# US 7,465,485 B2 · Process for dimensionalizing flocked articles or wear, wash and abrasion resistant flocked articles > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 7,465,485 B2 - Document ID: US7465485B2 - Status: Granted - Kind: B2 - Application number: 11/000,672 - Filed: 2004-11-30 - Published: 2005-07-21 - Granted: 2008-12-16 - Earliest claimed: 2003-12-23 - Assignees: High Voltage Graphics, Inc. - Inventors: Louis Brown Abrams - Web page: https://patentgrep.com/patent/US7465485B2 ## CPC - B32B 27/06: as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08)} - B32B 7/12: using interposed adhesives or interposed materials with bonding properties - B32B 27/00: Layered products comprising {a layer of} synthetic resin {(fibrous or filamentary layer made of a synthetic resin B32B5/02; particulate layer made of a synthetic resin B32B5/16; foamed layer made of a synthetic resin B32B5/18)} - B32B 27/365: {comprising polycarbonates} - B32B 38/06: Embossing - B44C 1/105: {comprising an adhesive layer (decalcomania B44C1/16; adhesive tapes C09J7/20)} - B32B 37/12: characterised by using adhesives - B32B 37/20: involving the assembly of continuous webs only - B32B 2305/22: Fibres of short length - B32B 2451/00: Decorative or ornamental articles - Y10T 428/14: Layer or component removable to expose adhesive - Y10T 428/1476: Release layer - Y10T 428/23929: Edge feature or configured or discontinuous surface - Y10T 428/23936: Differential pile length or surface - Y10T 428/23943: Flock surface - Y10T 428/23979: Particular backing structure or composition - Y10T 428/23993: Composition of pile or adhesive - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - B44C: PRODUCING DECORATIVE EFFECTS (processes for applying liquids or other fluent materials to surfaces, in general B05D; shaping of plastics or substances in a plastic state B29C; printing processes to produce transfer pictures B41M3/12; thermographic duplication or marking methods B41M5/00); MOSAICS; TARSIA WORK (imitation of mosaic or tarsia work patterns B44F11/04); PAPERHANGING {(labels G09F; multi-step processes for making paper labels or tags B31D1/02)} - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract In one embodiment, a method for producing a decorative article, comprising: (a) providing a flocked surface, the flocked surface comprising a plurality of flock fibers and an activatable adhesive, wherein the activatable adhesive is less than 50% activated; (b) dimensionalizing the plurality of flock fibers, such that a first set of fibers is embedded to a greater distance in the activatable adhesive than a second set of fibers; and (c) after dimensionalizing, at least substantially fully activating the activatable adhesive to form the decorative article. ## Claims ### Claim 1 An article manufactured by steps comprising: (a) providing a flocked surface, the flocked surface comprising a plurality of flock fibers and a pre-formed, self-supporting, solid, and thermosetting adhesive film, the thermosetting adhesive film being in a reversible state: (b) dimensionalizing the plurality of flock fibers to form compressed and uncompressed fibers, wherein the compressed fibers are embedded to a greater distance in the thermosetting adhesive film than the uncompressed fibers; and wherein the compressed and uncompressed fibers form a three-dimensional and pre-determined design; and (c) after dimensionalizing, activating the thermosetting to an irreversible state, the activated thermosetting adhesive film permanently locking the compressed and uncompressed fibers in position and form the decorative article. ### Claim 2 (depends on 1) The article of claim 1, wherein the uncompressed fibers are substantially orthogonal to the adhesive film. ### Claim 3 (depends on 1) The article of claim 1, wherein the article comprises flocked and unflocked surface areas and wherein flocked surface areas have a flock density of at least about 100,000 flock fibers per square inch. ### Claim 4 (depends on 1) The article of claim 1, wherein the providing step (a) comprises: (A1) providing a transfer, comprising the plurality of flock fibers having first and second opposing ends, wherein the first ends are adhered to a release adhesive coated on a carrier sheet; (A2) providing a cast or extruded film of the thermosetting adhesive; and (A3) heating and softening the film under pressure to embed the second opposing flock fiber ends of the transfer. ### Claim 5 (depends on 4) The article of claim 4, wherein the dimensionalizing step (b) further comprises: (B2) compressing selected flock fibers under pressure by air-embossing or contacting with a dimensionalizing die or roller, wherein the pressure applied to the compressed fibers is at least more than the pressure applied to the uncompressed fibers, and wherein the contacting comprises contacting the carrier sheet with the dimensionalizing die or roller. ### Claim 6 (depends on 1) The article of claim 1, wherein the flocked surface comprises a rigid or semi-rigid support layer, with the thermosetting adhesive film being located between the support layer and flock and further comprising, after the thermosetting adhesive is fully activated: (d) applying a second adhesive to the support layer, such that the support layer is positioned between the thermosetting adhesive film and second adhesive. ### Claim 7 The article of 6, wherein the support layer has the following properties: (i) a specific gravity of at least about 0.75; and (ii) a thickness of at least about 5 mil. ### Claim 8 (depends on 1) The article of claim 1, wherein the dimensionalizing step (b) further comprises: (B1) compressing selected flock fibers under pressure by air-embossing or contacting with a dimensionalizing die or roller, and wherein the pressure applied to the compressed fibers is at least more than the pressure applied to the uncompressed fibers. ### Claim 9 (depends on 1) The article of claim 1, wherein at least 75% of the flock fibers have the following properties: (i) a denier of about 5 or less; and (ii) a length of about 4 mm or less. ### Claim 10 (depends on 1) The article of claim 1, wherein the thermosetting adhesive is selected from the group consisting of a polyurethane, a polyester, and a mixture thereof. ### Claim 11 An intermediate decorative product, comprising: (a) a plurality of compressed and uncompressed flock fibers; and (b) a thermosetting adhesive film, wherein the thermosetting adhesive is in a reversible state, wherein the compressed fibers are embedded to a greater distance in the thermosetting adhesive film than the uncompressed fibers; and wherein the compressed and uncompressed fibers form a three-dimensional and selected design. ### Claim 12 (depends on 11) The intermediate decorative product of claim 11, wherein the uncompressed fibers are substantially orthogonal to the adhesive film. ### Claim 13 (depends on 11) The intermediate decorative product of claim 11, wherein the article comprises flocked and unflocked surface areas and wherein flocked surface areas have a flock density of at least about 100,000 flock fibers per square inch. ### Claim 14 (depends on 11) The intermediate decorative product of claim 11, further comprising: (c) a carrier sheet; and (d) a release adhesive adhering the flock fibers to the carrier sheet, wherein the flock fibers are positioned between the thermosetting adhesive film and carrier sheet. ### Claim 15 (depends on 11) The intermediate decorative product of claim 11, further comprising: (e) a rigid or semi-rigid support layer, wherein the thermosetting adhesive film is positioned between the flock fibers and the support layer. ### Claim 16 (depends on 15) The intermediate decorative product of claim 15, wherein the support layer has following properties: (i) a specific gravity of at least about 0.75; and (ii) a thickness of at least about 5 mil. ### Claim 17 (depends on 11) The intermediate decorative product of claim 11, wherein the thermosetting adhesive is selected from the group consisting of a polyurethane, a polyester, and a mixture thereof. ### Claim 18 (depends on 11) The intermediate decorative product of claim 11, wherein selected flock fibers are compressed under pressure by air-embossing or contacted with a dimensionalizing die or roller, and wherein the pressure applied to the compressed fibers is at least more than the pressure applied to the uncompressed fibers. ### Claim 19 (depends on 11) The intermediate decorative product of claim 11, wherein at least 75% of the flock fibers have the following properties: (i) a denier of about 5 or less, and (ii) a length of about 4 mm or less. ### Claim 20 A decorative product, comprising: (a) a plurality of compressed and uncompressed flock fibers; and (b) a thermosetting adhesive film, wherein the thermosetting adhesive film is in the irreversible state, wherein the compressed fibers are embedded to a greater distance in the thermosetting adhesive film than the uncompressed fibers; and wherein the compressed and uncompressed fibers form a three-dimensional and controlled design. ### Claim 21 (depends on 20) The decorative product of claim 20, wherein the uncompressed fibers are substantially orthogonal to the adhesive film. ### Claim 22 (depends on 20) The decorative product of claim 20, wherein the article comprises flocked and unflocked surface areas and wherein flocked surface areas have a flock density of at least about 100,000 flock fibers per square inch. ### Claim 23 (depends on 20) The product of claim 20, further comprising: (c) a carrier sheet; and (d) a release adhesive adhering the flock fibers to the carrier sheet, wherein the flock fibers are positioned between the thermosetting adhesive film and carrier sheet. ### Claim 24 (depends on 20) The product of claim 20, further comprising: (e) a rigid or semi-rigid support layer, wherein the thermosetting adhesive film is positioned between the flock fibers and the support layer. ### Claim 25 (depends on 24) The product of claim 24, wherein the support layer has the following properties: (i) a specific gravity of at least about 0.75; and (ii) a thickness of at least about 5 mil. ### Claim 26 (depends on 20) The decorative product of claim 20, wherein the thermosetting adhesive is selected from the group consisting of a polyurethane, a polyester, and a mixture thereof. ### Claim 27 (depends on 20) The decorative product of claim 20, wherein the flock fibers are compressed under pressure by air-embossing or contacted with a dimensioanlizing die or roller, and wherein the pressure applied to the compressed fibers is at least more than the pressure applied to the uncompressed fibers. ### Claim 28 (depends on 20) The decorative product of claim 20, wherein at least 75% of the flock fibers have the following properties: (i) a denier of about 5 or less; and (ii) a length of about 4 mm or less.