one or more transfer registrable positions indicated on the transfer, the transfer comprising a release adhesive positioned between a textile element and a release sheet; and thereafter produces an article of manufacture by: indicating one or more substrate registrable positions on a substrate; positioning an adhesive on the substrate; registering at least one of the one or more transfer registrable positions with at least one of the one or more substrate registrable positions; and contacting the textile element with the adhesive, the textile element and the adhesive being in registration. The textile element can comprise one or more of: 1) a plurality of flock fibers; 2) a plurality of flock fibers having differing colors of flock fibers; 3) a plurality of fibers having an insert; and 4) a woven textile. 
         [0096]    In another embodiment, a first party produces the insert  300  and a second party produces the adhesive  280  positioned on the substrate  270 , the substrate having at least one or more substrate registrable positions. A third party receives the insert  300  and the substrate having the one or more substrate registrable positions with the adhesive positioned on the substrate, and produces an article so manufacture by contacting and adhering the insert to the substrate in registration. 
         [0097]    The present invention, in various embodiments, includes components, methods, processes, systems and/or apparatus substantially as depicted and described herein, including various embodiments, sub-combinations, and subsets thereof. Those of skill in the art will understand how to make and use the present invention after understanding the present disclosure. The present invention, in various embodiments, includes providing devices and processes in the absence of items not depicted and/or described herein or in various embodiments 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. 
         [0098]    The foregoing discussion of the invention has been presented for purposes of illustration and description. The foregoing is not intended to limit the invention to the form or forms disclosed herein. In the foregoing Detailed Description for example, various features of the invention are grouped together in one or more embodiments for the purpose of streamlining the disclosure. The features of the embodiments of the invention may be combined in alternate embodiments other than those discussed above. This method of disclosure is not to be interpreted as reflecting an intention that the claimed invention 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 embodiment. 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 invention. 
         [0099]    Moreover, though the description of the invention has included description of one or more embodiments and certain variations and modifications, other variations, combinations, and modifications are within the scope of the invention, 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 embodiments 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.

Technology Classification (CPC): 3