Flocked transfer and article of manufacture including the application of the transfer by thermoplastic polymer film

Abstract

A flocked transfer is produced by applying a release agent to a release sheet, and then applying the flocking to a release agent. Unlike the traditional method, a binder and thermoplastic hot melt film is applied to the back of the flock. The transfer, which is essentially release sheet, is then applied to a substrate, such as item of clothing, a rubber pad, etc., by positioning a sheet of thermoplastic hot melt film on the substrate; placing the transfer on the hot melt with the flock in contact with the hot melt film, and applying heat and pressure. The heat melts the thermoplastic hot melt film to bind the flock to the substrate and binds the flocking together. This method reduces the cost involved in producing flocked articles, especially for articles produced on a continuous basis.

1 - 23 . (canceled) 
   
   
       24 . An article, comprising:
 (a) a flocked release sheet, comprising flock fibers, a release sheet, a release adhesive adhered to the release sheet, and a plurality of flock fibers, with the flock fibers being adhered to the release sheet by the release adhesive; and   (b) the plurality of flock fibers in contact with a pre-formed, solid, and self-supporting dual laminated film having first and second portions, with the flock fibers being substantially perpendicular to an adjacent surface of the pre-formed, solid, and self-supporting dual laminated film and the flock fibers being positioned between the release sheet and release adhesive one hand and the pre-formed, solid, and self-supporting dual laminated film on the other, wherein the flock fibers are positioned on the first portion.   
   
   
       25 . The article of  claim 24 , wherein the first and second portions have differing chemical compositions. 
   
   
       26 . The article of  claim 25 , wherein the first and second portions comprise thermoplastics. 
   
   
       27 . The article of  claim 24 , wherein the first and second portions have differing properties. 
   
   
       28 . The article of  claim 27 , wherein the first and second portions have differing melting points. 
   
   
       29 . The article of  claim 28 , wherein the second portion is in contact with a substrate and wherein the first portion has a higher melting point than the second portion. 
   
   
       30 . The article of  claim 27 , wherein the first and second portions have differing viscosities. 
   
   
       31 . The article of  claim 30 , wherein the first portion is in contact with the flock fibers and wherein the second portion is in contact with a substrate and wherein the first portion has a higher viscosity than the second portion. 
   
   
       32 . The article of  claim 24 , wherein the first portion comprises a polyurethane and wherein at least most of the flock is in direct contact with the first portion. 
   
   
       33 . The article of  claim 24 , wherein the second portion is in contact with a substrate. 
   
   
       34 . The article of  claim 24 , wherein there is no binder adhesive in contact with the pre-formed, solid, and self-supporting dual laminated adhesive film. 
   
   
       35 . The article of  claim 24 , wherein at least most of the flock is in direct contact with the first portion. 
   
   
       36 . The article of  claim 24 , wherein the second portion comprises a polyurethane and wherein the second portion is in contact with a substrate. 
   
   
       37 . The article of  claim 24 , wherein the first and second portion comprise polyurethanes and wherein the first and second portions differ in one or both of melting points and viscosities. 
   
   
       38 . The article of  claim 37 , wherein the first and second portions differ in one or both of properties and chemical composition. 
   
   
       39 . An article of manufacture, comprising:
 (a) a release sheet;   (b) a release adhesive deposited on the release sheet;   (c) flock fibers, a first surface of the fibers being adhered to the release adhesive; and   (d) a thermoplastic two-part adhesive layer adhered to a second surface of the fibers, a first part of the adhesive layer having at least one different property from a second part of the adhesive layer, wherein the first part of the adhesive layer is in contact with the second surface of the fibers.   
   
   
       40 . The article of  claim 39 , wherein the different property is chemical composition. 
   
   
       41 . The article of  claim 39 , wherein the first and second parts have differing melting points. 
   
   
       42 . The article of  claim 41 , wherein the first part has a higher melting point than the second part. 
   
   
       43 . The article of  claim 39 , wherein the first and second parts have differing viscosities. 
   
   
       44 . The article of  claim 43 , wherein the first part has a higher viscosity than the second part.