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N132 124 Patent Application Publication May 29, 2008 Sheet 1 of 8 US 2008/O124503A1

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N132 124 Patent Application Publication May 29, 2008 Sheet 1 of 8 US 2008/O124503A1 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. 177 104 108 IZI 112 1 16 175 128 120 -------------------------------N132 124 Patent Application Publication May 29, 2008 Sheet 1 of 8 US 2008/O124503A1 Patent Application Publication May 29, 2008 Sheet 2 of 8 US 2008/O124503A1 puOOÐS 832 Osée 9!8 Patent Application Publication May 29, 2008 Sheet 3 of 8 US 2008/O124503A1 ZOZ 829 88] i„”„~~~~)S |„*“(§93Z,! r-~~<-----------*---->-*---- r-----------------|---------; Patent Application Publication May 29, 2008 Sheet 4 of 8 US 2008/O124503A1 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 312 Material From a as . m . al Adhesive Film Fig. 3A Patent Application Publication May 29, 2008 Sheet 5 of 8 US 2008/O124503A1 300 PrOWide Flocked Bond Thermosetting 322 Carrier Sheet And Bicomponent Adhesives COntact Flocked 3O4 Carrier Sheet A Contact With ThermoSet Bicomponent - 32O Adhesive Film Adhesive Film with Substrate Remove Backing 312 Material From Heat Assembly 324 Adhesive Film to BOnd Bicomponent to Substrate p Make Cavity for 326 insert and POSition Insert in Cavity Final 328 Product Contact Thermoset 316 Adhesive With Bicomponent Adhesive Film Fig. 3B Patent Application Publication May 29, 2008 Sheet 6 of 8 US 2008/O124503A1 1. 138 134 226 134 Patent Application Publication May 29, 2008 Sheet 7 of 8 US 2008/O124503A1 Fig. 7B 17 '' Fig. 7c Patent Application Publication May 29, 2008 Sheet 8 of 8 US 2008/O124503A1 US 2008/O124503A1 May 29, 2008 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 adhesion 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 polymer, 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, hydrogen 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.
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