Patent Description:
Traditionally, water or hydrographic transfers to non-planar or 3D surfaces have included a construction having a water-dissolvable carrier film on which conventional inks and coatings are printed. The carrier film may be a cast polyvinyl alcohol (PVA) of sufficient thickness to serve as a carrier in subsequent printing processes. The inks printed on the carrier may be solvent based and applied via printing methods such as gravure, but could also be printed using gravure, flexography, lithography, screen printing, thermal transfer printing, ink jet printing, or other short-run printing techniques.

The inks may be printed with a variety of patterns and may also decorate multiple objects at the same time in the water-transfer process downstream of printing the inks onto the carrier film. Many decorated items are post-finished, such as by over-coating the items with clear polymer coatings on top of the decorated surfaces of the items to protect the decorations. This subsequent process can be accomplished with a spray application of the clear coat (e.g., spray painting).

But, the final products formed using the aforementioned transfer processes often are interior applications, as the pigments in the inks and the coatings employed are not suitable for exterior or harsh service environments.

The present inventive subject matter will be better understood from reading the following description of non-limiting embodiments, with reference to the attached drawings (which are not necessarily drawn to scale), wherein below:.

The technical elements described herein relate to laminate assemblies (and methods for manufacturing the laminate assemblies) that can be used for decorating objects such as objects having 3D surfaces, such as via a liquid transfer process (e.g., water transfer). In contrast to other liquid transfer processes, the laminate assemblies described herein may include one or more effect layers to provide for holographic, diffraction, security, textured, or brushed metallic patterns on a 3D surface of an object. The effect layers may be generated by printing, embossing, vapor depositing, or the like, metallic materials and/or high refractive index (HRI) materials to create the decorative or security effects. The HRI materials may be materials having a refractive index of at least <NUM> in one embodiment.

<FIG> is a schematic diagram of a hydrographic transfer system <NUM> according to one embodiment. The system <NUM> includes a vat <NUM> that holds a fluid <NUM>, such as water. A laminate assembly <NUM> is floated on top of the surface of the fluid <NUM>. As described below, this laminate assembly <NUM> may have a carrier film with one or more decorative layers disposed thereon. These decorative layers may include optical layers and/or effect layers that provide one or more decorative, electronic, or security features, ink printed layers, or the like. The carrier film may dissolve in the fluid <NUM> such that the decorative layers remain floating on the surface of the fluid <NUM>. An object to be decorated or laminated upon is then dipped into the fluid <NUM>. The decorative layers attach to the 3D surface of the object to decorate one or more images of the decorative layers onto the 3D surface of the object.

<FIG> illustrate cross-sectional views of a laminate assembly <NUM> during manufacturing of the laminate assembly <NUM> according to one embodiment. The laminate assembly <NUM> may represent the laminate assembly <NUM> shown in <FIG>. The laminate assembly <NUM> includes a carrier film <NUM> that supports additional layers of the laminate assembly <NUM>. The carrier film <NUM> may be formed from a material that can support the additional layers of the laminate assembly <NUM> during manufacture of the laminate assembly <NUM>, which may include printing images on one or more layers, metallizing one or more layers, carrying the laminate assembly <NUM> to the vat <NUM> for hydrographic transfer, and the like. The carrier film <NUM> can be formed from a material that dissolves upon contact with the fluid <NUM> and/or another chemical agent, such as polyvinyl alcohol (PVA) or another material.

An ink layer <NUM> is disposed on the carrier film <NUM>. The ink layer <NUM> represents one or more layers of ink that generate a visual image, design, or the like, to be at least partially visible on the 3D surface of the object to be decorated. The ink layer <NUM> may be formed on the carrier film <NUM> using one or more printing processes, such as thermal transfer printing, digital ink jet printing, three dimensional printing, gravure printing, or the like. The one or more inks that form the ink layer <NUM> may be free-radicals, ultraviolet and electron beam (UV/EB) inks or another type of ink. These types of inks and printing processes can reduce or eliminate the amount of residual solvents in the laminate assembly <NUM>, which can assist in the deposition of an effect layer <NUM>, described below. In one aspect, the inks used to form the ink layer <NUM> can be cross-linked, such as by exposing the inks to thermal, UV light or EB radiation. Cross-linking the inks after transfer of the ink layer <NUM> can reduce the need for additional coatings to protect the ink layer <NUM>.

A flood coat layer <NUM> may be disposed on the ink layer <NUM> such that the ink layer <NUM> is between and/or in direct contact with the carrier film <NUM> and/or the flood coat layer <NUM>. The flood coat layer <NUM> optionally may be referred to as an embossing, an emboss coat layer, or the like. The flood coat layer <NUM> is formed from a soft and/or malleable material that can deform when pressure is applied to the coat layer <NUM>, such as a thermoplastic material. For example, the coat layer <NUM> may be formed from one or more polymer materials, such as polyester, poly(methyl methacrylate) (PMMA), or the like.

The effect layer <NUM> can be deposited onto the coat layer <NUM> such that the coat layer <NUM> is between and/or in direct contact with the coat layer <NUM> and/or the effect layer <NUM>. In one embodiment, the effect layer <NUM> is a metallized layer formed from one or more reflective materials, such as metals or metal alloys. The effect layer <NUM> can be a continuous conductive layer or can be formed from two or more separate conductive bodies (that are not conductively coupled). The effect layer <NUM> can be formed by evaporating, sputtering, printing, vapor depositing, or the like, one or more metals or metal alloys onto the coat layer <NUM>. Optionally, the effect layer <NUM> can be formed using nanoparticles of ink, vacuum metalized pigments (VMP), super argents, or the like. The metals or metal alloys used to form the effect layer <NUM> may include aluminum, silver, or the like. Optionally, the effect layer <NUM> may be a refractive layer or diffractive layers (e.g., which result or cause a color shift) formed from one or more refractive layers, such as a refractive layer formed from one or more HRI materials.

The thickness of the effect layer <NUM> can be controlled in order to adjust the optical density of the surface of the object on which the effect layer <NUM> is printed for various optical effects and/or to positively influence the ease of transferring the ink layer <NUM>, the coat layer <NUM>, and/or the effect layer <NUM> onto the object.

As shown in <FIG>, in one case, the effect layer <NUM> can be deposited onto the coat layer <NUM> as a continuous sheet. As shown in <FIG>, an embossing die <NUM> may be used to emboss a pattern of relief in the effect layer <NUM>. The die <NUM> can be pressed down onto the effect layer <NUM> (and/or the laminate assembly <NUM> is pressed into the die <NUM>). The pressure exerted on the laminate assembly <NUM> by the die <NUM> can emboss relief patterns in the effect layer <NUM>. For example, the die <NUM> may include a body <NUM> that is cylindrical or flat, and that has one or more protrusions <NUM> extending therefrom. The die <NUM> can force the effect layer <NUM> onto the coat layer <NUM>. The coat layer <NUM> may be more flexible and/or malleable than the effect layer <NUM> and, as a result, the pressure exerted by the die <NUM> can separate the effect layer <NUM> into separate, spaced apart bodies <NUM>, as shown in <FIG>. For example, the die <NUM> can stress and tear apart the effect layer <NUM> such that the bodies <NUM> are formed, with the bodies <NUM> being separated from each other by gaps <NUM> (shown in <FIG>). The gaps <NUM> represent cracks, such as micro-cracks through all of the thickness of the effect layer <NUM>.

The embossing die <NUM> may be sufficiently large such that no seams between patterns formed by the die <NUM> are formed in the effect layer <NUM>. For example, a cylindrical die <NUM> may be sufficiently wide as to extend over all or substantially all (e.g., at least <NUM>% or another amount) of the width of the effect layer <NUM>, as shown in <FIG>. The die <NUM> may then be rolled over the effect layer <NUM> to emboss the relief pattern into the effect layer <NUM> across all or substantially all (e.g., at least <NUM>% or another amount) of the length of the effect layer <NUM>. As a result, the relief pattern is embossed on all or substantially all of the effect layer <NUM>, without having to lift the die <NUM> and place the die <NUM> on another portion of the effect layer <NUM> to separately emboss another portion of the effect layer <NUM>.

The relief pattern formed in the effect layer <NUM> by the bodies <NUM> and/or the gaps <NUM> can be combined with printed patterns formed by the printing of the ink layer <NUM>. After applying the ink layer <NUM>, coat layer <NUM>, and effect layer <NUM> on a surface of an object, the effect layer <NUM> and/or ink layer <NUM> can provide dramatic and optically variable (or kinetic) decorations that appear to move, shimmer, change color, etc., as the viewing angle of the object is altered. The effect layer <NUM> (and/or the ink layer <NUM>) can provide holographic, diffraction, textured, security or brushed patterns/designs/structures to be made and transferred to 3D surfaces. Alternatively, the relief pattern formed by the effect layer <NUM> can provide for relatively small security features, such as by forming microscopic text phrases, numbers, or the like.

Optionally, a black pigment and/or dye (or another color) could be printed directly behind (e.g., on top of) the embossing of the effect layer <NUM> to create the visual effect. The effect layer <NUM> can be reflective to provide a security feature, a functional feature, a decorative feature, and/or another feature for the object being decorated. For example, the effect layer <NUM> can provide a reflective layer used in a mirror or holographic layer on the surface of the object that assists in decorating the object, verifying authenticity of the object, or the like. Optionally, the ink layer <NUM> and/or effect layer <NUM> can be patterned to provide a variety of printed patterns of wood grains, marble, stone, metal finishes, textiles, geometric designs, carbon fiber, and so on, to achieve enhanced visual effects, security features, and ease of decoration of a 3D object.

The relief pattern in the effect layer <NUM> and/or the ink layer <NUM> can be patterned and registered with each other to provide registered, secure and unique effects to the surfaces of objects being decorated. Additionally, the effect layer <NUM> can provide for at least some scratch or mar resistance, chemical resistance, resistance to wear and tear due to weather, or the like, to the object being decorated. In one embodiment, the object on which the laminate assembly is transferred does not need a post-finishing operation, such as over-coating the object with a clear polymer coating, to protect the decorations formed by the laminate assembly.

<FIG> illustrate cross-sectional views of a laminate assembly <NUM> during manufacturing of the laminate assembly <NUM> according to another embodiment. The laminate assembly <NUM> may represent the laminate assembly <NUM> shown in <FIG>. The laminate assembly <NUM> includes the carrier film <NUM> and the coat layer <NUM> ("Emboss coat layer" in <FIG>) described above. One difference between the laminate assembly <NUM> and the laminate assembly <NUM> shown in <FIG> is the absence of the ink layer <NUM> (shown in <FIG>) in the laminate assembly <NUM>. For example, the coat layer <NUM> can be deposited directly onto the carrier film <NUM>.

Another difference between the laminate assemblies <NUM>, <NUM> is that the relief pattern formed by the die <NUM> can be formed in the coat layer <NUM> in the laminate assembly <NUM> shown in <FIG> instead of in the effect layer <NUM> (shown in <FIG>) of the laminate assembly <NUM> shown in <FIG>. As shown in <FIG> and <FIG>, the die <NUM> can directly engage the coat layer <NUM> and emboss the coat layer <NUM> to form embossed patterns <NUM>, or recesses, in the coat layer <NUM>. In the illustrated example, the patterns <NUM> extend into the coat layer <NUM> to form an undulating or otherwise uneven surface of the coat layer <NUM>.

As shown in <FIG>, an effect layer <NUM> can be formed on the embossed coat layer <NUM>. The effect layer <NUM> can be deposited onto the coat layer <NUM> such that the coat layer <NUM> is between and/or in direct contact with the coat layer <NUM> and/or the effect layer <NUM>. In one embodiment, the effect layer <NUM> is a metallized layer formed from one or more reflective materials, such as metals or metal alloys.

The effect layer <NUM> can be formed from one or more of the materials used to form the effect layer <NUM>. In the illustrated embodiment, the effect layer <NUM> includes discrete bodies <NUM> that are spaced apart from each other. For example, the bodies <NUM> may be separate from each other by gaps <NUM> such that the bodies <NUM> do not engage each other. The bodies <NUM> can be formed by selective deposition of metallic materials (e.g., "DEMET"), such as selective additive metallization or selective subtractive metallization. In selective additive metallization, an evaporative material, such as an oil, can be deposited onto the coat layer <NUM> in locations where the bodies <NUM> are not to be located (e.g., in the gaps <NUM>). The material used to form the bodies <NUM> (e.g., metals or metal alloys) are heated in a vacuum chamber to cause the material to evaporate from a source of the material and then condense on the coat layer <NUM> in the locations where the evaporative material is not located (e.g., in the gaps <NUM>) to form the bodies <NUM>. During deposition of the bodies <NUM>, the evaporative material can prevent deposition of the bodies <NUM> in the locations where the oil is present (e.g., in the gaps <NUM>). The evaporative material may evaporate from the coat layer <NUM> during deposition of the bodies <NUM>.

In selective subtractive metallization, a continuous layer of the materials used to form the bodies <NUM> of the effect layer <NUM> may be deposited onto the coat layer <NUM>. For example, a layer similar to the effect layer <NUM> shown in <FIG> may be deposited on the coat layer <NUM> in both the gaps <NUM> and the areas between the gaps <NUM>. A mask may be printed or placed onto the layer that has been deposited on the coat layer <NUM>. This mask may cover and protect some portions of the deposited layer from removal (e.g., the portions between the gaps <NUM>) during a subsequent etching operation that removes the other portions of the deposited layer. The mask may then be removed from the deposited layer. Due to the mask protecting the portions of the deposited layer between the gaps <NUM>, the bodies <NUM> may be left after removal of the mask.

In another example, the effect layer <NUM> may be formed by printing the layer <NUM> using reflective pigments or inks, diffractive pigments or inks (e.g., that change the wavelengths of light reflected off of the layer <NUM>), or the like. Optionally, the bodies <NUM> of the effect layer <NUM> may be formed using three dimensional printing.

The bodies <NUM> of the effect layer <NUM> form a relief pattern that can provide dramatic and optically variable (or kinetic) decorations that appear to "move" or "shimmer" as the viewing angle of the object are altered. Optionally, a black pigment and/or dye (or another color) could be printed on top of and/or below the effect layer <NUM> to create the visual effect. The effect layer <NUM> can be reflective to provide a security feature, a functional feature, a decorative feature, and/or another feature for the object being decorated. For example, the effect layer <NUM> can provide a reflective layer used in a mirror or holographic layer on the surface of the object that assists in decorating the object, verifying authenticity of the object, or the like. In one embodiment, the object on which the laminate assembly is transferred does not need a post-finishing operation, such as over-coating the object with a clear polymer coating, to protect the decorations formed by the laminate assembly.

<FIG> illustrate cross-sectional views of a laminate assembly <NUM> during manufacturing of the laminate assembly <NUM> according to another embodiment. The laminate assembly <NUM> may represent the laminate assembly <NUM> shown in <FIG>. The laminate assembly <NUM> includes the carrier film <NUM>, the coat layer <NUM> ("Emboss coat layer" in <FIG>), and the effect layer <NUM> described above. One difference between the laminate assembly <NUM> and the laminate assembly <NUM> shown in <FIG> is the absence of the ink layer <NUM> (shown in <FIG>) in the laminate assembly <NUM>. For example, the coat layer <NUM> can be deposited directly onto the carrier film <NUM>.

As shown in <FIG> and <FIG>, the effect layer <NUM> can be deposited onto the coat layer <NUM> as a continuous sheet. The embossing die <NUM> may be used to emboss a pattern of relief in the effect layer <NUM>. The relief pattern formed in the effect layer <NUM> can include the bodies <NUM> and/or the gaps <NUM> described above in connection with <FIG>. After applying the ink layer <NUM>, coat layer <NUM>, and effect layer <NUM> on a surface of an object being decorated, the effect layer <NUM> and/or ink layer <NUM> can provide dramatic and optically variable (or kinetic) decorations that appear to "move" or "shimmer" as the viewing angle of the object are altered. Optionally, a black pigment and/or dye (or another color) could be printed directly behind (e.g., on top of) the embossing of the effect layer <NUM> to create the visual effect. The effect layer <NUM> can be reflective to provide a security feature, a functional feature, a decorative feature, and/or another feature for the object being decorated. For example, the effect layer <NUM> can provide a reflective layer used in a mirror or holographic layer on the surface of the object that assists in decorating the object, verifying authenticity of the object, or the like.

The order in which two or more layers of the laminate assemblies shown in <FIG> are deposited can impact the transfer of the layers from the liquid <NUM> in the vat <NUM> to the object being decorated using the hydrographic transfer system <NUM> shown in <FIG>. For example, depositing the effect layer <NUM> prior to embossing the effect layer <NUM> (e.g., as described above in connection with the laminate assemblies <NUM>, <NUM>) can form the gaps <NUM> in the effect layer <NUM>. These gaps <NUM> can break up the effect layer <NUM> into smaller portions, which can ease the application of the laminate assemblies <NUM>, <NUM> onto the object in the transfer system <NUM> relative to the laminate assembly <NUM>.

While embossing is used to form the relief patterns in the effect layers <NUM> described herein, optionally, another technique may be used to form the relief patterns. For example, the materials forming the effect layers <NUM> can be selectively deposited or printed (e.g., using VMP inks, color-shift inks, or the like) in certain areas and not deposited or printed in other areas, deposited or printed in different thicknesses in different areas, or the like, to form a relief pattern. In one case, the object on which the laminate assembly is transferred does not need a post-finishing operation, such as over-coating the object with a clear polymer coating, to protect the decorations formed by the laminate assembly.

<FIG> illustrates a flowchart of a method <NUM> for manufacturing a laminate assembly for use in a hydrographic transfer system according to one embodiment. The method <NUM> may be used to manufacture the laminate assembly <NUM> shown in <FIG>. At <NUM>, one or more ink layers <NUM> are deposited onto or above the carrier film <NUM>. At <NUM>, the emboss or flood coat layer <NUM> is deposited onto or above the ink layer <NUM>. At <NUM>, the effect layer <NUM> is deposited onto or above the coat layer <NUM>. At <NUM>, a relief pattern is formed in the effect layer <NUM>, such as by embossing.

<FIG> illustrates a flowchart of a method <NUM> for manufacturing a laminate assembly for use in a hydrographic transfer system. The method <NUM> may be used to manufacture the laminate assembly <NUM> shown in <FIG>. At <NUM>, the emboss or flood coat layer <NUM> is deposited onto or above the carrier film <NUM>. At <NUM>, a relief pattern is formed in the effect layer <NUM>, such as by embossing. At <NUM>, the effect layer is deposited on or above the coat layer <NUM>, such as by using selective metal deposition or another technique.

<FIG> illustrates a flowchart of a method <NUM> for manufacturing a laminate assembly for use in a hydrographic transfer system. The method <NUM> may be used to manufacture the laminate assembly <NUM> shown in <FIG>. At <NUM>, the emboss or flood coat layer <NUM> is deposited onto or above the carrier film <NUM>. At <NUM>, the effect layer <NUM> is deposited onto or above the coat layer <NUM>. At <NUM>, a relief pattern is formed in the effect layer <NUM>, such as by embossing.

Occasionally, a laminate assembly for decorating an object in a hydrographic transfer system is provided. The laminate assembly includes a carrier film configured to be soluble when placed into the hydrographic transfer system, an optical effect layer configured to provide one or more of an optical effect or a security feature to the object, one or more ink layers disposed between the carrier film and the effect layer, and a coat layer disposed between the one or more ink layers and the optical effect layer. The effect layer includes a relief pattern configured to provide the one or more of the optical effect or the security feature to the object.

In one aspect, the effect layer is formed from one or more of a metal, a metal alloy, or a high refractive index material.

In one aspect, the optical effect provided by the effect layer includes one or more of a holographic design or a design that changes color based on a viewing angle.

In one aspect, the effect layer includes a relief pattern that provides the one or more of the optical effect or the security feature.

In one aspect, the relief pattern is defined by separate bodies of the effect layer separated by gaps.

In one aspect, the relief pattern is defined by separate bodies of the effect layer separated by microcracks.

In one aspect, the relief pattern is an embossed pattern in the effect layer.

Elsewhere, a laminate assembly for transferring decoration onto an object in a hydrographic transfer system is provided. The laminate assembly includes a carrier film configured to be soluble when placed into the hydrographic transfer system, an optical effect layer configured to provide one or more of an optical effect or a security feature to the object, and a coat layer disposed between the carrier layer and the optical effect layer. The effect layer includes a relief pattern configured to provide the one or more of the optical effect or the security feature to the object.

In one aspect, the effect layer is formed from one or more of a metal, a metal alloy, and/or a high refractive index material.

In one aspect, the optical effect provided by the effect layer includes one or more of a holographic design and/or a design that changes color based on a viewing angle.

In one aspect, the effect layer includes a relief pattern that provides the one or more of the optical effect and/or the security feature.

Claim 1:
A laminate assembly (<NUM>) for decorating an object in a hydrographic transfer system (<NUM>), the laminate assembly comprising:
a carrier film (<NUM>) configured to be soluble when placed into the hydrographic transfer system;
an optical effect layer (<NUM>) configured to provide one or more of an optical effect or a security feature to the object; the effect layer including a relief pattern formed by cracks extending through an entire thickness of the effect layer;
one or more ink layers (<NUM>) disposed between the carrier film and the effect layer;
and a coat layer (<NUM>) disposed between the one or more ink layers and the optical effect layer, wherein the relief pattern is configured to provide the one or more of the optical effect or the security feature to the object.