Source: https://patents.google.com/patent/US7338697B2/en
Timestamp: 2018-08-17 10:18:09
Document Index: 797995923

Matched Legal Cases: ['§119', '§ 1', '§ 1', '§ 1', 'Application No. 10', 'Application No. 10', 'Application No. 10', 'Application No. 01815554', 'Application No. 01815554', 'Application No. 2001277991', '§1', '§ 1']

US7338697B2 - Co-molded direct flock and flock transfer and methods of making same - Google Patents
Co-molded direct flock and flock transfer and methods of making same Download PDF
US7338697B2
US7338697B2 US10394357 US39435703A US7338697B2 US 7338697 B2 US7338697 B2 US 7338697B2 US 10394357 US10394357 US 10394357 US 39435703 A US39435703 A US 39435703A US 7338697 B2 US7338697 B2 US 7338697B2
US10394357
US20030207072A1 (en )
A method of decorating a molded article is provided that includes the steps of:
(c) introducing resin into the mold, such that a resin contacts the mold insert to form a molded article. The melting point of the permanent adhesive layer is preferably greater than a temperature of the resin during molding.
The present application is a continuation-in-part of each of U.S. patent application Ser. No. 09/629,746, filed Jul. 31, 2000 now U.S. Pat. No. 6,929,771; and 09/621,830, filed Jul. 24, 2000; and claims the benefits under 35 U.S.C. §119 of each of U.S. Provisional Application Ser. Nos. 60/366,580, filed Mar. 21, 2002; 60/393,362, filed Jul. 3, 2002; 60/416,098, filed Oct. 4, 2002; and 60/443,986 filed Jan. 30, 2003, each of which is to Abrams and is incorporated herein by this reference.
This invention relates generally to flocked articles and specifically to molded articles having flocked surfaces.
It is often desirable to decorate molded plastic parts for aesthetic or practical purposes. Injection molded articles are often decorated using inks, screen printing, pad printing, direct electrostatic flocking and hot stamping. These methods are most often post-molding operations requiring additional processing and cost and time. In addition, the resulting quality of the product is often low, due to the low quality of adhesion or unevenness of the coating.
These and other needs are addressed by the present invention. The invention generally provides a flocked molded article and methods for producing the article.
The present invention can have a number of advantages compared to conventionally decorated molded articles. First, attractive, multicolored flock insert molded articles can be manufactured inexpensively and in high volumes. Second, the process can be relatively simple and require at most a modest capital investment. Third, imaging techniques such as screen printing or cutting permits portions of the design to be easily omitted or separated, as desired. The ability to create voids in the finished design where desired, could eliminate subsequent cutting and/or picking out of material to be eliminated (like the center of the letter “O”). This ability permits novel design configurations, such as designs where the backing film is exposed as part of the overall design. Alternatively, part of the adhesive can be left exposed and the adhesive then sprinkled with or dipped into a design medium to fill the exposed area of the resin dispersion. The exposed area can thus be used for inclusion of different types of design media materials (like textiles, holograms, glitter particles, beads, etc.) incorporated into the molded article to create interesting, mixed media looks. Fourth, the various processes described herein can produce multi-colored flocked surfaces on molded articles. Such articles have higher perceived values (as one can make attractive multi-colored designs, simulated textile looks, logos, etc.) when compared to single colored molded articles. The (pre-colored or permanently colored) multi-colored flock (either producer colored (or pigment-in-colored) or dyed flock) can be selected to provide superior soil and stain concealment and resistance to chemical or high UV exposure, which can be particularly important in automotive or outdoor use. In contrast, single colored molded articles will readily show lint, soil, stains, etc. Additionally, multi-colored flock can have functional value, such as graphically or visually producing strips for a grip handle, insulation value, and other benefits, such as sweat absorption and comfort.
In one embodiment, a flock heat transfer type media is used rather than ink-printed film inserts or decorations to provide a plush, evenly-coated, three-dimensional single or multi-colored textured decoration molded together with the hot resins when the part is formed. Using flock transfer media, a plushly textured decoration is permanently attached to the surface of the molded part. To accomplish this the hot melt adhesive commonly used with flock heat transfer manufacturing is eliminated so it will not liquefy and ooze out around the decoration in the mold. In addition, another adhesive, such as a tie coat material or other compatible film, may be used instead of a normal hot melt to prevent oozing and to promote adhesion, melt bond and/or chemical compatibility with the molding resin, when injecting molding a flock transfer directly to the polymer molded article.
The mold may have a depression or locating pins or other mechanical parts to assist with aligning and holding the flock transfer in place. Additionally, “dams” built into the mold around the perimeter of the flock transfer may be included to prevent seepage of the molding resin into the interstitial spaces of the flock transfer, between the fibers.
To stabilize the position of the flock transfer in the injection mold, the molding process may be modified for example by purposely selecting resins of lower melting point or by injecting the resins in two separate stages, a first more “gentle” injection to set the transfer in place, followed up by a full-pressure normal injection of resin.
Referring to FIG. 1, a flock transfer 2 of the present invention is shown in place in a mold 4 to be co-molded with a plastic article 6. In FIG. 1. The transfer 2 is shown on top of the article 6. The transfer 2 comprises a dimensionally stable sheet 8 to which a conventional flock transfer release adhesive 10, usually silicone or latex wax, is applied in the reverse of a desired pattern or with overall coverage of the sheet, corresponding to the overall image which is to be flocked and transferred. The flock 12 which may be rayon or any other type of material with a conductive finish such as nylon, polyester or the like is applied to the activated adhesive 10 in any conventional manner, such as, conventional electrostatic techniques, vibration, air flow, gravity, or combination thereof. The method of applying the flock 12 to the adhesive 10 depends on the transfer to be achieved will the transfer be one color or several colors, will the transfer include any non-flock decorations, etc. Thus, the transfer itself, can be a conventional flock transfers, Lextra®, Lextra® II, or Lextra® 3-D type transfer, flocked roll goods such as made by Societe D'Enduction et de Flokage, located in Laval, France, from which pieces may be cut out and even pre-formed to fit better into molds where the surface of the finished product is not flat. The lower ends of the flock 12 are coated with a permanent binder adhesive 14, such as a water based latex or thermoset or thermoplastic film, which binds the flock into a unit. The binder 14 may contain an additional adhesive or compatible film, for promoting the adhesion of the transfer to the resin in molding.
As noted above, the flock 12 used in any of the processes discussed herein can be any electrostatically chargeable fiber, such as fibers made from rayon, nylon, cotton, acrylic, and polyester. Preferably, the flock has a melting and/or softening point that is greater than the temperatures experienced by the flock in the mold (which, conservatively, is no less than the maximum temperature of the resin during the molding process). Acrylic flock is therefore undesirable in many applications. The flock is also preferably resilient under the pressures experienced in the mold. Resilient flock, such as polyesters (e.g., poly(ethylene terephthalate) and other terephthalate polymers), and nylon flock, may matt down during molding but, after ejection from the mold, self-restore to its original orientation relative to the backing film. In most applications, the orientation is at least substantially orthogonal (perpendicular) to the surface of the backing film. An advantage of flock resiliency is the ability to compress the flock during molding to avoid “down-gauging” the wall thickness of the finished molded article. Compressible and less resilient flock is desirable in some applications, such as sublimation coloration or dying but would require additional process steps to restore the flock to its pre-mold orientation. Such post-molding processes include vacuuming the flock, mechanically brushing the flock, applying high voltages to the flock, heating the flock to high temperatures, and the like. Finally, it is preferable that the flock have high abrasion resistance and color fastness. Nylon and poly(ethylene terephthalate) flock is desirable due to its abrasion resistance and color fastness. In contrast, rayon flock, though resilient, is undesirable in certain applications due to relatively poor abrasion resistance and color fastness.
(a) applying the release adhesive 10 discontinuously to the sheet 8 (in a desired pattern) (which can be continuous over the sheet with later cutting in selected patterns, if desired);
(f) laminating the sized sheet/release adhesive/flock/adhesive transfer to the backing film 104 using conditions (time, temperature, and pressure) sufficient to fully activate the (permanent) adhesive and permanently attach the intermediate transfer to the backing film 104 to form the mold insert film 100. At this stage the residual randomly oriented flock fibers remaining in the release adhesive (e.g., the flock fibers poorly bonded or not bonded to the backing film) will prevent the sheet and release adhesive from leaving marks on the mold insert film 100. Alternatively, the sheet 8 could be removed firstly and replaced with a clean carrier sheet 8 free of randomly oriented, remaining residual flock fibers.
(g) removing the sheet 8 from the mold insert film 100, leaving the fiber image on the mold insert film 100 in the desired areas (e.g., the design is discontinuously distributed over the surface of the film backing).
In any of the above processes, another adhesive film 208 (FIG. 9) can be concurrently or later bonded to the adhesive film 14. The assembly is then bonded to the backing film 104. When the adhesive film 14 is fully activated during lamination, it is unable to later attach to the backing film 104. The adhesive film 208 is used to permit the assembly to be bonded to the backing film 104. Adhesive films 14 and 208 can be any suitable adhesive, with activatable adhesives, such as hot melt thermoplastic or thermoset adhesives, being preferred.
In one alternative embodiment, the adhesive 14 used in direct flocking inserts is a resin dispersion. As will be appreciated, a “resin dispersion” is a dispersion of one or more resins in one or more plasticizers or other additives, which forms a liquid or paste that gels and/or fuses when heated. A resin is an organic polymeric liquid that, when converted to its final state for use, becomes solid. The resin dispersion thus typically includes fine particles of polymers or copolymers and plasticizer(s). The resin dispersion can further include stabilizers, fillers, thickeners, curing agents, etc. The resin dispersion is typically dried and cross-linked with chemical reactions and/or heat.
Preferred resin dispersions include vinyls, such as PLASTISOL®, urethanes, nylons, acrylics, acetates, polyesters, and/or olefins. “Vinyls” refer to a compound including the vinyl grouping (CH2——CH——) or a derivative thereof; “urethanes” to a compound including the grouping CO(NH2)OC2H5 or a derivative thereof, nylons to a compound having the grouping —CONH or a derivative thereof, acrylics to a compound including the acrylonitrile grouping or a derivative thereof; acetates to an ester of acetic acid where the substitution is by a radical; and olefins to a class of unsaturated aliphatic hydrocarbons having one or more double bonds. As noted, the resins in the resin dispersion typically include polymers of the foregoing compounds. Such resin dispersions, though having a low melting temperature, may be usable for low temperature molding techniques.
The fusion temperature of a resin dispersion is that temperature necessary to completely fuse the resin dispersion. This temperature is typically dictated by the resins and plasticizers in the formulation and is typically (320)(dwell or residence time)° F./160° C. Typically, the heating temperature is at least about 340° F. and more typically ranges from about 320° F. to about 370° F. The residence time is typically at least about 0.5 minute and more typically ranges from about 1 to about 3 minutes.
In yet another embodiment, any number of molding techniques are employed. As will be appreciated, “molding” normally refers to creating a plastic or rubber article in a desired shape by application of heat and/or pressure, either in a negative cavity or in contact with a contoured metal or phenolic surface. Exemplary molding techniques that can be used with the present invention include but are not limited to high pressure injection molding, gas-assisted injection molding, fusible core injection molding, low pressure injection molding (including laminate molding and liquid-gas assist molding), advanced blow molding, blow molding, compression molding, thermoplastic sheet composite processing, reactive liquid composite molding, microcellular plastics, lamellar injection molding, and multimaterial, multiprocess technology, rotational molding, co-injection, in-mold decoration, encapsulation, stack molding, micro-injection molding, fusible core, vibration-assisted, injection molding extrusion, surface replication, direct compounding, vacuum forming, transfer molding, or any combination thereof. The finished plastic part need not be a flat plane, but by virtue of the flexibility of the flock transfer may be rounded, or portions of the part may be raised.
In yet another alternative embodiment, the backing film may be omitted, such as from a transfer. In this embodiment, the transfer is positioned in the mold, and resin is introduced into the mold at a low pressure and/or flow rate to avoid damaging or dislodging the transfer. The flow rate is controlled by resisting resin flow into and through the mold using a compressible fluid such as a gas (a “gas assist” process). In other words, a compressible fluid is introduced into the mold prior to or during resin injection, and the pressure of the fluid adjusted dynamically to produce a desired rate of resin flow into and through the mold. Typically, the resistant pressure exerted by the compressible fluid on the resin is around 200 psi. This process can be implemented using technology known as the INTELLIMOLD™ process.
US10394357 2000-07-24 2003-03-21 Co-molded direct flock and flock transfer and methods of making same Active US7338697B2 (en)
US09629746 US6929771B1 (en) 2000-07-31 2000-07-31 Method of decorating a molded article
US36658002 true 2002-03-21 2002-03-21
JP2004562631A JP2005532202A (en) 2002-07-03 2003-07-03 Flocking products and manufacturing method thereof
EP20030763332 EP1539488A2 (en) 2002-07-03 2003-07-03 Flocked articles and methods of making same
PCT/US2003/021299 WO2004005600A3 (en) 2002-07-03 2003-07-03 Flocked articles and methods of making same
US10613982 US20040050482A1 (en) 2002-07-03 2003-07-03 Flocked articles and methods of making same
US09621830 Continuation-In-Part US7344769B1 (en) 2000-07-24 2000-07-24 Flocked transfer and article of manufacture including the flocked transfer
US09629746 Continuation-In-Part US6929771B1 (en) 2000-07-31 2000-07-31 Method of decorating a molded article
US20030207072A1 true US20030207072A1 (en) 2003-11-06
US7338697B2 true US7338697B2 (en) 2008-03-04
ID=29273966
US10394357 Active US7338697B2 (en) 2000-07-24 2003-03-21 Co-molded direct flock and flock transfer and methods of making same
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