CA2103373A1

CA2103373A1 - Process for production of flexible laminate

Info

Publication number: CA2103373A1
Application number: CA002103373A
Authority: CA
Inventors: Richard Allan Sharpe; Mia Josephine Manners
Original assignee: Individual
Current assignee: Holotex Ltd
Priority date: 1991-05-17
Filing date: 1992-05-18
Publication date: 1992-11-18
Also published as: EP0585288A1; WO1992020533A3; HK57396A; GB9210401D0; WO1992020533A2; GB2255746A; GB2255746B; GB9110765D0

Abstract

2103373 9220533 PCTABS00017 The invention relates to a process for the production of a flexible laminate. The process comprises applying to a surface of a flexible substrate a curable composition in fluid form and comprising a plastics material as a pattern which can provide a desired image or imaging effect. Then, a metal foil bearing a holographic image and having a layer of plastics size is positioned with the size layer overlying the pattern while the composition remains fluid. Next there is applied to the combination sufficient heat and pressure at a level and for a time to adhere the foil to the substrate via the plastics material but insufficient to destroy the holographic effect. Thereafter excess foil not adhered to the substrate is removed to expose the desired image or imaging effect.
The result is a flexible laminate having a flexible holographic image which can be machine washable.

Description

1 21~373 PRQCESSFORPRODUCTlO~ O~F~E,YI~LELA~ AT~

The present in~ention relates to the production of ~
la~in~e, in pa~ticular ~o ~ process for ~ne production of a laminate in the lorm of a holo~raphic image, typically displayed on an ar~icle o~ clo~hin~.
- ~n our co-pending Application No gl ~2225. 8 ~her~ i~
described a~d clai~ed a pro~ess fo. t~e produc~ion of a ~lexible lamin~t0 in which an outer and visible layer provid~s a ho} ographic effe~, ~hiGh proGess compris~i b~inging togethex a metal foil bea~in~ ~ hoiographic image, and ~aving a layer or plastics ~ize, and a fl~xible substrate in ~hich ~t least an outer l~yer compris~s a pl~stic:s material -~hi~h is cc:mpatible with said si2e sufficient to enable the plastics material and 1~ size to adhere together under ~onditions of temperature and pressure which do not destroy th~ hol~graphic effect, the substra~e and foil being brought to~ether with t~eir plastics layers adjacent each other, ~nd applying to the combinatlon heat and p~essure at a level an~ for a time suf~icient to adh~re th~ foil to the subst~ate blt insuf~i~ient to destroy the holographic effect.

~he present invention relates ~o an improvement ~n ar.d/or modification of the earlier proçess in which the outer ~5 layer of pl~stics material comp~tible with sai~ si~e is

2~ plastics material which has been pro~ided e.g. by printin~, as a pat~ern which give~ a desired irnaq~ on a surface o a flexible substrate, typically 2 textile mat~ri al, and Jnore typically one already made up in~o an ~0 ~rticle of clothing.
-Ac~o~dingly, the present invention pro~.ides a p~ocess fo~the production of a flexi~le laminate, which process ~)Jg~t)~ 1 H ~ T~ 6!Z~ !T ~ T

~ 21~3373 comp~ises applying to a ~urface of a fleYible sukstrate a curahl~ oompositicn in fluid rorm ~nd eomprisin~ a plastics ~material as â pattern whic~ ean provide ~esired i~age or imaging ef~ect, positionin~ a ~eta~ roil S be~ri~ a ho~ograp~ic i~ag~ and having a 'aye~ of pl~ios size, with the si~e l~yer overlying the pa~'cern while ~he oomposition remains fluid, applying to the - com~ination heat an~ pressure at a level and ~or a tlme su~ficient to adhere the foil ~o the subst~ate via the plas~ics m~terial bUt insufficient to des~roy the hologr~phic: e~fect, and thereafter removin~ exc:ess foil n~t adher2d to the subctrate to expose the desi~ed image ox in ag ir~g e f f eot .

Ir~ c:arryir~g out the process of the invention the co~position comprising a plastics material m~y be applied a5 a pa~tern by any suitable means. Preferably, however, the composition is applie~ by silk screen printing and the screen mesh is ~hosen to match the fineness of the 2 O im~ e requ i red .

The process of the in~ention uses 2 comp~sition in fluid form comprising a plastics materia!. Such compositi~ns are );nown and generally are~-' Sc~reen print~bleOf sufficient ~riscosity ~o hold an ima~e ~hilst wet Flexible when cured, and Compatible with siz~d foil.

3~
Préferably, the process o~ the inven~ion uses a composition which comprises a plas~ics material suspended in a~.plas~ici~;er. Mo~e p~er'erably, in such oompositions the plaS~ics mat~rial is PVC and the pla~ticiser is a plasti~ol inlc. One such known conlposi~i~n ba~ed on PVC

~Z()~r)r)~ P~tl~ ~!ZrJ~ )rJ~ . TT~I
. .
,, " , ., 2ia3373 ~ 3 and a plastisol is ~h~t so~d as ~ta.ran.

In ~he pro~ess of th~ invention, th~ meta~ ~oil bearing a holographic image may be any rlexiblP metal oil, but pre~erably is ar, aluminium foil. - Su~h roils ar~
com~erci~lly a~ila~la ~s hot stampin~ foils be~ring a holo~raphic pattern which are produced ~o provide a f~il - to be applied to ~ ri~id substrate, typicall~ a rigid pla~tios mate~ial. The ~i~id subslrate provi~s a ~upport for the foil so t~at the holographic eff~t ma~
be st~bilize~. Typically, the s~ze o~ a com~rciai foi is a PVC [polyvinyl chloride), ~hich i~ preferre~ for the foil s used in the invention. bu~ other plastics size layers may be ~mployed in the present inv~ntion p~ovi~ed lS ~hey &~n be adhe~ed to a compa~ible pl~stios material i~
a c~mpo~ition as described a~ove.

Also, the foil used in the proces~ of ~he inven~ion preferably includ~s a release layer o~ ~hat surfa~e of ~he metal foil which does ~o~ ca~ry the iayer of plastics size. ~ha~ release layer ~an se-ve to provid~ a~ditional protect~on ~o~ the hologr~phic pattern and is ~emov~d after ~reatment in the process o~ the in~enLi~n and be~ore ~he hol~graphic eff~c~ is req~ire~. A typical release layer ~ay comprise a polymeric ~aterial, ror examplP ~ a p41~fester .

In ~he process of the invention ~ha flexible sub~trate may be any such substrate provided only that it is ~lexible. Pre~rably, however, the su~strate is a ~oven or non-woven web, typically a fabric, and more p~eferably on~ ~hich is both f~exible and st~etchable. Most prefe~ably, ho~ev r, the ~abric is ~ natural f~b~ic.

~ypically, the fabxic ~y be a silk, cotton, fBZ(J~L(J~)ffl ~ ~ q 1 7~ BITl- ~!Zfl~t !f~ fB, Tl~

210~373 ,, co~on~sy~hetic mi~:, L~ic~a, ~cetat~, ~a~in, or~a~a, ch~ffon, linen, ~'crofib~-e, ~is~ose or a ~ lated s~ede or any ~ther simila, fabric.

Pre-fer~bly, the flexib~e substrate is one which ha~
. ~lready been made up into 2 garment of clothing. Thus, typically the substr~te i5 ~ ra~ric fo~ming part of a finished yar~ent.

In c~rying out the p~ces~ o~ the inven~ion, the foil and subst~ate a~e fed to a laminating s~ation at w~i~h heat an~ pressu~e can b~ brou~ht to bear on their combination. ~he ~eeding to ~he laminating stati~n may be on â continuous or batch basi~ depending on the require~ents of the p~ocess ~eing e~fscted. ~hus, typically the foil or su~s~rate may be supplied continuously or int~r~ittently fro~ rollers on which they ~nay be stored.

The laminating station may comp~ise an~ form Qf appa~atus or devi~e'which can supply heat and precsure unde~ the general requirements stated~herein. Furt~r~ore, th~
- ~onst~u~tion an~ arrangement of the sta~io~ may ~e va~ied to suit ~ontinuous or batch operation. Thus, in one preferred aspect of t~e inven~ion the lamina~ing station may comprise at least two ~o~lers bet~een which the foil and substrate may be fed ~o be pressed togethe~ and h~ated. Alternatively, in another prefe~red ~spect ~he ~oil ~nd s~bs~rate may be b~ought together in a hea~ed press which typica~ly may ~ompris~ upper and lower heated pl~tes whi~h can be brought togethe~ under pr~ssure.

Gene~ally, the process of the invention is e~f~cte~ un~er conditions s~f temperature and time whi~h at le~s~
~5 essentially aYoid D~bbl~ formation. . In ~hat respect, .

. . .

Ri~ n ' ~r~ S I~ T r ~ . rl.~, s ~l - ! T '- 1~ T T S~ T
,..... . .

~ 1 03373 the temperatura i5 believ~.d to be ~he determining ~ctcr and prefera~ly the ~emperalure used ~o ef~ct adhesi~n or b~ndi~g is one in ~he ~ange cf ~rom abou~ ~00C to about 110~ and typically no higher than about 11~C.
A~o~e tha~ hi~her ~emperature bubble~ ~end to for~ too readily and ~olour~ a~e diminished or disappear.
Accordingly, for optimum results in terms of ad~sion ~n~
brightness of finished image a temperature in the given range sh~uld be used, and pre~era~ly about lOQ~.

As to pressure, it is pre~exred to u~e a~ high a pre~s~r~
as is p~sibls ~i~hin the limits of the press or o~her apparatus employed, an~ subject to the ~equirements of the image or ima~ing effect to be p~oduced. Typic~lly, a pr~ssure of a~ or above about 200 ym~cm~ ~ay ~e used, for ex~mpl~, a pressure of about 200 to ab~ut 210 ~m/~m~
such ~s a pressure o~ about ~o~ g~Jcm~ which may be applied in a ~000 ~ press ~ith a plate area o~ 0.4 m x ~0 1.2 m.

Generally speaking, in the pro~ess of the invention, the he~ ~nd p~essu~e are applied fo~ a suff i~ien~ time to - enable laminate formation to take pla~e, Thus, a variety of ~ell times may be employed, although a dwell ti~e of ab~ut 20 to ~bou~ 60 seconds is prefer~ed, ~ore prefer~bl~ a~out -~2 seconds, especia~ly under the r ' conditions mentioned above.

Fabric trçated by th~ p~ocess of the invention is a fully ~lexible lamin~te which generally has the same or a si~i~ar high degree ~f flexure as ~he flexible subs~rate ~ro~ ~1ch it is made. Thus, the laminate should always be ~apabls of ~ high degree o~ flexu~e an~ a ~eatad ~abric, ~or example, should ~e capable of beh~ing as a f~--r~ ~r~ S S, T ~' ~

~ 2103373 ,, fabri~ essentiall~ the same as th~ original fabric.

In the prior ~rt i~ is known to ~pply silver and gold foils to articles of clot~i~g u~ing a Metatran ~dhesive.
However, 1n prior art processes the ad~esive i~ always cure~ to a h~rd st~e before application of the foil and the tempe~atu~es used in the precsing operation are very mu~h higher, t~pi~lly about 170~.

In accordance ~ith ~he present inven~ion it is an unexpe~ted and surpri5ing erf~ct that b~ usin~ ~ fluid ~omposition and applying a foil while the composition is 5till fluid ~ne obtains a cleaner, ~learer, and ~ten finer print Al~o, by usinq preferred temperatures in 1~ the rang~ of ~bout 1~0C to about 110C, those at or above 170C whieh could destroy t~e holog~phic foil are avoided.

The inv~ntion will now be illustra~ed by the ~ollowing specific exa~pl~s:-~xample 1 A 100~ cotton tee-shirt ~as printed on its f~ont face wi~h a fine image involving half tones using a sil};
' screen mesh 4~T and a fluid composition comprising PVC
suspended. in a plastisol ink supplie~ ~s Metatran adhesive ~y seri~ol of London, United Kingdom. The tee-shirt was then while ~he adhesive w~s still in a fluid ~or un~ured) state laid adhesive side uppermost on a heat ~ransfer press as suppl~ed by IInagine Transfers of ~r~i"~:ree, t~nited Yingdom. Next, a sheet of holoy~aphic ~oil (EP49 with P~tC 6~ si7ing~ having dimensions to ~ove~
the im~ge w~s laid over the ir!~age with the sur~ace having the P~S size in contact with the wet o~ fluid adhesive.

, , , ., ~, ., , : ., .
, rt~ r r ,~ r ~ T T ~- r 211)3373 ~ 7 The laminate of tee-~ihir~ ~ront ~nd ~oil ~as ther, subjected to ~. ~emperature of abou~ 100C ~or ~bout ~
sec:oncls in the ~press, after which the combinatlon was allow~d t~ C:oC)l. Finally, the I ~il was e~refully peele~
away to remdve eXcess (unstuc};) foii to leavP. ~ tee-~hir~ f inely decorated with a hologr~phi~ pattern in th~
image of the pattern of adhesive laid do1,m wi~h ~he silk sc:~een .

The tee-shirt wi~h the holo~r?phic image ~as m~ ::hine wa~ihable at 40C and could be 'cu~nb~e drie~ without destruction of ~he image or ~he holographic ~ffe~t.

ExaJnpl e 2 Example 1 was ~epe2ted ex~ep~ that an ir~age was appl ied to the re2lr of a waistcoa~ made of z fleece fab~
5imilar resu}ts were obtained and again ~he waist~oat was mac~ine washable and abl~ to be tumble dried without des~ru~tion o~ ~he image or the hoiographi c efferet.

Exalr,ple ~

Example 1 was repeate :1, this tim~ ~ith a ~ee-shirt ~n~de - 25 of 50% cotcon and 50% polyescer ~,:ith essent~ ~lly the same ' results.

It is of course ~o be understood tha~_ the invei~ion is not limited ~c:) 'che specific ~etails given abo~,-e and numerous v~riations may be made ~ hin the spirit and sc:ope of the cl~i~ns which follow.

Z O ~ T T ~ 3 ~ T I ~ f~ !. Z h~ ~ ' B . I l ~ ~ T

Claims

1. A process for the production of a flexible laminate, which process comprises applying to a surface of a flexible substrate a curable composition in fluid form and comprising a plastics material as a pattern which can provide a desired image or imaging effect, positioning a metal foil bearing a holographic image and having a layer of plastics size, with the size layer overlying the pattern while the composition remains fluid, applying to the combination heat and pressure at a level and for a time sufficient to adhere the foil to the substrate via the plastics material but insufficient to destroy the holographic effect, and thereafter removing excess foil not adhered to the substrate to expose the desired image or imaging effect.

2. A process according to claim 1, wherein the composition is applied by silk screen printing.

3. A process according to claim 1 or claim 2, wherein the composition comprises a plastics material suspended in a plasticiser.

4. A process according to any one of the preceding claims, wherein the plastics material is PVC.

5. A process according to claim 3 or claim 4, wherein the plasticiser is a plastisol ink.

6. A process according to any one of the preceding claims, wherein the metal foil bearing the holographic image is an aluminium foil.

7. A process according to any one of the preceding claims, wherein the foil is a hot stamping foil bearing a holographic pattern.

8. A process according to any one of the preceding claims, wherein the size of the foil is a polyvinyl chloride.

9. A process according to any one of the preceding claims, wherein the foil includes a release layer on that surface of the metal foil which does not carry the layer of plastics size.

10. A process according to claim 9, wherein the release layer is removed after treatment and before the holographic effect is required.

11. A process according to any one of the preceding claims, wherein the flexible substrate is a woven or non-woven web.

12. A process according to claim 11, wherein the flexible substrate is a fabric.

13. A process according to claim 12, wherein the fabric is a natural fabric.

14. A process according to any one of the preceding claims, wherein the substrate is one which is not only flexible but also stretchable.

15. A process according to any one of the preceding claims, wherein the foil and substrate are fed to a laminating station at which heat and pressure can be brought to bear on their combination.

16. A process according to claim 15, wherein the feeding to the laminating station is on a continuous or batch basis.

17. A process according to any one of the preceding claims, wherein the foil and the substrate are supplied continuously or intermittently from rollers on which they are stored.

18. A process according to any one of the preceding claims, wherein the foil and substrate are brought together between at least two rollers.

19. A process according to any one of Claims 1 to 15, wherein the foil and substrate are brought together in a heated press which comprises upper and lower heated plates which can be brought together under pressure.

20. A process according to any one of the preceding claims, wherein the temperature conditions are from about 100°C to about 110°C.

21. A process according to any one of the preceding claims, wherein the temperature is about 100°C.

22. A process according to any one of the preceding claims, wherein the pressure is at least about 200 gm/cm2.

23. A process according to claim 22, wherein the pressure is from about 200 gm/cm2 to about 210 gm/cm2.

24. A process according to any one of the preceding claims, wherein the dwell time during which the temperature and pressure conditions apply is from about 20 to about 60 seconds.

25. A flexible laminate when produced by a process according to any one of the preceding claims.