GB2367265A

GB2367265A - Multi Ply Material

Info

Publication number: GB2367265A
Application number: GB0116444A
Authority: GB
Inventors: Neil Shinner
Original assignee: Worlds Apart Ltd
Current assignee: Worlds Apart Ltd
Priority date: 2000-07-07
Filing date: 2001-07-06
Publication date: 2002-04-03
Also published as: GB0016586D0; GB0116444D0

Abstract

A multi-ply material comprises at least a backing layer (10) and a film layer (6). An ink pattern (12) is applied to one of the surfaces of the film or backing layer such that the ink pattern is viewable through the film. The film used may be biaxially oriented polypropylene (BOPP) or biaxially oriented polythene (BOPE). The backing layer may be a non-woven material such as spun bonded polypropylene. The film may be embossed. An additional layer such as metallic foil may be present or alternatively the film may be metallised. The material may be used over a frame to form a children's play structure or tent. Other applications include display screens, furniture and clothing.

Description

Multi Ply Material The invention to which this application relates is a printed material which is a flexible material and which has many potential uses such as to form walls of collapsible structures, play mats or any purpose where the provision of high quality graphics would be of advantage.

At the present time there are many areas where the use of flexible material is desired and the following description relates to one such use in detail for the purpose of illustration although this should not be interpreted as limiting the potential uses of the printed material in accordance with the invention.

There is a considerable marketplace for structures which are typically, although not necessarily, used as a play structure. These play structures can be used as tents, storage articles and the like and typically comprise a frame structure formed by one, or a number of, members which are spaced apart and to which is attached, and suspended between the same, printed sheet material.

As these structures are typically play structures there is a need to make the same attractive to users, typically children, and conventionally the sheet material is provided in bright and contrasting colours. However, more recently the sheet material has been provided with printed matter to represent cartoon characters, or other toy characters thereby allowing the same to carry features of licensed characters and increasing the perceived value of the play structures.

The cartoon or other characters are typically provided on the outer surface of the sheet material by a conventional printing technique but there are considerable difficulties encountered in doing this.

Some difficulties encountered are, firstly achieving reasonable print quality and secondly preventing the printed material from flaking off in subsequent use. Known processes involve printing on any of plastics PVC or paper. The material known as TYVEK TM is one example of plastics material used. Ink needs to be applied as a separate process and the sheet material itself is expensive. A further problem is that in many countries there are import restrictions for goods containing certain materials and nylon, plastics, textile and paper material, in general, which again can add to the cost of the products made in this manner.

Another form of known material is non-woven material which is a polypropylene spun bonded material which is cheaper than nylon, and the majority of textiles, however the raw/uncoated material is absorbent and very large quantities of ink are required to be applied and, even then, the final results are visually poor. There are also a limited number of print processes which can be used, typically only screen printing can be used successfully which is time consuming and limited in scope.

The aim of the present invention is to provide a sheet material which can be printed and carry said printed material in both a visually attractive manner and also be resistant to deterioration after the use of the same, at a cost less than coated or processed textiles.

In a first aspect of the invention there is provided a sheet material having a surface onto which ink can be selectively applied to form a printed pattern thereon and characterised in that said sheet material is at least a two ply formation, with a first layer being formed of a film and the second layer formed by a sheet material which acts as a backing layer, said first and second layers adhered together to form the sheet material and the ink pattern, if provided, is carried on a surface of the film. In a preferred embodiment the ink is carried on a first surface of the film which faces the backing layer such that the printed pattern is viewable through the film which is substantially transparent.

Typically the ink pattern is applied in a reverse form to allow the same to be viewed in the required form through the film. The application of the ink pattern to be viewable through the film is found to provide a textural appearance and also provides significant protection to the pattern in that it is protected from wear by the film layer, the opposing face of which forms the outer surface of the sheet material in use. This arrangement also improves the colourfastness of the printed pattern as the ink pattern is protected and effectively bonded within the sheet material.

In one embodiment the ink is applied over the entire surface of the film.

In one embodiment the film used is a polypropylene film and in particular a biaxially orientated polypropylene (BOPP) with a Matt or Gloss finish, but could equally be biaxially orientated polythene (BOPE).

In one embodiment the ink is applied so as to allow the application of a high resolution printed image. It is found that the image can be applied with a fineness in the region of, for example, 200-300 DPI, but not limited thereto, which is significantly greater than can be achieved with the conventional printing techniques on sheet textile materials.

The sheet material formed in accordance with the invention is flexible.

Typically there is provided a layer of adhesive between the two ply of the sheet material so as to ensure that the ply are joined together over the area of the sheet material. The adhesive or other attachment medium is provided after printing and the sheet material then goes through a curing process to join the backing layer and the film together.

In one embodiment the backing layer is formed by a non-woven material.

In one embodiment the film layer is embossed. Embossing is a process whereby the film is impacted by a series of spaced members which cause the formation of an irregular surface such that light is reflected between the indentations and protrusions on the surface to generate an"oil"effect visual appearance.

In one embodiment the film layer may or may not include printed matter thereon but an additional layer of material is provided in the sheet material. In one embodiment the additional layer is a metallic foil. In one embodiment the foil is embossed.

In a further embodiment at least one of the layers of the sheet material which make up the sheet material is embossed.

In one embodiment the sheet material comprises a backing layer, typically of non-woven material, a foil layer which may or may not be embossed, and a layer of film. Typically the layer of film is either or both of embossed and/or carrying a printed ink pattern.

If required, an intermediate layer can be included between the backing material and foil layer to improve the adherence of the said layers to form the sheet material.

In a further embodiment the film may also be metallised. In a further embodiment the embossing of the film is in a particular pattern to add to the visual effect and the pattern, in one embodiment, is provide in register with a printed pattern. In addition the embossed pattern can be coloured with the introduction of coloured pigment during the embossing process.

In a further aspect of the invention there is provided a structure comprising a frame formed of at least one member and said frame serves to hold sheet material to complete the structure and wherein said sheet material is at least a two ply material formed of a backing layer joined to a film and an ink pattern is applied to one of the surfaces of the film or backing layer which are bonded together to form the sheet material and the ink pattern is viewable through the film.

In one embodiment the frame is formed from or a series of coilable members and the structure is moveable from an erected condition to a storage condition by coiling said members, with said sheet material folding and following the movement of the members to the storage condition.

In a further embodiment the sheet material is a three ply material wherein there is a centre or core ply formed of non-woven material and to each surface of the same is adhered a film, with a surface of each of the plastics film ply carrying printed matter.

Typically the ink pattern is applied to the surface of each of the film layers which faces the non-woven material.

In a further aspect of the invention there is provided a method of forming sheet material with at least one printed pattern thereon, said method comprising applying an ink pattern to a surface of a film, placing the surface of the film on which the ink pattern is applied onto a backing layer and bonding the film and backing layer together such that the printed pattern is viewable through the film.

Typically the film used is BOPP or BOPE and the printing process which is used is a gravure printing process and the backing layer used is a non-woven material.

A specific embodiment of the invention is now described with reference to the accompanying drawings wherein Figure 1 illustrates a printed sheet material in accordance with the invention ; Figure 2 illustrates a cross sectional elevation of the sheet material of Figure 1; Figure 3 illustrates a cross sectional perspective of the sheet material in a further embodiment of the invention; Figure 4 illustrates a cross sectional perspective of the sheet material in a yet further embodiment; and Figure 5 illustrates one possible use of the sheet material as part of a play structure.

Referring firstly to Figures 1 and 2 there is illustrated a sheet material in accordance with the invention. The sheet material has a first surface 2 which, in use, will be the external surface of the material, and a second, rear surface 4. The sheet material is a two ply material comprising a first ply 6 with the first surface of a polypropylene (BOPP) film which has a matt finish and it is onto the back 8 of this that the ink pattern 12 is applied as illustrated in Figure 2. With the ink pattern 12 applied, the film 6 is applied to the backing layer 10 to form the sheet material by bonding and laminating the same together. This can be achieved in one embodiment by using a curing process with a layer of adhesive provided to form the sheet material structure as illustrated in Figure 2. When formed, the printed pattern 12 can be viewed through the transparent film 6 This therefore allows the required printed pattern quality to be achieved with the pattern being protected by the film 6 thereby ensuring durability and colourfastness which is required when the material is to be used in an environment where wear characteristics are important.

The backing layer 10 used in this example is a non-woven material which provides the backing and strength to the sheet material and allows the same, when formed, to be used for purposes where the same has to be resistant to damage such as by repeated movement or manipulation of the sheet material or scratching and the like. It should however be appreciated that other forms of backing layer can be used as required.

In the example described the specification of the film and backing layer used are as follows: Film: Biaxially orientated polypropylene (BOPP) or polyethylene (BOPE) Description: extruded sheet polypropylene (Matt or gloss finish) depending on orientation of the film and the surface onto which it is printed.

Characteristics: Flexible clear film, permitting extremely high quality print capabilities. The material provides a permeable and colourfast protected surface. Backing layer: non-woven polypropylene spunbonded material Description: non woven fabric constructed from polypropylene fibres, spun bonded.

Properties: Various colours and weight grades Characteristics: Light weight woven textile alternative, water repellant and air permeable, non toxic and odourless, bacteria resistant.

The layers which make up the sheet material are typically bonded together by the application of adhesive between the layers, typically the adhesive is sprayed on and then subsequently cured.

As is indicated in Figure 1 the printed pattern which is applied is of considerable quality and is significantly better than that which can conventionally be achieved on sheet material used for the various desired purposes. Furthermore as the sheet material is resistant to wear and flexible so the uses available for the same are extensive.

Figures 3 and 4 illustrate further embodiments of the sheet material.

Figure 3 illustrates a front surface 100 of sheet material in which the visual effect is created by a combination of features from the layers of film 102, with a printed pattern 104 applied thereto, foil 106 and backing layer 108. Thus, the visual effect on the external surface 100 which is viewable is achieved by the combination of features of a layer of film which is metallised and embossed to give an effect indicated by 110, the print pattern 104 which is viewed from the rear surface of the film, through the film, and viewed in conjunction with an embossed effect 114 from the foil layer. Thus a combined effect is created using this embodiment. Figure 4 illustrates a further embodiment of the sheet material where in this case there is a film layer 120, a foil layer 122 and backing layer 124 of non-woven material, all as in Figure 3.

However in this case there is no printed pattern but an effective visual effect 128 is again created on the external surface by the combination of the embossed film and/or embossed foil. An intermediate layer 126 is indicated and this, or a number of these, can be included in any of the embodiments where two adjacent layers may not be easily bonded together. The intermediate layers allow this problem to be overcome.

One such purpose is to use the sheet material to form the walls of a children's play structure 15 as shown in Figure 5 wherein there are provided a series of members 14 which form the frame of the structure and which frame supports the sheet material 16 in accordance with the invention, with the printed material viewable.

It will therefore be appreciated that, as many of these structures carry licensed or well known children's characters thereon, the improved graphical image which can be applied to the sheet material in accordance with the invention represents considerable commercial as well as practical advantages.

Other applications for the sheet material in accordance with the invention can be for display screens, furniture, clothing and any use where sheet material can be used and to which the improve print technique would be of use and advantage.

Claims

Claims 1 A sheet material having a face onto which ink can be selectively applied to form a printed pattern thereon and characterised in that said sheet material is at least a two ply formation, with a first layer being formed of a film and the second layer formed by a sheet material which acts as a backing layer, said first and second layers adhered together to form the sheet material and the ink pattern, if provided, is carried on a surface of the film.
2 A sheet material according to claim 1 characterised in that the film is substantially transparent.
3 A sheet material according to claim 2 characterised in that the ink pattern is carried on the surface of the film which faces the backing layer such that the printed pattern is viewable through the film.
4 A sheet material according to claim 3 characterised in that the ink pattern is applied in a reverse form to allow the same to be viewed in the required form through the film.
5 A sheet material according to claim 1 characterised in that the ink pattern is protected and effectively bonded within the sheet material.
6 A sheet material according to claim 1 characterised in that the ink pattern is applied over the entire surface of the film.
7 A sheet material according to claim 1 characterised in that the film used is a polypropylene or polyethylene film.
8 A sheet material according to claim 7 characterised in that the sheet material is a biaxially orientated polypropylene (BOPP) or polyethylene (BOPE) with a matt or gloss finish.
9 A sheet material according to claim 1 characterised in that the sheet material formed is flexible.
10 A sheet material according to claim 1 characterised in that there is provided a layer of adhesive between the two ply of the sheet material so as to ensure that the ply are joined together over the area of the sheet material.
11 A sheet material according to claim 1 characterised in that the backing layer is formed by a non-woven material.
12 A sheet material according to claim 1 characterised in that the sheet material is a three ply material with a centre or core ply formed of non-woven material and to each surface of the same is adhered a film, with a surface of each of the plastics film ply carrying printed matter.
13 A sheet material according to claim 12 characterised in that the ink pattern is applied to the surface of each of the film layers which faces the non-woven material.
14 A sheet material according to any of the preceding claims wherein at least one of the layers of the sheet material is embossed and/or metallised.
15 A sheet material having an external face and a backing layer characterised in that said sheet material is at least a two ply formation, with a first layer being formed of a film and a second layer formed by a sheet material which acts as the backing layer, said first and second layers adhered together to form the sheet material and the film layer is embossed.
16 A sheet material according to claim 15 characterised in that the sheet material includes at least one further layer between the film and the backing layer.
17 A sheet material according to claim 16 characterised in that the additional layer is a foil which may or may not be embossed.
18 A sheet material according to any of claims 15-17 characterised in that the film layer includes printed matter applied thereto.
19 A sheet material according to any of the preceding claims characterised in that the sheet material includes at least one further intermediate layer, said intermediate layer chosen to improve the bond between other layers of the sheet material.
20. A method of forming sheet material with at least one printed pattern thereon, said method comprising applying an ink pattern to a surface of a film, placing the surface of the film on which the ink pattern is applied onto a backing layer and bonding the film and backing layer together such that the printed pattern is viewable through the film.
21. A method according to claim 20 characterised in that the film used is BOPP or BOPE and the printing process which is used is a four colour photographic image process and the backing layer used is a non-woven material.
22. A structure comprising a frame formed of at least one member and said frame serves to hold sheet material to complete the structure and wherein said sheet material is at least a two ply material formed of a backing layer joined to a film and an ink pattern is applied to one of the surfaces of the film or backing layer which are bonded together to form the sheet material and the ink pattern is viewable through the film.
23. A structure according to claim 22 characterised in that the frame is formed from or a series of coilable members and the structure is moveable from an erected condition to a storage condition by coiling said members, with said sheet material folding and following the movement of the members to the storage condition.