Flocked articles having noncompatible insert and porous film

Abstract

The present invention is directed to flocked articles comprising a metallized film and methods of manufacturing such articles.

What is claimed is: 
     
       1. A method, comprising:
 (a) providing a flock transfer, the flock transfer comprising a carrier sheet, a release adhesive, and a flock layer, a first surface of the flock layer being adhered to the carrier sheet by the release adhesive; 
 (b) applying a first permanent adhesive to a second surface of the flock layer to form a transfer assembly, the first and second surfaces being in an opposing relationship with one another; 
 (c) thereafter, removing a selected portion of the flock layer from at least one of the flock transfer and transfer assembly to form a void; 
 (d) positioning an insert substantially in the void of the transfer assembly, wherein the insert and the transfer assembly are positioned on a first substrate surface of a common substrate; and 
 (e) adhering the transfer assembly and insert to the first substrate surface. 
 
     
     
       2. The method of  claim 1 , wherein the insert comprises a design and a lamination adhesive positioned between first and second polymeric films. 
     
     
       3. The method of  claim 1 , wherein the insert is adhered to the common substrate before the transfer assembly is adhered to the common substrate and wherein the insert and transfer assembly are not adhered to one another before step (e). 
     
     
       4. The method of  claim 1 , wherein the common substrate is larger than the insert, the common substrate provides an overlapping edge and wherein step (d) comprises the sub-step of applying a tack adhesive to the overlapping edge, and wherein the overlapping edge contacts the second surface of the flock. 
     
     
       5. The method of  claim 1 , wherein a second permanent adhesive is positioned between the insert an and a first surface of the common substrate, and further comprising:
 (f) applying a third permanent adhesive to a second surface of the common substrate, the first and second surfaces of the common substrate being in an opposing relationship. 
 
     
     
       6. The method of  claim 4 , wherein the tack adhesive applied is a thermosetting adhesive. 
     
     
       7. A method, comprising:
 (a) providing a flock transfer, the flock transfer comprising a carrier sheet, a release adhesive, and a flock layer, a first surface of the flock layer being adhered to the carrier sheet by the release adhesive; 
 (b) applying a first permanent adhesive to a second surface of the flock layer to form a transfer assembly, the first and second surfaces being in an opposing relationship with one another; 
 (c) thereafter, removing a selected portion of the flock layer from at least one of the flock transfer and transfer assembly to form a void; 
 (d) positioning an insert substantially in the void of the transfer assembly, wherein the insert and the transfer assembly are positioned on a first surface of a common porous film substrate; and 
 (e) adhering the transfer assembly and insert to the first porous film common substrate surface. 
 
     
     
       8. The method of  claim 7 , wherein the insert comprises a design and a lamination adhesive positioned between first and second polymeric films. 
     
     
       9. The method of  claim 7 , wherein the insert is adhered to the porous film common substrate before the transfer assembly is adhered to the porous film common substrate and wherein the insert and transfer assembly are not adhered to one another before step (e). 
     
     
       10. The method of  claim 7 , wherein the porous film common substrate is larger than the insert, the porous film common substrate provides an overlapping edge and wherein step (d) comprises the sub-step of applying a tack adhesive to the overlapping edge, and wherein the overlapping edge contacts the second surface of the flock. 
     
     
       11. The method of  claim 7 , wherein a second permanent adhesive is positioned between the insert an and a first surface of the porous film common substrate, and further comprising:
 (f) applying a third permanent adhesive to a second surface of the porous film common substrate, the first and second surfaces of the porous film common substrate being in an opposing relationship. 
 
     
     
       12. The method of  claim 10 , wherein the tack adhesive applied is a thermosetting adhesive. 
     
     
       13. The method of claim 1, wherein the first permanent adhesive is a thermosetting adhesive.  
     
     
       14. The method of claim 1, wherein a thermoplastic hot melt adhesive is positioned between the insert and a first surface of the common substrate.  
     
     
       15. The method of claim 1, wherein flock layer and the insert are positioned side-by-side.  
     
     
       16. The method of claim 1, wherein the first surface of the flock is positioned above the insert and wherein the insert and flock layer are adhered to the first substrate surface.  
     
     
       17. The method of claim 7, wherein the first permanent adhesive is a thermosetting adhesive.  
     
     
       18. The method of claim 7, wherein a thermoplastic hot melt adhesive is positioned between the insert and a first surface of the common substrate.  
     
     
       19. The method of claim 7, wherein flock layer and the insert are positioned side-by-side.  
     
     
       20. The method of claim 7, wherein the first surface of the flock is positioned above the insert and wherein the insert and flock layer are adhered to the first substrate surface.