In-mold direct decorative transfers and process

Abstract

Decorative transfers that can be directly applied to a mold surface during the molding process are created. The decorative transfers include an uppermost intermediate layer that includes a tacky resin. The decorative transfers also include inks that specify a desired image. Tacky inks and/or tack-free inks are used in the decorative transfers. Preferred decorative transfers include crosslinkable polymers in all of the intermediate layers.

1 . A decorative transfer comprising a backing and one or more intermediate layers disposed on the inner surface of the backing, wherein the one or more intermediate layers comprise an ink film and a tacky resin.  
     
     
         2 . The decorative transfer of  claim 1  wherein the one or more intermediate layers comprise two intermediate layers, the first intermediate layer comprising an ink film on the inner surface of the backing and the second intermediate layer comprising a clear gel coat layer over the ink film, the clear gel coat layer comprising the tacky resin.  
     
     
         3 . The decorative transfer of  claim 2  wherein the clear gel coat layer comprises an unsaturated polyester resin.  
     
     
         4 . The decorative transfer of  claim 1  wherein the ink film comprises an unsaturated polyester resin.  
     
     
         5 . The decorative transfer of  claim 4  wherein a protective release liner is disposed over the one or more intermediate layers.  
     
     
         6 . The decorative transfer of  claim 2  wherein the ink film and the clear gel coat layer both comprise unsaturated polyester resin.  
     
     
         7 . The decorative transfer of claim wherein the clear gel coat layer and the ink film both comprise isopthallic/Neopentyl glycol™ resin.  
     
     
         8 . The decorative transfer of  claim 1  wherein the one or more intermediate layers comprises on intermediate layer forming the ink film, the ink film comprising the tacky resin.  
     
     
         9 . The decorative transfer of  claim 8  wherein the ink film comprises one or more pigments and is substantially free of other tack reducers.  
     
     
         10 . The decorative transfer of  claim 8  wherein the ink film comprises between about 1.0 percent by weight of tack reducers and about 10 percent by weight of tack reducers.  
     
     
         11 . The decorative transfer of  claim 1  comprising two intermediate layers, the first intermediate layer comprising a color gel coat layer on the inner surface of the backing and a second intermediate layer comprising the ink film having the tacky resin.  
     
     
         12 . A process of providing a decorative transfer comprising applying one or more intermediate layers to the inner surface of a backing, the one or more intermediate layers comprising an ink and a polymer base that becomes tacky upon drying.  
     
     
         13 . The process of  claim 12  wherein two intermediate layers are applied, the first intermediate layer comprising the ink film on the inner surface of the backing and the second intermediate layer comprising a clear outer gel coat layer is applied over the ink film, wherein the clear outer gel coat comprises the polymer base that becomes tacky upon drying.  
     
     
         14 . The process of  claim 12  further comprising placing a protective release liner over the one or more intermediate layers when the polymer base becomes tacky.  
     
     
         15 . The process of  claim 14 , wherein the ink film comprises substantially tack-free resin.  
     
     
         16 . The process of  claim 13 , wherein the clear outer gel coat layer comprises unsaturated polyester resin.  
     
     
         17 . The process of  claim 13  wherein the clear outer gel coat layer and the ink film both comprise unsaturated polyester resin.  
     
     
         18 . The process of  claim 12  wherein one intermediate layer is applied, the intermediate layer comprising the ink film wherein the polymer base of the ink film becomes tacky upon drying.  
     
     
         19 . The process of  claim 12  wherein two intermediate layers are applied, the first intermediate layer comprising a color gel coat layer is applied to the inner surface of the backing and the second intermediate layer comprising the ink film is applied over the color gel coat, wherein the ink film of the image comprises the polymer base that becomes tacky upon drying.  
     
     
         20 . The process of  claim 19 , wherein the color gel coat layer comprises substantially tack-free resin.  
     
     
         21 - 35  (Canceled)  
     
     
         36 . The process of claim  21  wherein the decorative transfer comprises one intermediate layer, the one intermediate layer comprising the ink film, wherein the ink film comprises the tacky resin.  
     
     
         37 . The process of claim  21  wherein the decorative transfer comprises two intermediate layers, the first layer comprising a color gel coat layer on the inner surface of the backing and the second intermediate layer comprising an ink film, wherein the ink film comprises the tacky resin that is contacted with the mold surface.  
     
     
         38 . The process of  claim 37  wherein the color gel coat layer comprises a substantially tack-free resin.