US 2008O124503A1 (19) United States (12) Patent Application Publication (10) Pub. No.: US 2008/0124503A1 Abrams (43) Pub. Date: May 29, 2008

(54) FLOCKED ADHESIVE ARTICLE HAVING Related U.S. Application Data MULT-COMPONENT ADHESIVE FILM (60) Provisional application No. 60/864,107, filed on Nov. (75) Inventor: Louis Brown Abrams, Fort 2, 2006. Collins, CO (US) Publication Classification Correspondence Address: (51) Int. Cl. SHERIDAN ROSS PC BSD L/6 (2006.01) 1560 BROADWAY, SUITE 1200 B32B I/06 (2006.01) DENVER, CO 80202 (52) U.S. Cl...... 428/34.1; 156/72; 428/90 (73) Assignee: HIGHVOLTAGE GRAPHICS, INC., Fort Collins, CO (US) (57) ABSTRACT (21) Appl. No.: 11/934,668 A design and process are provided in which a fully activated thermosetting adhesive layer and multi-layered thermoplastic (22) Filed: Nov. 2, 2007 adhesive are positioned between a flock layer and a substrate. 177

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Contact ThermoSet Adhesive with 316 Bicomponent Adhesive 300 Film PrOWide FOCKed Carrier Sheet

Heat Assembly to Bond 318 Thermosetting Adhesive to Contact Flocked Bicomponent Adhesive 3O4 Carrier Sheet With ThermoSet Adhesive Film Bicomponent - 32O Cure Fully Adhesive Film 308 ThermoSet With Substrate Adhesive to l FOCK Heat Assembly 324 to Bond Remove Backing : Bi SEt

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300 PrOWide Flocked Bond Thermosetting 322 Carrier Sheet And Bicomponent Adhesives

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FLOCKED ADHESIVE ARTICLE HAVING ing properties, morphologies, chemical properties, physical MULTI-COMPONENT ADHESIVE FILM properties, structural properties, and bond strengths. The first and second parts are preferably selected such that the first and FIELD OF THE INVENTION second parts are capable of being adhered to or associated with one another by co-extrusion, lamination, or other pro 0001. The invention relates generally to flocked articles cessing techniques, and that the first part is capable of being and particularly to flocked decorative articles having a multi adhered to or associated with a first material. Such as a polar component adhesive film. More specifically the invention Substrate, and the second part is capable of being adhered to relates to flocked decorative articles having non-compatible or associated with a second material. Such as a non-polar heat sealed materials. substrate. Preferably, the first and second parts do not flow BACKGROUND OF THE INVENTION together when the co-extruded film is softened or melted. 0006 While not wishing to be bound by any theory, the 0002 Flocked decorative articles are used in a wide vari inability of thermosetting adhesives to bond to certain types ety of applications. For example, flocked articles are used as of substrates is believed to be due to chemical and/or physical patches, transfers, coated molded objects, and the like. Flock differences between the thermosetting adhesive and sub applied to a decorative article can enhance the texture and strate, which provide for poor of the thermosetting perceived value of the decorative article. To maintain a high adhesive to the substrate. As for example, it is hard to realize level of plushness of the decorative flocked article, it is impor an adhesive joining of the materials when materials. Such as tant to not only to permanently anchor the flock fibers in a polar and non-polar substrates, have little, if any, affinity for substantially perpendicular orientation of the flocks fibers one another. relative to the substrate and it is also important to provide 0007. In one embodiment, the thermosetting adhesive space between the fibers so that fibers can move freely to layer is contacted with the flock fibers and fully thermoset create a feeling of plushness. before contact with the thermoplastic adhesive layer. It has 0003. One technique for accomplishing these objectives, been discovered that, when the two adhesive layers are permanently adhering the flock in a Substantially perpendicu applied simultaneously or Substantially simultaneously to the lar orientation to the Substrate and providing Substantially flock layer both adhesive layers can set irreversibly, even free movement of the flock fibers, is embedding the flock when one of the adhesive layers is a thermoplastic adhesive fibers in pre-formed, self-supporting (A- or B-staged) ther layer. While not wishing to be bound by any theory, the mosetting adhesive film and fully activating (that is, cross irreversible setting of the two adhesive layers is believed to be linking or C-staging) the thermosetting adhesive to perma due to thermosetting curing agents migrating into the ther nently adhere the flock fibers to the thermoset adhesive. Once moplastic adhesive layer causing it to cross-link in same fully cross-linked, the thermoset adhesive is no longer manner as the thermosetting adhesive layer. It has been found capable of being adhered to another material. A problem thus that applying and laminating the adhesive layers separately at exists in the need of a downstream user to adhere the fully differing times can solve this problem, for example, by com cross-linked thermoset adhesive to a substrate. pletely curing (C-staging) the thermosetting adhesive layer before applying the thermoplastic layer immobilizes (and/or SUMMARY OF THE INVENTION consumes) the curing agents in thermosetting adhesive layer 0004. These and other needs are addressed by the various thereby, preventing migration of the cross-linking agents into embodiments and configurations of the present invention. the thermoplastic adhesive layer. The fully cross-linked ther The present invention is directed generally to an article hav moset adhesive also can provide a barrier to inhibit flow of ing adjacent thermosetting and thermoplastic adhesive layers another adhesive, used to adhere the flock to a substrate, arranged so that the thermosetting adhesive layer is between flowing between and/or up the longitudinal axis of the flock the flock and thermoplastic adhesive layer. The thermoplastic fibers. adhesive layer is a laminate or co-extruded film having mul 0008. In another embodiment, the thermoplastic adhesive tiple, typically incompatible, components. In one application, layer is softened or at least partially liquefied and applied to a first part or layer of the thermoplastic adhesive has, as its the fully activated (or cross-linked) thermosetting adhesive primary component, a first , which is typically polar, layer firmly adhered to the flock fibers. The fully cross-linked and a second part or layer of the thermoplastic layer has, as its thermosetting adhesive inhibits the flow of the softened or primary component, a second polymer, which is different liquefied thermoplastic adhesive, during bonding application from the first polymer and is typically non-polar. As used of the thermoplastic adhesive, into and between the flock herein, “compatibility” refers to physical or chemical incom fibers, thereby maintaining a high degree of plushness in the patibility; that is, two materials are considered to be incom flock layer without compromising the bond strength between patible if they will not typically adhere directly to one another the fibers and thermosetting adhesive layer. unless formed and/or processed in intimate association or in 0009. Yet another embodiment of the present invention conjunction with one another. For example, polyesters and includes the use of a multi-component adhesive film to adhe polyolefins are generally chemically incompatible, as for sively bond normally incompatible Surfaces, such as polar example due to differing polarities; however, they can be and non-polar surfaces. The ability to adhesively join non adhered to or associated with one another by suitable process compatible materials can permit the manufacturing of a wide ing techniques, such as co-extrusion or lamination. variety of flocked articles, such as for example adhesively 0005. The first and second parts can beformulated to have joining flock labels to natural rubber HarmonyTMyoga mats one or more differing properties. By way of example, the first from Jade Industries, or adhesively joining a flock transfer to and second parts may have one or more differing melting natural rubber MOUSE RUGTM manufactured by Fiberlok(R) temperatures, softening points, viscosities, Surface energies, Inc. Multi-component adhesive films permit several steps to solubility parameters, degree of crystallinity, bond be performed simultaneously, e.g., gluing and finishing in a US 2008/O124503A1 May 29, 2008

single step. Because the multi-component film can be in the 60/703.925, filed Jul. 28, 2005, 60/704,681, filed Aug. 1, form a pre-formed and self-supporting film prior to use, the 2005,60/707,577, filed Aug. 11, 2005, 60/710,368, filed Aug. film can be easy to handle, and the manufacturing process can 22, 2005, 60/716,869, filed Sep. 13, 2005, 60/719,469, filed be clean and environmentally friendly, as opposed to liquid Sep. 21, 2005, and 60/719,098, filed Sep. 20, 2005, to adhesives. The thermoplastic adhesive film can also be three Abrams), and other known carriers. The carrier sheet 104 is dimensionally deep-drawn and thermoformed. preferably a porous film, Such as a porous film coated with 0010. These and other advantages will be apparent from release adhesive 108, which is preferably a water-based the disclosure of the invention(s) contained herein. release adhesive. A preferred porous film is discussed by 0011. As used herein, “at least one”, “one or more', and “and/or are open-ended expressions that are both conjunc Pekala in U.S. Pat. No. 6,025,068. A particularly preferred tive and disjunctive in operation. For example, each of the porous film is sold by PPG Industries Inc. under the trade expressions “at least one of A, B and C, “at least one of A, B, name TESLINTM. Battery separator membranes can also be or C, “one or more of A, B, and C. “one or more of A, B, or used. Examples include Daramic Industrial CLTM sold by C” and "A, B, and/or C' means A alone, Balone, C alone, A Daramic, Inc., and the uncoated, nono-layer, highly filled and B together, A and C together, B and C together, or A, B polyolefin sheet battery separator membranes sold by Cel and C together. gard or by Daramic, Inc. under the trade name ArtisynTM. 0012. The above-described embodiments and configura Typically, but not always, the carrier is a discontinuous as tions are neither complete nor exhaustive. As will be appre opposed to a continuous sheet on a running web line. ciated, other embodiments of the invention, are possible uti 0024. The release adhesive 108 can be any adhesive that lizing, alone or in combination, one or more of the features set adheres more strongly to the carrier sheet than the flock fibers forth above or described in detail below. but adheres to both enough to hold them together. For example, the release adhesive 108 can be any temporary BRIEF DESCRIPTION OF THE DRAWINGS adhesive. Such as a resin or a copolymer, e.g., a polyvinyl 0013 FIG. 1 is a side view of a flocked article produced acetate, polyvinyl alcohol, polyvinyl chloride, polyvinyl according to an embodiment of the present invention; butyral, acrylic resin, polyurethane, polyester, polyamides, 0014 FIG. 2A is a side view of a manufacturing line for cellulose derivatives, rubber derivatives, starch, casein, dex the flocked article of FIG. 1; trin, gum arabic, carboxymethyl cellulose, rosin, silicone, or 0015 FIG.2B is a side view of a manufacturing line for the compositions containing two or more of these ingredients. flocked article of FIG. 7E: The release adhesive is preferably awater-based release adhe 0016 FIG. 3A is a flow chart of the manufacturing line of S1V. FIG. 2A; 0025. The flock112 used in any of the processes discussed 0017 FIG. 3B is flow chart of the manufacturing line of herein can be any electrostatically chargeable fiber, such as FIG. 2B: fibers made from rayon, nylon, cotton, acrylic, and polyester. The flock preferably is resilient under and has a melting 0018 FIG. 4 is a side view of a flocked article according to and/or softening point that is greater than the temperatures an embodiment of the present invention; and pressures experienced in design, manufacturing, and later 0019 FIG. 5 is a side view of another flocked article application processes to resist Softening, deformation, and according to an embodiment of the present invention; melting. Due to its low melt point, acrylic flock is undesirable 0020 FIG. 6 is a side view of another flocked article in many applications. Resilient flock, Such as rayon, nylon, according to an embodiment of the present invention; and and terephthalate (e.g., poly(cyclohexylene-dimethylene 0021 FIGS. 7 A-E are side and top views of another terephthalate) polymer flock, is particularly preferred. In flocked article according to an embodiment of the present most applications, the flock orientation is at least Substan invention. tially orthogonal (perpendicular) to release sheet 104 and the flock fibers are at least substantially parallel to one another. In DETAILED DESCRIPTION one configuration, a conductive coating or finish is applied 0022 FIG. 1 shows a flocked article 100 according to an continuously or discontinuously over the exterior Surface of embodiment of the present invention. The article 100 includes the flock fibers to permit the flock fibers to hold an electrical a carrier sheet 104, release adhesive layer 108, flocklayer 112 charge. The flock fibers 112 may be pre-colored (yarn-dyed or having a plurality offlock fibers, thermosetting adhesive layer spun dyed) before application to the release adhesive 108 or 116, thermoplastic adhesive layer 120, and optional substrate after the carrier 104 is removed, such as by sublimation dye 124. As can be seen from FIG. 1, the flock fibers in the flock transfer printed. layer 112 are substantially parallel to one another along their 0026. The adhesive 116 can be any suitable water- or length and are substantially perpendicular to the planes of the solvent-based adhesive. The adhesive is preferably a high carrier sheet 104 and adhesive layers 116 and 120 to provide temperature permanent adhesive. Such as polybenzimida a plush feel. Zoles and silica-boric acid mixtures or cements, hot-melt 0023 The release or carrier sheet 104 can be any material adhesives, thermosetting adhesives, thermoplastic adhesives, that is dimensionally stable under the temperatures and pres polyurethane, polyester, and combinations and blends Sures encountered during the manufacturing process. The thereof. "Hot-melt adhesives' generally refer to a solid mate carrier 104 can be any low-cost, dimensionally stable sub rial that forms an adhesive bond upon heating and Subsequent strate. Such as paper, plastic film, and the like, preferably in cooling, “thermosetting adhesives' generally refer to a poly the form of a discontinuous sheet or a running web line mer that solidifies or “sets irreversibly when heated, and material (such as described in U.S. Pat. No. 6,025,068 and “thermoplastic' generally refers to a polymer that can be copending U.S. Provisional Application Ser. Nos. 60/628, repeatedly softened when heated and hardened (re-solidified) 836, filed Nov. 16, 2005, 60/676,124, filed Apr. 28, 2005, when cooled. The irreversible setting ofathermosetting adhe US 2008/O124503A1 May 29, 2008

sive is commonly affected by cross-linking of at least most, if 0030. During manufacture flocked intermediate assembly not all, of the cross-linking reactive entities contained in the 134 may be adhered to substrate 124. In one embodiment, adhesive polymer. when thermosetting adhesive layer 116 and substrate 124 are 0027 More preferably, adhesive 116 is an activatable, per compatible; that is, are capable of forming a Substantially manent thermosetting adhesive in the form of a pre-formed strong, permanent adhesive bond, thermosetting the adhesive 116 and the substrate 124 are contacted and heat and pressure self-supporting film before contact with the flock. Adhesive applied to the carrier sheet 104. In another embodiment, when 116 is preferably activated fully when it is heated above an the thermosetting adhesive layer 116 and substrate 124 are activation temperature for a sufficient period of time. As will Substantially non-compatible, that is, are not capable of form be appreciated, thermosetting adhesives solidify, activate, ing a substantially strong, permanent adhesive bond, or it is and/or set irreversibly (that is, become infusible and relatively desirable to adhesively bond flocked intermediate assembly insoluble in solvents) when chemical entities comprising the 134 to the substrate 124 by an adhesive other than the ther thermosetting adhesive chemically react (that is, cross-link) mosetting adhesive 116, adhesive layer 120 is interposed to form covalent bonds at least mostly between the reactive between the adhesive layer 116 and the substrate 124, and chemical entities comprising the thermosetting adhesive. The heat and pressure are applied to the carrier sheet 104. chemical, cross-linking reaction is typically initiated and/or 0031. To understand the need for positioning adhesive maintained by a chemical initiator, thermal energy or radia layer 120 between thermosetting adhesive layer 116 and sub tion (Such as, an beam or electromagnetic energy). strate, one should understand polymer blends and the theories The thermosetting adhesive 116 can be any high polymer that behind adhesion. While not wishing to be bound by any solidifies or sets irreversibly (e.g., B- or C-staged) when theory, several theories have been proposed to explain poly heated above a specific temperature (typically its softening mer blends and adhesion. temperature). In other words, the adhesive is commonly non 0032. A polymer blend or alloy is the polymeric material tacky and thermoplastic (or A-staged) in nature as prepared that results from mixing two or more of differing and, upon heating to a Suitable temperature, fuses and chemical compositions. Polymer blends are affected by at becomes thermoset (e.g. B- or C-staged) or Substantially least the following: the equilibrium phase behavior and mor infusible and insoluble. The thermoset state is usually asso phology of the mixture; the interfacial properties of the mix ciated with a cross-linking reaction of the molecular constitu ture; the type and magnitude of the physical and chemical ents induced by heat or radiation. Curing agents, such as interactions between the components comprising the mix organic peroxides and sulfur (in the case of rubber), may be ture; and the rheological properties of mixture. For example, incorporated in the adhesive 116 to facilitate or catalyze the depending on the free energy of mixing, two amorphous cross-linking reaction. For example, linear polyethylene can polymers can form a single miscible phase when the poly be cross-linked to a thermosetting material either by radiation meric components are intimately mixed or the two compo or by chemical reaction. Examples of thermosetting adhe nents can form two distinct phases comprised primarily of the sives include acrylics, polyethylene, polyamides, epoxides, individual polymeric components. In general, for two or more polyurethanes, phenolics, alkyds, amino resins, polyesters, polymers of differing chemical compositions to be miscibil epoxides, rubbers, and silicones. ity AG,<0 and (6 AG,/0d.),>0, where: 0028. In one formulation, the thermosetting adhesive 116, AG,AF-TAS (1) when in the thermoplastic state, includes a compound con taining three or more isocyanate groups per (such as triphenylmethane, triisocyanate, benzene triisocyanate, tolylene triisocyanate, silicon triisocyanate, ethylene tetrai and where AH and AS represent, respectively the enthalpic socyanate, and diphenyl triisocyanate) in which a number of and entropic parts, T the temperature, P the pressure, V the the isocyanate groups are blocked or masked with an isocy volume, and dd, the volume fraction of component i. The anate splitter-type material (such as a phenols and malonic thermodynamic principles of mixing can be combined with ester), and a polyester containing three or four hydroxyl the Flory-Huggins Theory to further understand how poly groups (such as glycerin, trimethylol propane, pentaerythri meric properties, such as molecular weight, dispersive inter tol, various polyesters with excess hydroxyl groups, and phe actions, solubility parameters, hydrogen bonding, can affect nol formaldehyde resins). To convert the adhesive to the ther polymer miscibility (or mixing). moset state, the adhesive is heated to a higher temperature, for 0033. The two most common techniques for preparing example about 125 degrees Celsius or higher, for a short polymer blends are solution casting and melt mixing, Such as period of time to free the isocyanate groups from the masking by blow, sheet or co-extrusion. The mixing (or miscibility) or blocking material and permit their reaction with the can be complete, where polymeric materials A and B are hydroxyl groups of the polyester. To accelerate the decompo combined to form a polymer blend AB, wherein polymers A sition reaction or the splitting off of the splitter-type material, and B are combined to produce polymer AB. Or, the mixing a small amount of an accelerator Such as a tertiary amine can be localized to a contact Zone, for example a heated compound, tributyl amine, and tris-(dimethyl aminomethyl) polymeric film (or softened or melt) of polymer A and the phenol, may be added. heated polymeric film (or softened or melt) of polymer B are 0029. The preformed, self-supporting adhesive film can contacted, Such that within the contacting Zone polymers A include fine particles of polymers or copolymers, as well as and B combine to form polymer AB, while outside of the one or more of plasticizer(s), stabilizer(s), curing agent(s) contacting Zone polymer film polymer A remains Substan (such as an isocyanate), pigment(s), etc. The pigment, if any, tially polymer A and polymer B remains Substantially poly determines the color and opacity of the adhesive film. The mer B. stabilizer, used when pigment is added, prevents discolora 0034. It is important to note that the above only briefly tion of the resin film. outlines the general principles encompassing polymer-poly US 2008/O124503A1 May 29, 2008

mer interactions. Further more those skilled in the art recog adhesive 116 is capable of adhesively bonding to substrate nize that there is not a method to a priori predict polymer 124 in response to the application of heat and pressure during polymer interactions and resulting equilibrium-phase the cross-linking process by one or more of the following: a) behavior. the flow of the adhesive into roughened surface areas of 0035. While not wishing to be bound by any theory, sev substrate 124 that when cross-linked mechanically interlocks eral theories have been proposed to explain adhesion, the five the adhesive 116 with the substrate 124; b) dispersive inter most commonly accepted theories being: 1) mechanical inter actions (dispersive interactions typically improve adherence lock, 2) dispersive, 3) chemisorption, 4) electrostatic, and 5) when the adhesive 116 has a lower than the diffusion. No one theory explains completely adhesion or the substrate 124); c) the formation of covalent (or ionic) bonds adhesion process. However, one should understand the five when the substrate 124 contains chemical entries capable of theories and how they impact the adhesion of materials being chemically reacting with the adhesive 116; d) the use of attached. The five theories are summarized below. electrostatic interactions, as in the case of dispersive interac 0036. The mechanical interlocking theory postulates good tions, electrostatic interactions typically improve when the adhesion when an adhesive penetrates a roughen adherent adhesive 116 has a lower surface energy than substrate 124; Surface having crevices, pores, and/or holes, and is cured and e) the use of diffusional interactions are less restrained within the crevices, pores and/or pores of the adherent, prior to the adhesive 116 being fully cross-linked, wherein the thereby mechanically interlocking the cured adhesive with polymer chains comprising adhesive 116 become covalently the adherent. Optimal mechanical interlocking of the adhe interconnected and substantially prevented from any diffu sive to the adherent occurs when the adhesive wets and/or sional movement. It can be appreciated that conditions can be penetrates the roughened adherent Surface. Maximum bond such that thermosetting adhesive 116 is not capable of form strength is typically the mechanical strength of the adhesive. ing a sufficiently strong permanent bond with Substrate 124 as 0037 Dispersive theory involves intermolecular Van der for example, but not limited to, the adhesive 116 having a Waals dispersive forces between closely adjoining surfaces higher surface energy than substrate 124, the adhesive 116 due to Keesom and/or London forces between the adherent and Substrate 124 are not miscible and cannot form a strong and adhesive. Keesom and London forces are due to diffusional bond, or the polarities of adhesive 116 and sub dipole attractive forces. Optimal adhesion occurs when the strate 124 are such that dipole-dipole interactions do not favor adhesive and the adherent are in intermolecular contact, opti adhesion. mal intermolecular contact is achieved when the adhesive has 0042. In the instance where thermosetting adhesive layer a lower surface energy than the adherent and is able to wet and 116 and substrate 124 are not substantially compatible, that spread on the substrate surface. The strength of a Van der is, are not capable of forming a Substantially strong, perma Waals dispersive force is typically about 0.1-40 KJ/mole and nent adhesive bond, or it is desirable to adhesively bond varies by 1/r power, where r is the distance separating the flocked intermediate assembly 134 to substrate 124 by an . adhesive other than a thermosetting adhesive 116, adhesive 0038. In the chemisorption theory an ionic or covalent layer 120 is interposed between the layer adhesive 116 and bond is formed between the adhesive and the adherent, typi Substrate 124, and heat and pressure are applied to the carrier cally bond formation is across the adhesive adherent inter sheet 104. In such a case the adhesive layer 120 is preferably face, either directly across the interface or through a chemical comprised of at least a first part 128 and a second part 132, coupling agent. In some instances the adherent Surface is more preferably the first and second parts having at least one chemically modified or derivatized to facilitate the formation differing chemical or physical property. As for example, the of chemical bonds. The adhesive strength of a covalent bond first and second parts can differ in one or more of polarity, is typically in the range of about 60-700 KJ/mole. chemical property, physical property, and any combination 0039. In the electrostatic theory the adhesive force is thereof. In an even more preferred embodiment, the first part attributed to dipole-dipole attractive forces across the bound 128 of adhesive layer 120 is positioned adjacent to the ther ary separating the adhesive and adherent, the dipoles can be mosetting adhesive 116, and the first part 128 comprises one permanent or induced. The attractive force is typically the or more of a chemical property, physical property and any order of 4-20 KJ/mole and varies by 1/r, where r is the combination thereof that provides for enhanced adhesion of distance separating the dipoles. the adhesive layer 120 to the adhesive layer 116 compared to 0040. The diffusion theory is typically associated with the adhesion of the adhesive layer 116 to the substrate 124. polymer-polymer adhesion where the polymeric adhesive Similarly, in another even more preferred embodiment, the and adherent inter-penetrate. Optimal interpenetration typi second part 132 of adhesive layer 120 is positioned adjacent cally occurs when the adhesive and adherent are mutually to the substrate 124, with the second part 132 including one or compatible and miscible and where the movement and more of a chemical property, physical property, and any com entanglement of the long polymeric chains comprising the bination thereof that provides for enhanced adhesion of the adhesive and adherent occurs. Diffusion is affected by contact adhesive layer 120 to the substrate 124 compared to the adhe time, temperature, and molecular properties, such as but not sion of the adhesive layer 116 to the substrate 124. It is also to limited to: molecular weight (e.g., number average, weight be appreciated that the interaction of the first part 128 with the average or polydispersity average); physical form (i.e., liquid adhesive layer 120 is preferably substantially strong and sub or solid); and physical properties, such as for example, crys stantially permanent to Sufficiently maintain a strong, perma tallinity, degree of cross-linking, and solubility parameters. nent adhesive bond of the flocked assembly 134 to the sub 0041 Returning to the adherence offlocked assembly 134 strate 124. Likewise, it is to be appreciated that the interaction to substrate 124, one embodiment adheres the thermosetting of the second part 132 with the adhesive layer 120 is substan adhesive layer 116 and substrate 124 to form a substantially tially strong and Substantially permanent to Sufficiently main strong, permanent adhesive bond. While not wanting to be tain a strong, permanent adhesive bond of the flocked assem bound by theory, it can be appreciated, that the thermosetting bly 134 to the substrate 124. US 2008/O124503A1 May 29, 2008

0043. The first part 128 and the second part 132 can or 0047. The first polymer can be the same as the primary cannot be chemically compatible. For example, the chemi polymer of the thermosetting adhesive layer 116. The second cally incompatible first and second parts can be separated in polymer may be the same as the primary polymer of the adhesive layer 120 by at least one or more other parts (not adjacent surface of the substrate 124. Potential first or second depicted in FIG. 1) or the first and second parts can be parti polymers for the first or second parts include rubber, polyes tioned within the adhesive layer 120 in such a manner that ters, polyurethanes, polyolefins, polyvinyl chloride, nylon, chemically incompatibility is not detrimental to the form polyamides, fluorocarbon, linear polyethylene, polystyrene, and/or function of the adhesive layer 120 or the flocked deco polypropylene, and cellulosic and acrylic resins and mixtures rative product 100. Chemically compatible or chemically and co- and terpolymers thereof. For example, the first poly incompatible first and second parts can be combined to form mer, which is preferably non-polar, can be, for example, a the adhesive layer 120, as for example, a multi-layered adhe polyester, polyolefin, and the like, and the second polymer, sive film can be extruded by means of blow or sheet extrusion which is preferably polar, can be rubber, a polyurethane, a (e.g., flat extrusion or chill-roll extrusion). In these extrusion copolyolefin, polystyrene, polyvinyl chloride, polyethylene, processes, the raw materials are softened or at least partially copolyesters such as polyethylene terephthalate, and the like. liquefied and then formed into a flat film using a sheet die or Particularly preferred multi-component films are the multi into a tube using a ring die. In co-extrusion, multiple films are layered films manufactured by Collano Xiro. extruded one-on-top-of-the-other in a flat extrusion installa 0048. The thermoplastic adhesive layer 120 can be any tion. high polymer, or mixture or combination of high polymers, 0044) The thickness of the film 120 ranges from about 5 to capable of being repeatedly softened when heated and hard about 2,500 mu and more preferably from about 10 to about ened when cooled. In other words, the post-heated state of 1,000 mu. adhesive layer 120 is preferably substantially reversible while 0045 Preferably the first and second parts 128 and 132 that of thermosetting adhesive 116 is not. The cross-linking have differing compositions, more preferably compositions process irreversibly hardens the thermosetting adhesive layer that differ physically and/or chemically from one another. 116. In one configuration, the thermoplastic adhesive layer Even more preferably, the first part 128 and the second part 120 is a dual laminated or co-extruded, solid, and self-sup 132 compositions differ in at least one chemical and/or physi porting film. In another embodiment the thermosetting adhe cal adhesion property. Or stated another way, one or more sive layer 116 and the thermoplastic adhesive layer 120 are chemical and/or physical adhesive properties of the first part pre-cut or configured, prior to contacting the Substrate 124 128 and the second part 132 differ, such that, the adhesive and/or flocked assembly 134. interaction of the first part 128 with the adhesive layer 116 0049. The first and second parts 128 and 132 may also be differs from the adhesive interaction of the first part 128 with formulated to have one or more differing properties. By way the substrate 124, and the adhesive interaction of the second of example, the first and second parts may have one or more part 132 with the adhesive layer 116 differs from the adhesive of differing melting temperatures, softening points, viscosi interaction of the part 132 with the substrate 124. Or stated yet ties, Surface tensions, adhesion properties (such as, perma another way, the adhesive interaction of the second part 132 nent or induced dipole moments, Surface roughness proper with the Substrate 124 is greater, that is, forms a stronger, ties, chemical entities, or Such) and bond strengths. In one more permanent bond, than the adhesive interaction of the configuration, the first and second parts have differing adhe substrate 124 with previously fully cured, thermoset adhesive sive properties, wherein the adhesive properties of the part layer 116; and the adhesive interaction of the part 128 with 128 are such that a strong, permanent adhesive bond is formed previously fully cured, thermoset adhesive layer 116 is with the thermosetting adhesive layer 116, and wherein the greater, that is, forms a stronger, more permanent bond, than adhesive properties of the part 132 are Such that a strong, the adhesive interaction of substrate 124 with previously fully permanent adhesive bond is formed with the substrate 124. cured, thermoset adhesive layer 116. Stated another way, the For example, the adhesive part 128 can provide for a surface first part 128 forms a stronger adhesive bond with the adhe tension of the surface of the adhesive layer 120 in contact with sive layer 116 than the second part 132, and the second part the adhesive layer 116 to be about less than or about equal to 132 a stronger adhesive bond with the substrate 124 than the the surface tension of the adhesive layer 116, thereby provid first part 128. ing for enhanced adhesion. Similarly, the adhesive part 132 0046 By way of example, a first part of the layer has, as the can provide for a surface tension of the surface of the adhesive primary component, a first polymer, which has a first adhesive layer 120 in contact with the substrate 124 to be about less property (such as polarity), and the second part of the layer than or about equal to the surface tension of the substrate 124, has, as the primary component, a second polymer, which thereby providing for enhanced adhesion. It is to be appreci differs from the first polymer and typically has a second ated that the surface tensions of the adhesive layer 116 and the adhesive property (such as a polarity) that differs from the substrate 124 are preferably substantially different, and that, first adhesive property. Preferably, the first and second parts for the adhesive layer 120 to substantially, respectively, wet are formulated and joined together to form adhesive layer 120 the adhesive layer 116 and the substrate 124 the respective so that they do not weaken and/or degrade their respective surfaces of the adhesive layer 120 should have differing sur adhesive interactions within the adhesive layer 120 when face tensions. heated. Such as for example, when first and second parts flow 0050. In one configuration, the first part 128 has a different together to form an adhesively weak phase when melted. (preferably lower) melting point than the second part 132. In While not wanting to be bound by theory, it can be appreci one configuration, the first part 128 has a different (preferably ated that, when the first and second parts are substantially lower) viscosity, at a given temperature, than the viscosity of immiscible it is preferred that the first and second parts do not the second part 132. In one configuration, the first part 128 has flow together when melted to substantially adhesively a different (preferably lower) softening point than the soften weaken the adhesive layer 120. ing point of the second part 132. US 2008/O124503A1 May 29, 2008

0051. The adhesive layers 116 and 120 may be in the form insoluble and infusible. In this thermoset state the adhesive of a liquid or solid film, with solid being preferred, and may layer 116 will, as noted below, form a blocking layer to be manufactured by any Suitable techniques. For example, the inhibit, in Subsequent lamination stages, the thermoplastic films may be solvent cast onto a backing material and, after adhesive layer 120 from flowing into and between the flock Solidification, be self-supporting, pre-formed, Solid films. fibers and thereby compromising the degree of plushness of The first and second parts of the adhesive layer 120 are the flock fibers. bonded together to form a film by known techniques. The 0057 The intermediate flocked assembly 138 is allowed adhesive film 120 can have an optional backing material. The to cool to a temperature below the maximum temperature optional backing material 220 can be any sacrificial material, experienced in the first laminating station 208. including those identified above for the carrier sheet 104. In a 0058. In step 312, the backing material 118 is removed preferred embodiment the adhesive film 120 does not have the from the substantially fully activated thermosetting adhesive optional backing material 220. layer 116. This can be done by any suitable technique known 0052. The system and process for manufacturing the to those of ordinary skill in the art. article 100 will now be discussed with reference to FIGS. 2-8. 0059. In step 316, the fully activated thermosetting adhe 0053. In step 300, a flocked carrier sheet 126 (depicted in sive layer 116 (that is, adhesive layer 116 is substantially fully FIG. 1) is provided. The flocked carrier sheet 126 is prefer cross-linked or C-staged) is contacted with the thermoplastic ably formed by screen printing the release adhesive film 108 adhesive film 216, which is a combination of the thermoplas in a desired pattern (which typically is the mirror image of the tic adhesive layer 120 and the optional backing material 220, desired final flock pattern) on the carrier sheet 104 followed FIG. 5, to formathird intermediate assembly 228, comprising by flocking electrostatically the carrier sheet 104. In the sys intermediate flocked assembly 134 and thermoplastic film tem of FIG. 2, the flocked carrier sheet 126 is dispensed on a 216. In one embodiment the thermoplastic adhesive film 216 first roll 200. does not have optional backing material 220, that is, the 0054) In step 304, the flocked carrier sheet 126, while on a thermoplastic adhesive film is comprised of the thermoplastic moving web 202, is contacted with a pre-formed, self-sup adhesive layer 120. In the system of FIG. 2, the film 216 is porting thermosetting adhesive film 316 which is a combina dispensed on a third roll 224. tion of the thermosetting adhesive layer 116 in the thermo 0060. While in contact, the intermediate flocked assembly plastic state, that is the thermosetting adhesive 116 is 134 and film 216 enter into a second lamination station 232, Substantially in the A- and/or B-stage, and a sacrificial back where heat and pressure are applied to the third intermediate ing material 118 to form a second intermediate flocked assembly 228. In the station 232, the film 216 is preferably assembly 138 as shown in FIG. 4. In the system of FIG. 2, the heated to a temperature of at least about 150 degrees F. and film 316 is dispensed on a second roll 204, where the adhesive more preferably from about 175 to about 375 degrees F. (or 116 contacts the free ends offlock112. Or stated another way, preferably above the softening point of the adhesive layer the opposing ends of the flock not in contact with the release 120) while pressure (which depends on the density of the adhesive 108 contact the adhesive layer 116 in step 304. flock fibers), preferably of at least about 1 psi and more 0055 While in contact, the flocked carrier sheet 126 and preferably ranging from about 5 to about 25 psi, is applied to adhesive film 316 enter into a first lamination station 208, the backing material 220 to cause the first part 128 of the wherein the second intermediate flocked assembly is heated thermoplastic adhesive layer 120 to firmly contact and adhere and subjected to pressure. In the station 208, the film 316 is to the thermosetting adhesive layer 116. As will be appreci preferably heated to a temperature of at least about 300 ated, the orientation can be reversed, with the adhesive layer degrees F. and more preferably from about 310 to about 450 116 in contact with the adhesive layer 120, such that the degrees F. (or preferably above the softening point of the carrier sheet 104 is on top and the backing material 220 on adhesive layer 116) while pressure (which depends on the bottom. In the latter, pressure is applied to the carrier sheet density of the flock fibers), preferably of at least about 1 psi 104. In this step, the adhesive layer 120 is heated for a time and more preferably ranging from about 5 to about 25 psi, is typically ranging from about 1 to about 60 seconds. In either applied to the backing material 118. Preferably the applied orientation the thermosetting adhesive layer 116 forms a pressure is at least Sufficiently enough to cause the flock fibers blocking layer to inhibit the thermoplastic adhesive layer 120 to penetrate the surface of the adhesive layer 116 and be at from flowing into and between the flock fibers. least sufficiently permanently embedded in the adhesive layer 0061. The adhesive layers 116 and 120 have differing 116. The heat and pressure are applied for at least about 0.5 properties. As will be appreciated, the C-staged, thermoset minutes, more preferably at least about 1 minute. As will be ting adhesive layer 116, when heated, is more viscous (and appreciated, the orientation of flocked carrier sheet 126 and therefore more resistant to flow) than the thermoplastic adhe adhesive film 316 can be reversed, such that the carrier sheet sive layer 120, which softens and flows when heated to a 104 is on top and the backing material 118 on bottom, while temperature at least about equal to or above its softening still maintaining the contacting of the free ends of flock 112 and/or melt temperature(s). While not wishing to be bound by with adhesive 116. When the orientations of flocked carrier any theory, the highly viscous, infusible state of the C-staged, sheet 126 and adhesive film 316 are reversed the lamination thermosetting adhesive 116 is due to the cross-linking reac pressure is applied to the carrier sheet 104. tions when adhesive layer 116 was laminated to flocked 0056. In step 308, the intermediate flocked assembly 138 assembly 126 in step 308. This highly viscous, infusible state is heated for a sufficient time (typically from about 15 sec substantially limits the ability of the C-staged, thermosetting onds to about 5 minutes) for the adhesive layer 116 to reach at adhesive layer 116 to flow between the flock fibers and/or least a temperature to thermoset, cross-link, or Substantially limits the ability of the softened and/or liquefied thermoplas completely C-stage adhesive layer 116. To C-stage athermo tic adhesive layer 120 to penetrate and diffuse through the setting adhesive means to achieve the final stage in the reac C-staged thermosetting adhesive 116 into flocklayer 112 and tion ofathermosetting resin in which the material is relatively thereby penetrate between the flock fibers comprising the US 2008/O124503A1 May 29, 2008

flock layer. The fully activated adhesive layer 116 thus main appliqués or transfers. In another preferred embodiment the tains the plushness of the flock layer 112. Typically, the tem design medium 174 is a woven textile product sold under the perature at which the C-staged, thermosetting adhesive layer trade name ObiTexTM by FiberlokR, having an enhanced 116 softens, if at all, in step 308 is greater than the tempera surface texture and luster that provides an embroidered or ture at which the thermoplastic adhesive layer 120 softens in hand-stitched embroidered appearance. A preferred woven step 318. textile design medium can be a loosely, woven polyester with 0062. The final product 328 comprises adhesively joined increased Surface dimensionality or character, with or with assembly 228. The adhesively joined assembly 228 can also out a printed image. Such as a Sublimation dye printed image. be cut to form a decorative flocked transfer assembly 328. Exemplary heat transfers that can be modified by the present 0063. The optional backing material 220 may be then invention are Lextra 3DTM with Tackle Twill and Lextra 3D removed from the thermoplastic layer 120, to form a fourth NXTM, both sold by Fiberlok(R). In one configuration, the intermediate assembly 226. design medium 174 is formed from one or more polymeric 0064. In optional step 320, the free surface of the thermo light diffusing films. Such as polycarbonate and/or polyester plastic layer 120 of the fourth intermediate assembly 226 is light diffusion films sold under the trade names MakrofolTM contacted with an optional Substrate 124 to form an optional and/or BayfolTM. An exemplary heat transfer that may be assembly 238. Optional substrate 124 is provided by optional modified by the present invention is Lextra 3DTM with metal fourth roll 236. In optional step 324, the optional assembly lic textile design medium sold by FiberlokR). 238 is passed through an optional third laminating station 240 0067. The opposing side 176 of the insert 175 can be the where heat and pressure are applied to the assembly 238 to same as the design medium side 174 or it can differ, as for form a final product 328. In the optional station 240, the film example the opposing side 176 can be any adhesive material, 120 is preferably heated to a temperature of at least about 150 polymeric material, or other material adhered to or fabricated degrees F. and more preferably from about 175 to about 375 to the design medium side 174. degrees F. (or preferably above the softening point of the 0068. When the insert 175 is positioned in registration adhesive layer 120) while pressure (which depends on the with the cavity 173 it is contacted the thermosetting adhesive density of the flock fibers), preferably of at least about 1 psi 116 while the thermosetting adhesive 116 is in a substantially and more preferably ranging from about 5 to about 25 psi, is thermoplastic (that is A-staged) condition. While not wanting applied to the optional substrate 124 to cause the adhesive to be bound by theory, the A-staged thermosetting adhesive layer 120 containing the second part 132 to firmly contact and 116 is tacky and capable of substantially holding the insert in adhere to the substrate. As will be appreciated, the orientation registration with the cavity to form a second insert interme can be reversed, while the contact of the free surface of the diate (not depicted). The second insert intermediate is con adhesive layer 120 with the substrate is still maintained, such tacted with the thermoplastic adhesive film 216 in step 316. In that the carrier sheet 104 is on top and the optional substrate step 322 the thermosetting adhesive is bonded to the flock 124 on bottom in which case pressure is applied to the carrier fibers and to the insert 175 as described above in step 312 and sheet 104. In optional 240 laminating station, the adhesive the adhesive layer 120 is bonded to the thermosetting adhe layer 120 is heated for a time typically ranging from about 1 sive layer 116 and to the insert 175 as described above in step to about 60 seconds to where adhesive layer 120 is adhesively 318. It can be appreciated that the surface 174 of the insert 175 adhered to substrate 124 in flocked assembly 238 to from is substantially compatible with and capable of forming a flocked decorative article 328. It can be appreciated that substantially strong, permanent adhesive bond both with the flocked assembly 238 can be cut to form decorative flocked thermosetting adhesive 116. It can also be appreciated that the product 328 prior to or after laminating station 240. It can also first part 128 of the thermoplastic adhesive layer 120 is com be appreciated that substrate 124 can be pre-cut prior to patible with and capable of forming a substantially strong, contacting 320. permanent adhesive bond both with the surface 176 of the 0065. In another embodiment, in step 326 (FIG.3B) insert insert 175 and the cross-linked thermosetting adhesive 116. station 252 (FIG. 2B) removes a portion of the intermediate Stated another way, the lower surface 176 of the insert 175 138, to form an insert intermediate assembly 172 having a and adhesive 116 can have substantially the same or different, cavity 173 bordered by flock fibers, FIGS. 7 A-C. An insert compatible, Surface properties. 175, having a design medium side 174 and a second opposing 0069. It can be appreciated, that step 312 can optionally side 176, is positioned in registration with the cavity 173, occur within step 326. For example, step 312 can occur after depicted in FIG. 7D such that the design medium side 174 is a portion of intermediate 138 is removed to create the cavity bordered by the flocked fibers. 173 but prior to the second insert intermediate contacting the 0066. The design medium 174 can be any design media thermoplastic adhesive layer 216. including metallic or synthetic or natural polymeric design 0070 The thermal bonding processes of the thermosetting media, and can be woven or non-woven design media. adhesive 116 and the adhesive layer 120 in step 322 occur in Examples of design medium materials include reflective a fourth lamination station 242 to produce a flocked decora materials (such as those having a metallic sheen or luster), tive article 177 with the insert 175 surrounded by flock. textiles (such as a woven nylon or polyester material textile Optionally the flocked decorative article 177 can be attached and twill), a material containing a hologram or print image, to a substrate 124 in steps 320 and 324 to form the flocked and the like. In one configuration, the design medium 174 is decorative article 177 adhered to the substrate 124. an extremely durable, woven nylon textile that strongly (0071. A number of variations and modifications of the resembles embroidery. In another configuration, the design invention can be used. It would be possible to provide for medium 174 is a twill material. Another particularly preferred some features of the invention without providing others. design medium is an embossed or molded article, preferably 0072. In another alternative embodiment, the thermoset containing a permanently raised three-dimensional Surface or ting and/orthermoplastic adhesive layers are applied in liquid pattern in the textile material, such as but not limited to form rather than solid form. US 2008/O124503A1 May 29, 2008

0073. In yet another alternative embodiment flocked What is claimed is: assembly 134 can be the flock transfer assembly comprising 1. A method for manufacturing a decorative flocked article, a carrier sheet 104, release adhesive 108, flock layer 112 and comprising: a binder adhesive as disclosed by Abrams in U.S. Pat. No. (a) contacting a first adhesive with flock; and 4,810,549. (b) contacting an adhesive film with the first adhesive, the 0074. In yet another alternative embodiment, the flock is adhesive film comprising a first part in contact and com applied directly to the thermosetting layer 116 with or with patible with the first adhesive and a second part, the out an intermediate adhesive on the surface of the film 316 to second part being less compatible with the first adhesive hold the flock in position until the flock is pressed into the than the first part. softened thermosetting layer 116 in a lamination station. In 2. The method of claim 1, wherein the first and second parts one configuration, the thermosetting adhesive layer is heated have at least one differing property selected from the group to the point of being tacky (while still in the thermoplastic consisting of mechanical adhesion, dispersive adhesion, state) and the flock fibers electrostatically flocked into the chemisorption adhesion, electrostatic adhesion, diffusion tacky adhesive layer. The adhesive layer may then be heated adhesion, Solubility parameter, polarity and any combination to a higher temperature to soften further and cross-link the thereof. 3. The method of claim 2, wherein the at least one differing adhesive to the thermoset state while the flock fibers are property comprises having the first part forming an adhesive pushed into the softened adhesive. In this embodiment, steps bond with the first adhesive, the adhesive bond being stronger 304,308, 312,316, 320, 326, and 324 remain the same, and than an adhesive bond formed by the second part with the first the intermediate assembly does not have the carrier sheet 104 adhesive. and release adhesive 108 positioned on top of the flock layer 4. The method of claim 1, wherein a primary component of 112. the first part and a primary component of the second part 0075. The present invention, in various embodiments, differ in polarity. includes components, methods, processes, systems and/or 5. The method of claim 4, wherein the primary component apparatus Substantially as depicted and described herein, of the first part is a polar polymer and the primary component including various embodiments, Subcombinations, and Sub of the second part is a polymer that is less polar than the sets thereof. Those of skill in the art will understand how to primary component of the first part. make and use the present invention after understanding the 6. The method of claim 1, wherein the first adhesive is a present disclosure. The present invention, in various embodi thermosetting adhesive and the adhesive film is a thermoplas ments, includes providing devices and processes in the tic adhesive and wherein step (a) comprises the Substeps: absence of items not depicted and/or described herein or in (a1) fully activating the thermosetting adhesive to adhere various embodiments hereof, including in the absence of such permanently to the flock fibers; items as may have been used in previous devices or processes, (a2) contacting the fully activated thermosetting adhesive e.g., for improving performance, achieving ease and\or of substep (a1) with the thermoplastic adhesive, wherein reducing cost of implementation. the thermosetting adhesive is positioned between the 0076. The foregoing discussion of the invention has been flock fibers and the thermoplastic adhesive; and presented for purposes of illustration and description. The (a3) heating the thermoplastic adhesive to adhere the ther foregoing is not intended to limit the invention to the form or moplastic adhesive to the thermosetting adhesive. forms disclosed herein. In the foregoing Detailed Description 7. The method of claim 6, wherein step (a) further com for example, various features of the invention are grouped prises after substep (a1) and before substep (a2): together in one or more embodiments for the purpose of (b1) removing at least a portion of the decorative flocked streamlining the disclosure. This method of disclosure is not article to create a cavity surrounded by flock; and to be interpreted as reflecting an intention that the claimed (b2) positioning and adhering an insert in registration with invention requires more features than are expressly recited in the cavity, wherein a first surface of the insert is sur each claim. Rather, as the following claims reflect, inventive rounded by flock, and wherein the opposing second aspects lie in less than all features of a single foregoing surface of the insert is free for contacting the thermo disclosed embodiment. Thus, the following claims are hereby plastic adhesive in Substep (a2) and adhering the ther incorporated into this Detailed Description, with each claim moplastic adhesive to one or more of the thermosetting standing on its own as a separate preferred embodiment of the adhesive and the insert during heating Substep (a3). invention. 8. The method of claim 6, wherein a first surface of the 0077 Moreover, though the description of the invention flock fibers is adhered to a release adhesive, the release adhe has included description of one or more embodiments and sive being adhered to a carrier sheet and an opposing second certain variations and modifications, other variations and surface of the flock fibers is adhered to the thermosetting modifications are within the scope of the invention, e.g., as adhesive; wherein the thermosetting and thermoplastic adhe may be within the skill and knowledge of those in the art, after sives, prior to step (a), are each in the form of a pre-formed, understanding the present disclosure. It is intended to obtain self-supporting Solid film; wherein the thermosetting adhe rights which include alternative embodiments to the extent sive is attached to a backing sheet; wherein the backing sheet permitted, including alternate, interchangeable and/or of the thermosetting adhesive film is removed before step (b) equivalent structures, functions, ranges or steps to those to provide a surface for adhering to the thermoplastic adhe claimed, whether or not such alternate, interchangeable and/ sive film; and wherein step (b) further comprises optimally or equivalent structures, functions, ranges or steps are dis contacting the second part with a Substrate, and wherein the closed herein, and without intending to publicly dedicate any second part being more compatible with the substrate than the patentable Subject matter. first part. US 2008/O124503A1 May 29, 2008

9. The method of claim 8, wherein at least one of the 15. The article of claim 14, wherein the first and second following is true when the thermosetting adhesive is heated: parts have at least one differing property selected from the (i) the thermosetting adhesive is more viscous than the group consisting of mechanical adhesion, dispersive adhe thermoplastic adhesive film; and Sion, chemisorption adhesion, electrostatic adhesion, diffu (ii) the softening point of the thermosetting adhesive film is sion adhesion, Solubility parameters, polarity and any com greater than the softening point of the thermoplastic bination thereof. 16. The article of claim 15, wherein the at least one differ adhesive film. ing property comprises having the first part forming an adhe 10. The method of claim 1, wherein the first and second sive bond with the first adhesive, the adhesive bond being parts are co-extruded; wherein the first and second parts are stronger than an adhesive bond formed by the second part substantially immiscible when melted; and wherein the first with the first adhesive. and second parts are Substantially permanently adhesively 17. The article of claim 14, wherein a primary component joined. of the first part and a primary component of the second part 11. The decorative flocked article manufactured by the differ in polarity. steps of claim 1. 18. The method of claim 17, wherein the primary compo 12. A method, comprising: nent of the first part is a polar polymer and the primary (a) contacting a first Surface of a thermosetting adhesive component of the second part is a polymer that is less polar having a first and second opposing Surfaces with flock; than the primary component of the first part. (b) at least Substantially fully activating the thermosetting 19. The article of claim 14, wherein the flock layer is adhesive to adhere permanently the flock and thermo permanently adhered to the fully activated thermosetting setting adhesive; and adhesive layer; and wherein the thermoplastic adhesive is (c) thereafter contacting the second Surface of the thermo permanently adhered to the thermosetting adhesive layer. setting adhesive with a thermoplastic adhesive to form a 20. The article of claim 19, further comprising: flocked article, wherein the thermoplastic adhesive has a (d) a cavity surrounded by the flocked layer; and first parta second part, wherein the first and second parts (e) an insert positioned in registration with the cavity and have at least one differing property selected from the positioned between the fully activated thermosetting group consisting of mechanical adhesion, dispersive adhesive layer and the thermoplastic adhesive layer. adhesion, chemisorption adhesion, electrostatic adhe 21. The article of claim 14, wherein a first surface of the sion, diffusion adhesion, Solubility parameters, polarity flock layer is adhered to a release adhesive, the release adhe and any combination thereof. sive being adhered to a carrier sheet and an opposing second 13. The method of claim 12, wherein at least one of the surface of the flock layer is adhered to the thermosetting following is true for the at least one differing property of the adhesive layer, and wherein the thermosetting and thermo first part: plastic adhesive layers are each pre-formed, self-supporting (i) the first is more compatible than the second part with the solid films. thermosetting; 22. The article of claim 14, wherein at least one of the following is true for the thermosetting adhesive layer: (ii) the first forms an adhesive bond with the thermosetting (i) when heated the thermosetting layer is more Viscous adhesive than second part; than the thermoplastic adhesive layer, and (iii) the polarity of the first part is more compatible with the (ii) the softening point of the thermosetting adhesive film is thermosetting adhesive than the second part; and greater than the softening point of the thermosetting (iv) the first part is less compatible with a substrate than the adhesive layer. second part. 23. The article of claim 14, wherein the first and second 14. A flocked decorative article, comprising: parts are co-extruded; wherein the first and second parts are (a) a flock layer, substantially immiscible when melted; and wherein the first (b) a fully activated thermosetting adhesive layer; and and second parts remain Substantially permanently adhe (c) a thermoplastic adhesive layer having a first part and a sively joined. second part, the first part of the thermoplastic adhesive 24. The article of claim 14, further comprising: layer being bonded to the thermosetting adhesive layer, (f) the second part of the thermoplastic layer being bonded the thermosetting adhesive layer being positioned to a substrate. between the flock layer and the thermoplastic adhesive layer.