AU2016202954A1 - Improved Method for Transferring Images to Powder Coated Objects by Sublimation - Google Patents
Improved Method for Transferring Images to Powder Coated Objects by Sublimation Download PDFInfo
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- AU2016202954A1 AU2016202954A1 AU2016202954A AU2016202954A AU2016202954A1 AU 2016202954 A1 AU2016202954 A1 AU 2016202954A1 AU 2016202954 A AU2016202954 A AU 2016202954A AU 2016202954 A AU2016202954 A AU 2016202954A AU 2016202954 A1 AU2016202954 A1 AU 2016202954A1
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- powder coated
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Abstract
A method for transferring an image to an object, comprising the steps of: (a) providing an electrically conductive object to which the image is to be transferred, (b) applying a coloured powder coating to a surface of the object to a thickness of from about 40 microns to about 60 microns at room temperature to form a coloured powder coating layer, (c) partially curing the coloured powder coating layer in a heating device for about 6 to about 10 minutes whilst the temperature of the object is between about 1800 C and about 2000 C to form a coloured partly cured powder coated layer, (d) applying a clear coat powder coating to the coloured partly cured powder coated layer to a thickness of from about 60 microns to about 100 microns at room temperature to form a clear coat powder coating layer over the underlying coloured partly cured powder coated layer, (e) fully curing, but not over curing, the clear coat powder coating layer and the underlying coloured partly cured powder coated layer together in a heating device for about 15 to about 25 minutes whilst the temperature of the object is between about 2000 C and about 2100 C to enable complete polymerisation to occur, and so form a powder coated surface of the object having a clear coat powder coated outer layer, (f) providing a sublimation transfer medium on which is printed with sublimable inks a desired image which is to be transferred to the powder coated surface, (g) placing the sublimation transfer medium against the powder coated surface and applying a pressure between the sublimation transfer medium and the powder coated surface so as to adhere the medium tightly to the surface, (h) heating the sublimation transfer medium and the powder coated surface, whilst under pressure, in an oven until a sublimation temperature of the inks is reached, whereupon the desired image is transferred to the clear coat powder coated outer layer of the powder coated surface, and then removing the medium and the powder coated surface from the oven, and (i) releasing the pressure and allowing the sublimation transfer medium and the object to cool sufficiently, before removing the medium from the object, leaving the desired image in the powder coated surface.
Description
1 2016202954 06 May 2016
IMPROVED METHOD FOR TRANSFERRING IMAGES TO POWDER COATED OBJECTS BY SUBLIMATION TECHNICAL FTETD 5
The present invention relates to an improved method for transferring images, for both functional and artistic purposes, by the process of sublimation to powder coated objects, particularly to metal or alloy sheet objects, such as aluminium kitchen splashbacks, metal or alloy castings, and elongated structural panels and extrusions that can be used 10 in building, for example in the areas of building design, furnishing and construction. Some specific uses may include wet area linings, interior linings, ceilings, building facades, perforated panels, signage, window frames, shutters and doors.
In particular, the present invention relates to a method that enables a flat surface or a 15 three dimensional surface of powder coated objects to have transferred thereto an image printed with sublimable inks or dyes on a film, paper or other thin and flexible medium and transferred to the surface by a sublimation process.
The method according to the invention enables any type of image, such as words, 20 designs, photographic images of city skylines and patterns that reproduce the veining of wood or marble, to be transferred to the objects.
BACKGROUND ART 25 The process of powder coating is well known and generally involves spraying a dry, fine powder, usually made up of a melt blend of resins, pigments and curing agents but with no liquid carrier or solvent, directly onto an electrically conductive surface under suitable electrostatic conditions, and then curing the resulting coating with heat to cause it to flow and fuse into a smooth powder coated surface. 30 06/05/16 2 2016202954 06 May 2016
Sublimation is a process which involves the change of state or transition of a sublimable substance from the solid phase to the vapour phase, without passing through the liquid phase, by providing the substance with heat up to a temperature necessary for the process to occur. 5
The sublimation process, when applied to a method for transferring images to powder coated objects, uses a sublimation transfer medium, such as a thin and flexible film or paper that withstands high temperatures of about 250° C without spoiling, is impermeable to air (either when used alone or when combined with an air impermeable 10 material), and has printed on it with sublimable inks or dyes an image, such as a decorative design. For the purposes of this specification and claims, inks, dyes and any other colouring substance used in sublimation will all be referred to herein as inks.
In order to transfer the image from, say, the film to an object, all of the surfaces of the 15 object to be imaged are wrapped in the film (with the image being on a side of the film facing the surfaces), and a force is applied to keep the film tightly adhered to the surfaces.
The object wrapped in the film is then heated, such as in an oven, kiln or other heating 20 device, until it reaches a preset temperature at which the inks sublimate, allowing the inks, now exerting a vapour pressure, to penetrate the surfaces of the object and transfer the image thereto.
Although the aforementioned general method for transferring images to powder coated 25 objects by sublimation is known and has been successfully employed in various forms, there are still aspects of the method which, in practice, are problematic and may lead to an unsatisfactory outcome
Furthermore, the process of powder coating an object for the purpose of subsequent 30 transfer of an image thereto by sublimation also includes aspects which are problematic and may lead to poor image transfer or poor quality or durability of the imaged object. 06/05/16 3 2016202954 06 May 2016
DISCLOSURE OF INVENTION
It is, therefore, an object of the present invention to overcome or substantially ameliorate the disadvantages and problems of the aforementioned prior art method, or 5 at least provide a useful alternative.
According to a first aspect of the present invention, there is provided a method for transferring an image to an object, comprising the steps of: (a) providing an electrically conductive object to which the image is to be 10 transferred, (b) applying a coloured powder coating to a surface of the object to a thickness of from about 40 microns to about 60 microns at room temperature to form a coloured powder coating layer, (c) partially curing the coloured powder coating layer in a heating device for 15 about 6 to about 10 minutes whilst the temperature of the object is between about 180° C and about 200° C to form a coloured partly cured powder coated layer, (d) applying a clear coat powder coating to the coloured partly cured powder coated layer to a thickness of from about 60 microns to about 100 microns at room temperature to form a clear coat powder coating layer over the underlying coloured 20 partly cured powder coated layer, (e) fully curing, but not over curing, the clear coat powder coating layer and the underlying coloured partly cured powder coated layer together in a heating device for about 15 to about 25 minutes whilst the temperature of the object is between about 200° C and about 210° C to enable complete polymerisation to occur, and so form a powder 25 coated surface of the object having a clear coat powder coated outer layer, (f) providing a sublimation transfer medium on which is printed with sublimable inks a desired image which is to be transferred to the powder coated surface, (g) placing the sublimation transfer medium against the powder coated surface and applying a pressure between the sublimation transfer medium and the powder 30 coated surface so as to adhere the medium tightly to the surface, 06/05/16 4 2016202954 06 May 2016 (h) heating the sublimation transfer medium and the powder coated surface, whilst under pressure, in an oven until a sublimation temperature of the inks is reached, whereupon the desired image is transferred to the clear coat powder coated outer layer of the powder coated surface, and then removing the medium and the powder coated 5 surface from the oven, and (i) releasing the pressure and allowing the sublimation transfer medium and the object to cool sufficiently, before removing the medium from the object, leaving the desired image in the powder coated surface. 10 In a preferred form, the electrically conductive object is a metal object or an alloy object, and the coloured powder coating is a white powder coating, although any suitable colour may be used, such as light grey.
Preferably, the coloured powder coating is applied to a thickness of from 50 microns to 15 55 microns and is a polyester powder coating or, more broadly, is a non-polyurethane powder coating.
In a preferred embodiment, the method includes a further step between step (c) and step (d), the further step comprising deionising the coloured partly cured powder coated 20 layer to remove any contaminants or impurities from its surface,
Preferably, the clear coat powder coating is applied to a thickness of from 70 microns to 100 microns and is a polyurethane powder coating. 25 It is preferred that the sublimation transfer medium is a plastic film or paper that withstands high temperatures used for sublimation.
The pressure between the sublimation transfer medium and the powder coated surface is preferably a vacuum pressure. This is especially applicable when the sublimation 30 transfer medium is an air impermeable film. 06/05/16 5 2016202954 06 May 2016
In another embodiment, the pressure between the sublimation transfer medium and the powder coated surface is applied by placing an air impermeable membrane or an air impermeable film upon the sublimation transfer medium and then applying a vacuum between the membrane or film and the sublimation transfer medium which causes the 5 sublimation transfer medium to tightly adhere to the powder coated surface. This is especially applicable when the sublimation transfer medium is an air permeable film or paper.
In yet another embodiment, the pressure between the sublimation transfer medium and 10 the powder coated surface is applied by a weighted object, such as a mechanical press, or by a glue or other adhesive substance.
Preferably, the removing of the sublimation transfer medium and the powder coated surface from the oven in step (h) is done immediately after the sublimation temperature 15 of the inks is reached.
According to another aspect of the present invention, there is provided a method for improving the transfer of an image to a surface of a powder coated object, the image being printed with sublimable inks on a sublimation transfer medium, and the surface 20 having a clear coat powder coated outer layer overlying a coloured powder coated inner layer, the method including the step of: applying pressure between the sublimation transfer medium and the clear coat powder coated outer layer so as to adhere the medium tightly to the surface, before heating the sublimation transfer medium and the surface of the powder coated object to 25 cause, by sublimation, the transfer of the image to the clear coat powder coated outer layer.
According to yet another aspect of the present invention, there is provided a method for improving the powder coating of an object having a clear coat powder coated outer 30 layer overlying a coloured powder coated inner layer, the method including the step of: 06/05/16 6 2016202954 06 May 2016 deionising the coloured powder coated inner layer to remove airborne contaminants from its surface, before applying the clear coat powder coated outer layer.
According to still another aspect of the present invention, there is provided a method 5 for improving the powder coating of an object having a clear coat powder coated outer layer overlying a coloured powder coated inner layer, the method including the step of: partially curing the coloured powder coated inner layer by heating over a sufficient time and temperature so as to form a coloured partly cured powder coated layer before applying the clear coat powder coated outer layer thereon, and heating over 10 a sufficient time and temperature to fully cure, but not over cure, the clear coat powder coated outer layer and the underlying coloured powder coated inner layer.
There has been thus outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better 15 understood and put into practical effect, and in order that the present contribution to the art may be better appreciated.
There are additional features of the invention that will be described hereinafter. As such, those skilled in the art will appreciate that the conception, upon which the 20 disclosure is based, may be readily utilized as the basis for designing other process steps and system configurations for carrying out the objects of the present invention. It is important, therefore, that the broad outline of the invention described above be regarded as including such equivalent features in so far as they do not depart from the spirit and scope of the present invention. 25
DETAILED DESCRIPTION OF THE INVENTION A metal object (such as an aluminium sheet or panel) to which an image is to be transferred by sublimation is pretreated by known chemical or mechanical means. 06/05/16 7 2016202954 06 May 2016
The object is then subject to a first stage of powder coating with, in this embodiment, a white polyester powder coating that is applied to the surface of the object to a thickness of from about 50 microns to about 55 microns at room temperature, although a thickness within the range of from about 40 microns to about 60 microns may be 5 suitable in some circumstances, to form a white polyester powder coating layer.
Although this example requires the coloured powder coating to be a white powder coating, any suitable colour may be used, such as light grey.
The white polyester powder coating layer on the surface of the object is then partially 10 cured in a heating device for about 6 to about 7 minutes, although a time within the range of from about 6 to about 10 minutes may be suitable in some circumstances, whilst the temperature of the metal is about 190° C, although a temperature within the range of from about 180° C to about 200° C may be suitable in some circumstances, to form a white partly cured powder coated layer. To achieve a metal temperature of about 15 190° C, the air temperature in the heating device is between about 195° C and about 225° C, and preferably about 220° C. Partially curing the white polyester powder coating layer at this stage is important to ensure durability of the finished product, as the white partly cured powder coated layer can complete its curing when a second stage of powder coating and curing, to be described later, is completed. If the white polyester 20 powder coating layer were to be completely cured before the second stage, there may be defective bonding between the polyester powder coated layer and the overlying powder coated layer added in the second stage.
After partial curing, the object is returned to room temperature and, in a preferred 25 embodiment of the method, the white partly cured powder coated layer is subject to deionisation to remove any airborne contaminants that have landed on its surface. This is achieved by blowing deionised air from a deionisation gun over the surface of the white partly cured powder coated layer. Deionisation of the white partly cured powder coated surface is desirable because, during the time between the partial curing of the 30 white polyester powder coated layer and the application of the overlying powder coated layer added in the second stage (which may be about an hour for some powder coating 06/05/16 8 2016202954 06 May 2016 lines), airborne dust and other material may land or be attracted by electrostatic forces onto the surface of the white polyester powder coated layer. Any such contaminants, if allowed to remain on the white polyester powder coated layer, will adversely affect the quality and appearance of the final product. The contaminants are preferably removed 5 immediately prior to the application of the aforementioned overlying layer.
The object is then subject to the aforementioned second stage of powder coating, in which a clear polyurethane powder coating is applied to the white partly cured powder coated layer to a thickness of from about 60 microns to about 100 microns at room 10 temperature, to form a clear coat polyurethane powder coating layer over the underlying white partly cured powder coated layer.
The clear coat polyurethane powder coating layer and the underlying white partly cured powder coated layer are then fully cured, but not over cured, together in a heating 15 device for about 20 to about 22 minutes, although a time within the range of from about 15 to about 25 minutes may be suitable in some circumstances, whilst the temperature of the metal is about 200° C, although a temperature within the range of from about 200° C to about 210° C may be suitable in some circumstances, to enable complete polymerisation to occur, and so form a powder coated surface of the metal object 20 having a clear coat polyurethane powder coated outer layer which is ready for image transfer by sublimation. Care must be taken not to over cure the polymers, as this may cause discolouration. A sublimation transfer medium which, in this embodiment, is an air permeable plastic 25 film on which is printed with sublimable inks a desired image, is then wrapped over the powder coated surface (with the image being on a side of the film facing the powder coated surface) and the plastic film is secured around its edges to the surface in an air tight position, such as with use of masking tape. 30 An air impermeable membrane, in the preferred form of a heavy, heat conductive, silicone rubber heat pad or mat, is then placed upon the film. 06/05/16 9 2016202954 06 May 2016 A vacuum pressure is applied between the membrane and the film which causes the film to tightly adhere to the surface.
Whilst under vacuum pressure, the film and the powder coated surface of the object are 5 heated in an oven until the sublimation temperature of the inks is reached, which in this embodiment is 200° C, and then immediately removed from the oven. Transfer of the image from the film to the powder coated surface is completed as soon as the temperature reaches 200° C. 10 After the vacuum pressure has been released and the film and the object have cooled sufficiently, the membrane is lifted from the film and the film is removed from the object, leaving an image in the clear coat polyurethane powder coated outer layer of the powder coated surface which is of a high quality and durability. 15 In an alternative embodiment, instead of using an air permeable plastic film as the sublimation transfer medium together with an air impermeable membrane placed upon the film, an air permeable paper that withstands high temperatures used for sublimation is used as the sublimation transfer medium together with a clear, air impermeable film which is placed upon the paper, before a vacuum is applied between the clear, air 20 impermeable film and the paper which causes the paper to tightly adhere to the powder coated surface.
In another alternative embodiment, instead of using an air permeable plastic film or paper as the sublimation transfer medium, an air impermeable plastic film is used as the 25 sublimation transfer medium, and a pressure is applied between the film and the powder coated surface that may be a vacuum applied between the film and the powder coated surface which causes the film to tightly adhere to the surface.
It is important that, for each of the different embodiments of sublimation transfer 30 medium described above, the pressure must be maintained during the time required to reach the sublimation temperature of the inks, as otherwise the vapour pressure of the 06/05/16 10 2016202954 06 May 2016 sublimable inks would detach the film or paper from the surfaces causing the image transferred to the surfaces to be faded.
It will be readily apparent to persons skilled in the art that various modifications may be 5 made in details of the process steps and the system configuration of the above embodiments of the method of the invention without departing from the scope or ambit of the present invention.
For example, the coloured powder coating layer may alternatively be selected from the 10 group consisting of a polyurethane, an epoxy polymer, a polyester-epoxy polymer, and an acrylic polymer. The clear coat powder coating layer may alternatively be selected from the group consisting of a polyester, an epoxy polymer, a polyester-epoxy polymer, and an acrylic polymer. 15 The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgement or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates before the filing 20 date of this patent application. 06/05/16
Claims (14)
- THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS: E A method for transferring an image to an object, comprising the steps of: (a) providing an electrically conductive object to which the image is to be transferred, (b) applying a coloured powder coating to a surface of the object to a thickness of from about 40 microns to about 60 microns at room temperature to form a coloured powder coating layer, (c) partially curing the coloured powder coating layer in a heating device for about 6 to about 10 minutes whilst the temperature of the object is between about 180° C and about 200° C to form a coloured partly cured powder coated layer, (d) applying a clear coat powder coating to the coloured partly cured powder coated layer to a thickness of from about 60 microns to about 100 microns at room temperature to form a clear coat powder coating layer over the underlying coloured partly cured powder coated layer, (e) fully curing, but not over curing, the clear coat powder coating layer and the underlying coloured partly cured powder coated layer together in a heating device for about 15 to about 25 minutes whilst the temperature of the object is between about 200° C and about 210° C to enable complete polymerisation to occur, and so form a powder coated surface of the object having a clear coat powder coated outer layer, (f) providing a sublimation transfer medium on which is printed with sublimable inks a desired image which is to be transferred to the powder coated surface, (g) placing the sublimation transfer medium against the powder coated surface and applying a pressure between the sublimation transfer medium and the powder coated surface so as to adhere the medium tightly to the surface, (h) heating the sublimation transfer medium and the powder coated surface, whilst under pressure, in an oven until a sublimation temperature of the inks is reached, whereupon the desired image is transferred to the clear coat powder coated outer layer of the powder coated surface, and then removing the medium and the powder coated surface from the oven, and (i) releasing the pressure and allowing the sublimation transfer medium and the object to cool sufficiently, before removing the medium from the object, leaving the desired image in the powder coated surface.
- 2. The method of claim 1 wherein the electrically conductive object is a metal object or an alloy object, and the coloured powder coating is a white or light grey powder coating.
- 3. The method of claim 1 or claim 2 wherein the coloured powder coating is applied to a thickness of from 50 microns to 55 microns and is a non-polyurethane powder coating.
- 4. The method of any one of claims 1 to 3 wherein the coloured powder coating is a polyester powder coating.
- 5. The method of any one of claims 1 to 4 wherein the method includes a further step between step (c) and step (d), the further step comprising deionising the coloured partly cured powder coated layer to remove any contaminants or impurities from its surface,
- 6. The method of any one of claims 1 to 5 wherein the clear coat powder coating is applied to a thickness of from 70 microns to 100 microns and is a polyurethane powder coating.
- 7. The method of any one of claims 1 to 6 wherein the sublimation transfer medium is a plastic film or paper that withstands high temperatures used for sublimation.
- 8. The method of any one of claims 1 to 7 wherein the pressure between the sublimation transfer medium and the powder coated surface is a vacuum pressure.
- 9. The method of any one of claims 1 to 7 wherein the pressure between the sublimation transfer medium and the powder coated surface is applied by placing an air impermeable membrane or an air impermeable film upon the sublimation transfer medium and then applying a vacuum between the membrane or film and the sublimation transfer medium which causes the sublimation transfer medium to tightly adhere to the powder coated surface.
- 10. The method of any one of claims 1 to 7 wherein the pressure between the sublimation transfer medium and the powder coated surface is applied by a weighted object, a mechanical press, or by an adhesive substance.
- 11. The method of any one of claims 1 to 10 wherein the removing of the sublimation transfer medium and the powder coated surface from the oven in step (h) is done immediately after the sublimation temperature of the inks is reached.
- 12. A method for improving the transfer of an image to a surface of a powder coated object, the image being printed with sublimable inks on a sublimation transfer medium, and the surface having a clear coat powder coated outer layer overlying a coloured powder coated inner layer, the method including the step of: applying pressure between the sublimation transfer medium and the clear coat powder coated outer layer so as to adhere the medium tightly to the surface, before heating the sublimation transfer medium and the surface of the powder coated object to cause, by sublimation, the transfer of the image to the clear coat powder coated outer layer.
- 13. A method for improving the powder coating of an object having a clear coat powder coated outer layer overlying a coloured powder coated inner layer, the method including the step of: deionising the coloured powder coated inner layer to remove airborne contaminants from its surface, before applying the clear coat powder coated outer layer.
- 14. A method for improving the powder coating of an object having a clear coat powder coated outer layer overlying a coloured powder coated inner layer, the method including the step of: partially curing the coloured powder coated inner layer by heating over a sufficient time and temperature so as to form a coloured partly cured powder coated layer before applying the clear coat powder coated outer layer thereon, and heating over a sufficient time and temperature to fully cure, but not over cure, the clear coat powder coated outer layer and the underlying coloured powder coated inner layer.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2015901635 | 2015-05-06 | ||
| AU2015901635A AU2015901635A0 (en) | 2015-05-06 | Improved method for transferring images to powder coated objects by sublimation |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| AU2016202954A1 true AU2016202954A1 (en) | 2016-11-24 |
Family
ID=57321499
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| AU2016202954A Abandoned AU2016202954A1 (en) | 2015-05-06 | 2016-05-06 | Improved Method for Transferring Images to Powder Coated Objects by Sublimation |
Country Status (1)
| Country | Link |
|---|---|
| AU (1) | AU2016202954A1 (en) |
-
2016
- 2016-05-06 AU AU2016202954A patent/AU2016202954A1/en not_active Abandoned
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MK4 | Application lapsed section 142(2)(d) - no continuation fee paid for the application |