CN101380864A - 植绒的转移层及其制造方法、和包括该转移层的制品 - Google Patents

植绒的转移层及其制造方法、和包括该转移层的制品 Download PDF

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CN101380864A
CN101380864A CN200810092832.5A CN200810092832A CN101380864A CN 101380864 A CN101380864 A CN 101380864A CN 200810092832 A CN200810092832 A CN 200810092832A CN 101380864 A CN101380864 A CN 101380864A
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路易斯·B·艾布拉姆斯
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Abstract

本发明公开了一种植绒的转移层、具有该转移层的制品以及该转移层的制造方法。通过将剥离剂(5)涂敷在剥离片(3)上，然后将植绒短绒加在该剥离剂(5)上，可以制造植绒的转移层(1)。与传统方法不同，在植绒短绒的背面不加粘合剂和热熔性薄膜。通过将热固化的热熔性薄膜片材放置在衬底上；将转移层放在热熔性薄膜上，使植绒短绒与热熔性薄膜接触；并加热量和压力，可以将转移层(1)(基本上为植绒的剥离片)加在衬底上，即，布、橡胶垫等。热量使热固化的热熔性薄膜熔化，将植绒短绒粘合在衬底上，并将植绒短绒粘接在一起。该方法降低了制造植绒制品的成本。

Description

植绒的转移层及其制造方法、和包括该转移层的制品
本申请是申请号为01814634.1、申请日为2001年7月23日、申请人为高压制图公司、发明名称为“植绒的转移层和包括该植绒的转移层的制品”的发明专利申请的分案申请。
技术领域
本发明涉及植绒的转移层(flocked transfers)，更具体地说，涉及一种可以大大降低生产转移层的成本和所需时间的制造植绒的转移层的改进的方法。
背景技术
以前，一般是将剥离剂(release agent)涂在剥离片(release sheet)上来制造植绒的转移层的。在剥离片上加上所希望图案的植绒短绒。将粘合剂和永久性的热熔性粘接剂涂在植绒短绒的背面，再将转移层进行干燥。粘合剂用于保持所希望图案的植绒短绒。作为粉末涂在转移层上的热熔性粘接剂用于将转移层粘接在一个衬底(例如布、氯丁橡胶垫等)上。将该转移层放置在衬底上，使干燥的热熔性粘接剂与衬底接触，可以将转移层加在衬底上。然后，将热(例如，熨斗产生的热)加在剥离片上。热量使热熔性粘接剂熔化，使热熔性粘接剂流动，与衬底紧密接触，与衬底形成机械和分子粘合。剥离剂可使剥离片从转移层除去，留下植绒短绒暴露在衬底上。
图1表示现有技术的植绒的转移层101。如图所示，这种转移层包括一个尺寸稳定的剥离片103，在该片上涂敷传统的植绒的转移层用的剥离粘接剂105，该粘接剂涂敷的图案与要植绒的总图案相适应。植绒短绒107利用静电方法涂敷在剥离粘接剂105上。粘合剂粘接剂109涂在植绒短绒的露出的末端上，将植绒短绒粘合在一起成为一个部件。最后，涂敷热熔性粘接剂111。然后，使转移层干燥。通过将转移层放置在衬底(例如衬衣或其他衣服)上，使热熔性粘接剂与衬底接触，并将热量加在转移层上，即可将转移层加在衬底上。热量激活热熔性粘接剂，使转移层与衬底粘接起来。这种方法在本人先前的专利-美国专利4810549号，以及2000年4月13日提出的，序列号为09/548839的本人正在审查中的申请中作了说明。这里引入该两个专利供参考。
这种传统的方法多年来一直使用得较好。然而，通过降低制造转移层的成本以及包含该转移层的物品的成本，可以改进该方法。
发明内容
一般来说，根据本发明，本发明的植绒的转移层是通过将剥离剂涂敷在剥离片上，然后将植绒短绒加在剥离剂上制成的。与传统方法不同，在植绒短绒的末端不加粘合剂和粘接剂。
为了制造带有植绒的转移层的制品，将热固化的热熔性薄膜(片材形式或切成规定形状)放置在要加转移层的衬底上。该热固化的热熔性薄膜最好为聚酯或聚氨酯薄膜，但可以为任何热固化薄膜。将带有剥离粘接剂和剥离片(即转移层)的植绒短绒放置在热熔性薄膜片上，使剥离片在上面，这样，植绒短绒可与热固化的热熔性薄膜接触。再将热量加在转移层上。热量使热固化的热熔性薄膜熔化，并使植绒短绒与衬底固定。
附图说明
图1为现有技术的植绒的转移层的横截面图；
图2为本发明的植绒的转移层的横截面图；
图3为用于制造一个制品的转移层、热熔片和衬底的分解图；
图4为使用本发明的转移层的一个制品的横截面图，它表示加在衬底的一部分上的转移层的一部分和与衬底隔开一定距离的一部分转移层和热熔性薄膜；
图5为用于连续地生产制品(例如，鼠标垫、杯垫等)的过程的示意图。
在附图中，采用相应的附图标记表示相同的部件。
具体实施方式
以下的详细说明只是说明本发明的一个例子，而不是对本发明的限制。以下对本发明的优选实施方式的说明可使本领域技术熟练的人制造和使用本发明。
本发明的植绒的转移层1表示在图2中。本发明的转移层1包括一个剥离片3，在该剥离片上涂敷传统的剥离剂5(例如蜡)。剥离剂涂在剥离片上的形状为植绒的图案。将植绒短绒7加在剥离剂上，因而也是加在剥离片上以形成转移层。植绒短绒7可按本人先前的专利-美国专利4810549号所述的方法加上去。这里引入该专利供参考。与现有技术的方法不同，制造转移层1时不使用粘合剂粘接剂或热熔性粘接剂。如下面所述，使用一个热固化薄膜将该转移层粘接在衬底上。
例如，加上转移层1的布、鼠标垫或其他具有植绒表面的物品一类的制品，很容易使用转移层1来制造。将热固化的热熔性片材13放在衬底15和植绒的剥离片之间来制造制品11。该热固化的热熔性片材，例如为Bostik公司销售的热固化聚酯片。热固化的热熔性片材也可以由热固化聚氨酯制成。任何其他热固化薄膜也可以使用。衬底可以为布、橡胶垫(用于制造鼠标垫或杯垫)等。热固化的热熔性片材可以预先切成与转移层1的形状相适应。再将转移层1放置在热固化的热熔性片材上，使植绒短绒5与热固化的热熔性片材13相对。将热量通过剥离片加在转移层上，以激活热固化的热熔性片材。热固化的热熔性片材将植绒短绒5粘合在一起，并将植绒短绒5与衬底15粘接起来。最好，在组装制品时，将植绒的剥离片、热固化的热熔性薄膜和衬底放在一起，并通过一台热层压压力机，在该压力机中，上述三个部分在大约300℉(大约150℃)的温度和大约__磅/英寸2的压力下，层压大约30秒。压力和热量使热固化的热熔性薄膜粘接到植绒短绒和衬底上。另外，热固化的热熔性薄膜会交联或硬化，使植绒短绒牢固地固定在衬底上。
如图5所示，诸如制品的整个顶面都被植绒短绒覆盖的鼠标垫或杯垫一类的制品可以连续地制造。设置了植绒的剥离片1，热固化的热熔性薄膜13和衬底15的辊子21、23和25。这三种材料在层压工位33上被放置在一起。在工位33的前面可以设有辊子，使三种材料在进入层压工位时，互相靠近。在层压工位上，将热量和压力加在三种片材上(植绒的剥离片、热固化的热熔性薄膜和衬底)，使热固化的热熔性薄膜熔化。如上所述，熔化的热固化热熔性薄膜将会硬化或交联，将植绒短绒粘接在衬底上。织物35从层压工位输出。再将织物35冷却。最后，将织物35送至切割工位，在此将它切成单件制品。一旦织物35冷却，可以立即送至切割工位(在织物35冷却后)；或者，如果织物卷绕在一个卷入辊子上，则可在以后或在不同的位置切割成单个的制品。在切割工位，将剥离片从植绒短绒上取下，并收集在一个卷入辊子上或清除掉。在从植绒短绒上取下剥离片以后，将粘接着植绒短绒的衬底切断，形成制品11。
最好，如图5所示，剥离片以一卷的形式进行植绒和供应。然而，剥离片的植绒可以是该方法的一部分。
为了生产诸如衬衣、夹克等一类不容易连续地进行植绒的植绒制品，可以在将转移层加在衬底上以前，将热固化的热熔性片材加在转移层1上。为了做到这点，可使热固化的热熔性薄膜与转移层的植绒短绒接触，并且将转移层和剥离片加热至热固化的热熔性薄膜变粘但低于热固化的热熔性薄膜开始硬化和交联的温度。通过放置转移层，使热固化的热熔性薄膜在制品(即，一块布)的某个位置上，并用例如熨斗在转移层上加上足以熔化该热固化的热熔性薄膜的热量和压力，使热固化的热熔性薄膜硬化和交联，可以将热固化的热熔性薄膜与转移层1粘接在一起，形成以后可以加在制品上的转移层。
该方法去除了现有技术的方法的两个步骤:(1)涂敷粘合剂粘接剂；和(2)涂敷、清洁、烧结和干燥热熔性粘接剂。而且在连续的过程中，本方法不需要涂敷粘合剂和热熔性粘接剂的工位，以及干燥完工的转移层的工位。因为不需要将粘合剂和热熔性粘接剂涂敷(即，印制)在作为转移层的一部分的植绒短绒上的工位，因此，生产制品11所需的机械价格很低廉(实际成本和维修成本)。另外，因为不使用粘合剂粘接剂和热熔性粘接剂，因此，制品的成本也大大降低。
在不偏离本发明的范围的条件下，可对上述结构作各种改变，因此，上述说明和附图中所包含的一切均是示例性的，而不是限制性的。

Claims (18)

1.一种植绒的转移层，包括:
剥离片；
位于剥离片上的剥离剂；
位于剥离剂上的植绒短绒，植绒短绒作成所希望的图案，剥离剂将植绒短绒的第一端固定在剥离片上；和
接合所述植绒短绒的热固化的热熔性薄膜，
其中，植绒短绒的第二端没有被施加粘合剂粘接剂而直接接触该热固化的热熔性薄膜。
2.如权利要求1所述的转移层，其中，该热固化的热熔性薄膜为聚氨酯薄膜或聚酯薄膜。
3.一种包括如权利要求1所述的转移层的制品，其中，该转移层粘接在衬底上，并且该热固化的热熔性薄膜位于衬底和植绒短绒之间。
4.如权利要求3所述的制品，其中，该热固化的热熔性薄膜为聚氨酯薄膜或聚酯薄膜。
5.如权利要求3所述的制品，其中，该热固化的热熔性薄膜硬化并交联。
6.一种制造具有植绒表面的制品的方法，该方法包括:
提供植绒的剥离片，该剥离片与植绒短绒的第一端粘接；
提供热固化的热熔性薄膜；
将该热固化的热熔性薄膜粘接在植绒的剥离片上，其中该植绒的剥离片上的植绒短绒的第二端直接接触该热固化的热熔性薄膜；和
将热固化的热熔性薄膜与一衬底粘接。
7.如权利要求6所述的方法，其中，将热固化的热熔性薄膜粘接在植绒的剥离片上的步骤包括:
在热固化的热熔性薄膜与植绒短绒接触的情况下，将热固化的热熔性薄膜加热至热固化的热熔性薄膜变粘的温度，但低于该热固化的热熔性薄膜开始硬化和交联的温度；以及
向被加热的该热固化的热熔性薄膜施加压力，以将植绒短绒的第二端嵌入在该热固化的热熔性薄膜中。
8.如权利要求6所述的方法，其中，
将热固化的热熔性薄膜粘接在衬底上的步骤包括:将热固化的热熔性薄膜加热至该热固化的热熔性薄膜硬化和交联的温度，并且
所述方法不包括施加粘合剂粘接剂和干燥热固化的热熔性薄膜的步骤。
9.如权利要求8所述的方法，其中，将该热固化的热熔性薄膜加热至大约300℉，其中不需要用于在植绒短绒上施加粘合剂和热熔性粘接剂的工位。
10.如权利要求8所述的方法，其中，将热固化的热熔性薄膜粘接在植绒的剥离片上的步骤和将热固化的热熔性薄膜粘接在衬底上的步骤同时在一道工序中进行，并且其中没有使用粘合剂粘接剂。
11.如权利要求6所述的方法，其中，该方法是连续的。
12.如权利要求6所述的方法，其中，该热固化的热熔性薄膜为聚氨酯薄膜或聚酯薄膜，并且该热固化的热熔性薄膜作为固体薄膜施加在植绒短绒的第二端上。
13.如权利要求7所述的方法，其中，通过剥离片将热量施加在热固化的热熔性薄膜上，以激活该热固化的热熔性薄膜。
14.如权利要求6所述的方法，其中，在粘接步骤之前，将热固化的热熔性薄膜预先切成对应于将由所述植绒的剥离片形成的转移层的形状。
15.如权利要求6所述的方法，其中，在植绒短绒粘接到热固化的热熔性薄膜上之后，热固化的热熔性薄膜具有平坦的上表面和下表面以及均匀的厚度。
16.如权利要求6所述的方法，其中，植绒短绒和热固化的热熔性薄膜之间的界面上没有粘合剂粘接剂。
17.如权利要求6所述的方法，其中，所述热固化的热熔性薄膜被加热之该薄膜的熔点以上的温度。
18.一种通过权利要求6所述的方法制造的制品。
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US20030186019A1 (en) 2003-10-02
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US7344769B1 (en) 2008-03-18
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CN101380864B (zh) 2013-03-13
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US20030211279A1 (en) 2003-11-13
US7390552B2 (en) 2008-06-24
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CA2415680A1 (en) 2002-01-31
US7402222B2 (en) 2008-07-22
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US7381284B2 (en) 2008-06-03

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