CA2104661A1 - Method of fabricating sign panels - Google Patents
Method of fabricating sign panelsInfo
- Publication number
- CA2104661A1 CA2104661A1 CA 2104661 CA2104661A CA2104661A1 CA 2104661 A1 CA2104661 A1 CA 2104661A1 CA 2104661 CA2104661 CA 2104661 CA 2104661 A CA2104661 A CA 2104661A CA 2104661 A1 CA2104661 A1 CA 2104661A1
- Authority
- CA
- Canada
- Prior art keywords
- graphics
- panel
- laminate film
- structural
- structural mount
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- G—PHYSICS
- G09—EDUCATION; CRYPTOGRAPHY; DISPLAY; ADVERTISING; SEALS
- G09F—DISPLAYING; ADVERTISING; SIGNS; LABELS OR NAME-PLATES; SEALS
- G09F7/00—Signs, name or number plates, letters, numerals, or symbols; Panels or boards
- G09F7/02—Signs, plates, panels or boards using readily-detachable elements bearing or forming symbols
-
- G—PHYSICS
- G09—EDUCATION; CRYPTOGRAPHY; DISPLAY; ADVERTISING; SEALS
- G09F—DISPLAYING; ADVERTISING; SIGNS; LABELS OR NAME-PLATES; SEALS
- G09F7/00—Signs, name or number plates, letters, numerals, or symbols; Panels or boards
Abstract
Abstract The present invention relates to a method of assembling structural and non-structural panels into a durable, aesthetically pleasing composite sign panel.
The layers of the sign panel consist of a reusable structural mount on which a flexible graphics panel is applied through the use of an adhesive or the like. On top of the flexible panel, a transparent layer of a durable sheet material, such as a laminate is applied.
Text and graphics are printed onto the face of the flexible panel before application of the transparent laminate facing, thus resulting in coverage and protection of the graphics. The method of making the sign panels is cheap, quick and easy to use. Contact between the structural mount and the flexible panel is such that the latter can be easily removed thereby allowing for reuse of the structural mount when the graphics of the sign panel must be changed.
Alternatively, new graphic layers can be placed successively on top of one another when a change is to be made.
The layers of the sign panel consist of a reusable structural mount on which a flexible graphics panel is applied through the use of an adhesive or the like. On top of the flexible panel, a transparent layer of a durable sheet material, such as a laminate is applied.
Text and graphics are printed onto the face of the flexible panel before application of the transparent laminate facing, thus resulting in coverage and protection of the graphics. The method of making the sign panels is cheap, quick and easy to use. Contact between the structural mount and the flexible panel is such that the latter can be easily removed thereby allowing for reuse of the structural mount when the graphics of the sign panel must be changed.
Alternatively, new graphic layers can be placed successively on top of one another when a change is to be made.
Description
:
METHOD OF F ~ ~W~ SIGN PANELS
Field of Invention The present invention relates to a method of making signs, and more particularly wlth a method of ~abricating durable, inexpensive, architectural sign panels.
Backaround of the Invention There are many applications in which a simple, inexpensive and quick method of making durable sign panels would be desirable. For example, potential users of such sign panels include, but are not limited to institutions such as hospitals, schools and libraries, office buildings, recreational facilities, retail establishment, hotels, etc. Durable sign panels indicating where certain departments in a building are located, who occupies a certain office, etc. are required in order to direct the public to those locations.
Desirable qualities of any sign making process include the c~eanliness of the process, the ease with which information on a sign panel can be changed, the low cost of making such changes, the durability of the finished product, the ability to create detailed graphics, and the ability to standardize graphics over m ny sign units. Preferably, the process requires inexpensive equipment that is relatively easy to use so 25 that institutions and users may use the process ~-themselves and create the sign panels in-house rather than having to hire specialized help or having to contract the work out to an outside source.
There are several methods disclosed in the art for making sign panel~. For example, United States Patent No. 4,225,369 issued to Felchlin discloses a method for securing pictures to a base. The method includes the steps of bringing the sheet or poster into contact with a base made of at least one plastic material and causing the sheet to adhere to the base by wetting the base or by wiping it with means suitable for producing an electro-static charge. Preferably, the base is made of polyvinyl chloride, although it may be made of other materials such as wood, iron, glass, etc.
~lU~Lb~1 United States Patent No. 4,742,631 issued to Zimbel discloses a device used for mounting transparencies or x-rays. The device includes a support sheet made of a transparent material. On one side, low tack adhesive is applied which permits a transparency to be readily mounted in position and to be conveniently detached when desired. As well, a removable cover sheet may also be applied to the front face in order to protect the transparencies.
United States Patent No. 5,073,424 issued to Dressler discloses a sign having a base and a single graphics upper layer. The graphics layer is a composite of a coloured film having good release properties and an undercoating of pressure sensitive adhesive. In order to produce the graphics, a blade is used to cut the upper layer in the desired shape without cutting through the base. Once the desired shape has been cut, the unwanted portion of the upper layer surrounding the graphics is peeled off, thereby leaving only the graphics on the ~-base.
United States Patent No. 3,849,913 issued to Williams and United States Patent No. 4,864,755 issued to Owens both disclose methods for creating sign panels intended to be adhered to the windshields or windows of motor vehicle~. On the other hand, United States Patent No. 5,209,959 issued to McNaul discloses a sign for use on the side of trailer trucks. This outdoor signage includes: 1) a polyvinyl film having and exterior surface on which graphics can be printed, 2) an application tape, and 3) a carrier tape. The application tape is adhered to one surface of the plastic film using pressure ~ -sensitive adhesive. The carrier tape is then attached on top of the application tape, also using pressure sensitive adhesive. Therefore, the PVC film, application tape and carrier tape are joined together in a composite structure. ~he desired graphics are then printed on the other surface of the PVC iEilm in reverse image. Once the graphics have been printed, the transfer tape i8 laminated over the printed surface o~ the sheet material and the carrier tape can then be removed. The sign is attached to the side of a tractor trailer by removing the transfer tape and thereby exposing the layer of pressure sensitive transfer adhesive.
In addition to the methods and products disclosed in the patent art, there are other sign panels currently available in the marketplace. These sign panels, however, rely on the use of materials, processes and skills that are generally beyond the resources of a typical signage user. This has resulted in the creation ~ -~
of an industry which specializes in supplying signs to end users on an "as needed" basis, which is both costly and time consuming for the end user.
There have been attempts made to develop a sign making method which is easy and inexpensive so that end users can make the sign panels in-house. One such method ~
uses computerized vinyl cutters while another method uses -an "engraving" process. The~e methods, however, have the following disadvantages. Computerized vinyl cutters are relatively inexpensive, but production of graphics using these cutters is time consuming. Most importantly, the finished sign panel has poor durability, unless the product is applied to the rear surface of a clear material, which then must also have a background applied.
This approach is generally not undertaken by end users, as the background is created with either a solid layer of vinyl, being expensive and of undesirable appearance, or paint which is a process many users do not wish to undertake.
The engraving process is preferable to vinyl cutting because of the product's superior durability. However, engraving is a messy process, has relatively high material costs and has very limited graphics capabilities.
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Other processes that are somewhat relevant to sign making include "face-to-plastic" lamination. This is the lamination of a graphics panel, such as a photograph, onto the rear face of a sheet of clear plastic, typically acrylic, polycarbonate or other polymer. Face-to-plastic lamination is currently used mainly in the fine art or poster industries; it is rarely used for architectural signs. The graphics panel is attached to the plastic sheet using clear, pressure or heat sensitive adhesive, thereby allowing for visibility of the image through the plastic panel. In this process, however, the materials used cannot be reused if the graphics on ths panel are to be changed. Therefore the face-to-plastic process is costly over the long run. -The "fiber-glass embedment" process consists of creating graphics on a substrate, such as paper and/or structural mounting panels, and then coating them with a layer of transparent fiber-glass resin. The resin soaks into the substrate, thus creating a durable bond. This -process is like the "face-to-plastic" lamination process in that it achieves similar results and it does not have the characteristic of reusability of the structural components. It is therefore relatively costly to implement in the long run. Furthermore, this process involves the use of messy and potentially toxic substances (resins) which has prevented its use by anyone other than specialized fabricators.
There is, therefore, a need for a method of making sign panels that is inexpensive and easy to use.
Summary of the Invention It is, therefore, an object of one aspect of the present invention to provide a simple, quick and inexpensive method of making sign panels.
Accordingly, there iæ provided a method of fabricating a sign panel for displaying graphics and text, comprising: a) applying the graphics and text to a front surface of a graphics panel; b) releasably ' ,' ~ ' ' ' ' ' ' .' ' :;: ,' ,,: ` " " ., " ' " '. .' ' ' ' " ' ' ,~ ' ' - :' , ' attaching the rear surface of the graphics panel to a first side of a relatively rigid reusable structural mount with adhesive: and c) laminating the graphics panel with a clear, transparent laminate film, whereby the graphics and text can be changed by removing the graphics panel and laminate film from the reusable structural mount and repeating steps a) through c).
In another aspect of the present invention a method is provided for fabricating a sign panel for displaying graphics and text, comprising: a) applying the graphics and text to a front surface of a graphics panel: b) laminating the front surface of the graphics panel with a clear, flexible transparent laminate film; and c) releasably attaching a rear surface of the graphics panel to a first side of a relatively rigid, curved reusable structural mount with adhesive: whereby the graphics and ~ :
text can be changed by removing the graphic~ panel and laminate film from the curved reusable structural mount and repeating steps a) through c).
Brief Description of the Drawinqs Embodiments of the present invention are shown in the accompanying drawings in which like numerals denote like parts, and in which~
Figure 1 is a perspective exploded view of one embodiment of the present invention, having a flexible laminate film on a flat structural mount; --Figure 2 is a cross-sectional view taken along line 2-2 of the embodiment of Figure l;
Figure 3 is a perspective exploded view of a further embodiment of the present invention, having a rigid laminate film on a flat structural mount;
Figure 4 is a perspective exploded view of a further embodiment of the present invention, having a flexible laminate film on a curved structural mount;
Figure 5 is a perspective exploded view of a further embodiment of the present invention, having a rigid laminate film on a curved structural mount;
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Figure 6 is a perspective exploded view of yet a further embodiment of the present invention, having an encapsulating laminate film on a flat structural mount;
and Figure 7 is a perspective exploded view of yet a further embodiment of the present invention, having an sncapsulating laminate film on a curved structural mount.
Detailed Description of the Present_Invention Generally, the present invention is a method of easily and inexpensively making architectural sign panels that display graphics and text. The sign panels can also be readily and inexpensively changed should new graphics or text be required. A further aspect of the present invention is a method of fabricating sign panels that is clean, quiet and easy to use so that non-professional users can acquire and use the method, thereby providing in-house manufacturing capabilities.
The following description of the present invention is divided into three parts: first, a description of the equipment required to carry out the method; secondly, a description of the materials required; and thirdly a description of the method itself and the sign panels made by using the method.
EquiPment Generally, there are two main pieces of equipment required to carry out the method of the present invention. Firstly, a "graphics creation device" is required in order to create the graphics or text that is displayed on the sign panel. Throughout this disclosure, it will be understood that "graphics" includes both graphic images and/or text material. The sign's graphics can be created by a variety of graphics creation devices, including vinyl cutters, computer-driven devices, printers for oversized printing, and high resolution colour or black and white output devices.
Vinyl cutters are standard sign making equipment.
Essentially, a vinyl cutter cuts outlines of characters 4~l and graphics out of sheets of adhesive backed, coloured vinyl films. Typically, vinyl cutters are computer driven and they create graphics that are 3 or 5 mil thick. The graphics, however, have to be "weeded" once cut, which i5 the process of peeling away excess sheet material. The cut graphics must then be applied to a sign panel manually.
Computer-driven devices suitable for use in the method of the present invention include laser printers or ink jet printers. These are, essentially, any type of printer that is used in association with a personal computer. A personal computer, such as an Apple Macintosh or IBM PC computer is used to create the graphics and text material of the sign, and the printer is used to apply the graphics or text to paper or other substrate. Nost of the laser printers or ink jet printers currently available in the marketplace are, however, restricted to 8 1/2" X 14" output, although some printers can accommodate 11" X 17" output. Therefore, typical laser and ink jet printers may not accommodate some commonly required sign sizes.
A particular type of ink jet somputer-driven printer that can print oversized pages with an acceptable level of quality is the GCC Widewriter (a trade-mark~. The oversize capability of a GCC Widewriter is about 17" X
22" or 14.5" X 90" maximum. The GCC Widewriter uses a Canon Ink Jet "engine" which only works well with certain types of paper (as discussed more fully below). The GCC
Widewriter has been found to be the preferable graphics creation device for use with the method of the present invention because its large size graphics capability allows sign panels of almost all desired sizes to be made. As well, the GCC Widewriter is relatively inexpensive compared to other oversized printers currently on the market.
The method of the present invention may also include the use of high resolution colour or black and white , "~:è, ~ "
i'*~! ~lU~b~l output devices to create the graphics and text. The graphics created by these high resolution output devices result in higher quality sign panels, however, they are relatively more expensive than the other devices. High resolution colour output devices include printers such as the Canon Laser Copier and the Iris colour printed.
Although these output devices are relatively more expensive at present, it is likely that their cost will decrease substantially in the near future and therefore will make their use in the overall method more attractive.
The second major piece of equipment that is used in the method of the present invention is a lamination -press. A lamination press is not strictly required as ~-lamination may be done by hand application, although the quality of the finished product is generally much better when a press is used. The press can be either mechanically operated or vacuum operated. A mechanically operated lamination press includes one where a hand crank screws a flat plate down onto a support bed with the material in between, thus "sandwiching" it. Another type of mechanical press is a "roller" press where the material is run between rollers. On the other hand a vacuum operated lamination press is one where a vacuum is applied to force the laminate onto the substrate, thereby decreasing the possibility of air bubbles being entrapped. There are numerous lamination presses available in the marketplace that would be suitable for use in the method of the present invention. One such press that has been found to be suitable is the Model 2638 sold by Drytac Canada Inc.
Materials and Components There are essentially six components that can be ~
used in the method of the present invention: a structural ~ -fastener, a reusable structural mount, an adhesive layer, a disposable graphics panel, text and graphics,- and a protective laminate facing.
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The structural fastener is used in conjunction with a reusable structural mount or with a rigid laminate facing if no structural mount is used. Typical structural fasteners include mechanical tape or silicone or a custom designed double-sided fastener. In addition, any means for fastening the sign panel to a structure can be used, such as screws, clips, hooks, etc. The structural fastener should, but does not strictly have to allow easy removal of the sign panel from its site location, or allow easy access to change the sign panels on site. Structural fasteners are intended to be permanent components that attach assembled sign panels to permanent structures such as walls or to secondary mounts which are then permanently mounted to walls or ceilings.
The reusable structural mount may be made of any material that is "structural", that is, any material that holds its shape over time. Likely materials that can be used include steel, aluminum, stainless steel, plastic sheets such as acrylic, polycarbonate, polyvinyl chloride (PVC), expanded PVC foam, semi-rigid foam board, styrene, or acrylonitrile-butadiene-styrene (ABS). In addition, the reusable structural mount can be made of wood, glass, fiber-glass, etc. By "reusable", it is meant that the structural mount can: a~ be cleaned of previous graphics panels (to be discussed more fully below), and b) be either removed from its location or the graphics panel can be applied to it on site and a new sign panel created.
The adhesive layer is located between the structural 3~ mount and the disposable graphics panel. The adhesive should bond the surface of the structural mount to the rear surface of the disposable graphics panel. The adhesive may be available in any form, such as a spray on compound, a transfer film (preferable), or a layer preapplied to the disposable graphics panel (also preferable). The adhesive layer should bond permanently to the disposable graphics panel, but only temporarily to ~` ~lU4b~ 1 the structural mount. Therefore, a "low tack" adhesive is used on the side for bonding to the structural mount.
However, if no structural mount is used, that is only a structural fastener and a rigid laminate is used, then the bonding layer on both sides of the adhesive should be permanent. The disposable graphics panel either has the adhesive applied in a factory operation, or the adhesive is applied at the back of the panel as an assembly operation.
The graphics panel is where the graphics are applied. It is, but need not strictly have to be, a flexible material. Possible materials from which the graphics panel may be made are paper, some plastic films, acetate, textile fabric, or metal foil. The preferable material is paper as it is cheap and flexible. The graphics panel is disposable and usually coloured. It does not have to be a single uniform colour but may include a printed pattern or image that is applied to it in a preparatory manufactllring process. Individual sign-specific text or graphics are then applied to thesegraphics panels. If a GCC Widewriter is used as the graphics creation device, the graphics panel should be paper with specific porosity characteristics so that high quality yraphics can be created with the GCC Widewriter.
The graphics panel is typically provided in stock of standard sizes which can be trimmed to exact size in the assembly process. Since the panels are disposable, they are very inexpensive to use.
The graphics and text that are displayed by the sign panel are applied to the disposable graphics panel using one of the graphics creation devices described above.
The graphics are applied with material such as ink, vinyl, laser printer or photocopier toner, "ink jet" ink, paint, etc. The preferable material is "ink jet" ink used in the GCC Widewriter. The graphics are created by hand, or preferably with a computer and any suitable graphics software package. As mentioned earlier, other u ~
ll high resolution colour or black and white output devices can also be used to create full colour graphics.
The protective laminate facing used with the method of the present invention can be of 3 types: flexible protective laminate facing, rigid protective laminate facing, or encapsulating protective laminate facing. The laminate facing protects the disposable graphics panel from damage, and also provides a uniform and aesthetically pleasing surface and texture to the sign panel.
Flexible protective laminate facing is intended to wrap around the edges of the structural mount and to attach around the perimeter of the mount's rear surface.
As such, this reduces the possibility of the laminate film being picked apart at its edges, thereby providing a durable product. The flexible laminate film has adhesive on its rear surface so as to bond to the disposable graphics panel. The adhesive can be pressure or heat activated. The flexible laminate film is applied with a lamination press as described above, or by hand application, although the latter does not usually provide a quality product as air bubbles are difficult to remove.
Rigid protective laminate facings also protect the disposable graphics panel from damage and provide a uniform and aesthetically pleasing surface and texture.
Rigid laminate facings have a higher durability than the flexible laminate film, but they do not wrap around the edges of the mount, thus making them susceptible to peeling by vandalism or the like. A rigid laminate film also has pressure or heat-activated adhesive on its rear surface in order to bond to the disposable graphics panel. As was the case with the flexible laminate facing, the rigid laminate facing is applied with a lamination machine or by hand application, although the former is preferable.
The encapsulating protective laminate facing achieves the advantages of both the flexible laminate and ib~
the rigid laminate. It is, essentially, a rigid laminate facing with wrapped edges, thereby it provides maximum surface durability and reduces the possibility of picking the layers apart at the edges. The encapsulating laminate facing is applied to the disposable graphics panel by distorting the flat laminate material to wrap around the sign panel without creasing the laminate. One such method is vacuum forming, using heat to soften the laminate and suction to pull the film inward around the sign panel. Another method is shrink-wrapping, which uses heat only.
Method of the Present Invention With reference to Figure 1, there is shown an exploded view of one embodiment of a sign panel 10 made using the method of the present invention. The embodiment shown in Figure 1 includes a flexible laminate film 11 mounted on a flat structural mount 12. The graphics and text 13 displayed by the sign panel 10 are created using one of the graphics creation devices referred to above and printed or applied to a front surface of a disposable graphics panel 14. The size of the graphics panel 14 is slightly larger than required for the finished sign panel 10. Once the graphics 13 are applied to the graphics panel 14, an adhesive layer 15 is applied to the rear surface of the disposable graphics panel 14 unless the graphics panel 14 used already has preapplied adhesive to it. The oversized graphics panel 14 is then attached to a first side of a structural mount 12 and trimmed to size. An oversized piece of flexible laminate film 11 is then cut and applied to the top surface of the graphics panel 14. If a lamination press ;
is to be used, then the laminate film 11 is applied lightly to the surface of the graphics panel 14 and run in the press. However, if a press is not used, the laminate film must be applied firmly by hand.
once the laminate film 11 is applied to graphics panel 14, the corners 17 are notched out as shown in b ~ l Figure 1 and the four edges 18 of the laminate film 11 are foldsd over the back of the structural mount 12 and stuck to the second side of the structural mount 12.
Once this i9 done, a structural fastener 16 may 5 optionally be applied to the back of the structural mount 12 for easy attachment to a wall (not shown).
The sign panel 10 of Figuxe 1 can easily be altered by cutting and peeling away the graphics panel 14/laminate film 11 composite from the structural mount 10 12. The steps of the method described above are then repeated re~sing the structural mount 12 and the structural fastener 16. Alternatively, a new graphics panel/laminate composite may be applied directly on top of the existing laminate film 11, thereby avoiding the 15 necessity of cutting and peeling away. It will be appreciated that in sign panels using a flexible laminate film wrapped around the edges, it is not strictly necessary to have adhesive layer 15 between the graphics panel 14 and the structural mount 12. However, the use 20 of adhesive layer 15 is preferable to ensure complete attachment of the graphics panel 14 to the structural mount 12.
Figure 2 is a cross sectional view of sign panel 10.
Flexible laminate film 11 is attached to the front 25 surface 20 of graphics panel 14. The graphics and text appear on front surface 20 so that they are visible through laminate film 11. On the rear surface 21 of graphics panel 14 is applied adhesive layer 15, which in turn is applied to a first side 22 of structural mount 30 12. As mentioned above, adhesive layer 15 is, in a preferred embodiment, of "high tack" on rear surface 21 and of "low tack" on first side 22. Finally, in the embodiment shown in Figure 2, a structural fastener 16 is attached to second side 23 of structural mount 12. As 35 well, edges 18 of laminate film 11 are also attached to second side 23.
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With reference to Figure 3, there is shown a sign panel 30 in which a rigid laminate film 32 is used on a flat structural mount 34. The graphics and text 36 are applied to a front surface of an oversized disposable graphics panel 38 and the graphics panel 38 is attached to a first side of the structural mount 34 using adhesive layer 40. The graphics panel 38 is trimmed to size. An oversized rigid laminate film 32 is applied to the front surface of the graphics panel 38 using a lamination press or by hand application. The oversized rigid laminate film 32 is then trimmed to size. Optionally, a structural fastener 42 may be attached to the second side of the structural mount 34 for easy attachment to a wall (not shown).
As was the case with the sign panel 10 illustrated in Figure 1, in order to change the graphics panel 38 -when a rigid laminate 32 is used as in sign panel 30, the graphics panel 38/laminate film 32 composite is merely peeled away from the structural mount 34 and the steps ~ -described above repeated. Alternatively, a new graphics panel/laminate composite may be applied directly on top of the existing laminate film, thereby avoiding the necessity of peeling away.
In Figure 4, there is shown a sign panel 60 similar ~ -to sign panel 10 shown in Figure 1, except that the structural mount 62 is curved rather than flat. The first side of structural mount 62 can have a convex curve as shown in Figure 4 or a concave curve (not shown). As well, the curve may be oriented horizontally as shown in Figure 4, or vertically (not shown). The sign panel 60 of Figure 4 with its curved appearance may, in some cases, present a more attractive and desirable sign panel for the end user.
The method for making curved sign panel 60 is somewhat similar to the method for making the sign panel 10 of Figure 1, however, because the structural mount is curved, a slight variation is required. The graphics 64 a. ? ~ "
are created and applied to a front surface of an oversized disposable graphics panel 66 which is then trimmed to size. A flexible laminate film 68 is applied to the front face of graphics panel 66 using a lamination press or by hand application. The graphics panel 66/flexible laminate film 68 composite is then attached to a first side of the curved structural mount 62 using adhesive layer 76. The corners of the oversized laminate film 68 are notched out as shown in Figure 4 and the edges 72 are tightly folded over and adhered to the second side of structural mount 62. Optionally, a structural fastener 74 may be used for easy fastening to a wall (not shown).
Once the sign panel 60 of Figure 4 has been created, it is easy to change the graphic~ by simply cutting and peeling away the graphics panel 66/laminate film 68 composite from the structural mount 62 and repeating the steps of the method. Alternatively, a new graphics panel/laminate film composite may be applied directly on top of the existing laminate film 68, thereby eliminating the need of cutting and peeling.
Sign panel 80 of Figure 5 is an alternative to sign panel 30 of Figure 2, wherein a curved structural mount 82 is used. Here again, a first side of the structural mount 82 may have a convex curve as shown or a concave curve (not shown). As well, the curve may be oriented horizontally as shown in Figure 5, or vertically (not shown). The method for making sign panel 80 is similar to that for sign panel 30, except that a rigid laminate film 84 is applied to a disposable graphics panel 86 prior to the graphics panel 86/rigid laminate film 84 composite being attached to the first side of curved structural mount 82 using adhesive layer 88. A
structural fastener 90 may optionally be used. ~-once the sign panel 80 of Figure 5 has been created, it is easy to change by simply peeling away the graphics panel 86/laminate film 84 composite from the curved "'`' . ~llU~6 structural mount 82 and repeating the steps of the method. Alternatively, a new graphics panel/laminate film composite may be applied directly on top of the existing laminate film 84, thereby eliminating the need of peeling.
In Figure 6, there is shown a sign panel 100 made using an encapsulating laminate film 102. The method for making sign panel 100 includes creating the graphics 104 and applying them to a front surface of an oversized disposable graphics panel 106. The rear surface of the graphics panel 106 is coated with an adhesive layer 108 unless graphics panel 106 already has preapplied adhesive. The oversized graphics panel 106 is then attached to a first side of a structural mount 110 and trimmed to size. An oversized piece of encapsulating laminate film 102 is cut and the encapsulating film 102 and graphics panel 106/structural mount 110 composite are inserted into an encapsulating press (not shown). The encapsulating press operation causes the encapsulating laminate film 102 to adhere to the front surface of the disposable graphics panel 106 and causes the edges 112 of the laminate film 102 to be folded over and adhered to `~
the second side of structural mount 110. As will be appreciated, since the edges 112 of encapsulating laminate film 102 folds over to the rear of structural mount 110, the adhesive layer 108 is not strictly necessary, although preferable. Optionally, a structural -~
fastener 114 may be used for easy fastening to a structure (not shown).
As well, it will be appreciated that, although -Figure 6 illustrates a sign panel 100 having a flat structural mount 110, a curved structural mount similar to structural mount 82 shown in Figure 5 may also be used.
Figure 7 illustrates a sign panel 120 having a curved structural mount 122. The method of fabricating sign panel 120 is similar to the method for sign panel 100 described above. The same numerals are used in Figure 7 as in Figure 6 to denote the same parts.
Also, changing sign panel 120 is quick and easy by simply cutting and peeling away the graphics panel 106/encapsulating laminate film 102 composite from structural mount 122 and replacing it with a new one.
Alternatively, a new graphics panel/encapsulating aminate film is attached directly on the existing laminate film 102.
While embodiments of the present invention have been described hereinabove, it will be evident to a person skilled in the art that operations and modifications may be made from those embodiments without departing from the essence of this invention as set out in the claims appended hereto.
METHOD OF F ~ ~W~ SIGN PANELS
Field of Invention The present invention relates to a method of making signs, and more particularly wlth a method of ~abricating durable, inexpensive, architectural sign panels.
Backaround of the Invention There are many applications in which a simple, inexpensive and quick method of making durable sign panels would be desirable. For example, potential users of such sign panels include, but are not limited to institutions such as hospitals, schools and libraries, office buildings, recreational facilities, retail establishment, hotels, etc. Durable sign panels indicating where certain departments in a building are located, who occupies a certain office, etc. are required in order to direct the public to those locations.
Desirable qualities of any sign making process include the c~eanliness of the process, the ease with which information on a sign panel can be changed, the low cost of making such changes, the durability of the finished product, the ability to create detailed graphics, and the ability to standardize graphics over m ny sign units. Preferably, the process requires inexpensive equipment that is relatively easy to use so 25 that institutions and users may use the process ~-themselves and create the sign panels in-house rather than having to hire specialized help or having to contract the work out to an outside source.
There are several methods disclosed in the art for making sign panel~. For example, United States Patent No. 4,225,369 issued to Felchlin discloses a method for securing pictures to a base. The method includes the steps of bringing the sheet or poster into contact with a base made of at least one plastic material and causing the sheet to adhere to the base by wetting the base or by wiping it with means suitable for producing an electro-static charge. Preferably, the base is made of polyvinyl chloride, although it may be made of other materials such as wood, iron, glass, etc.
~lU~Lb~1 United States Patent No. 4,742,631 issued to Zimbel discloses a device used for mounting transparencies or x-rays. The device includes a support sheet made of a transparent material. On one side, low tack adhesive is applied which permits a transparency to be readily mounted in position and to be conveniently detached when desired. As well, a removable cover sheet may also be applied to the front face in order to protect the transparencies.
United States Patent No. 5,073,424 issued to Dressler discloses a sign having a base and a single graphics upper layer. The graphics layer is a composite of a coloured film having good release properties and an undercoating of pressure sensitive adhesive. In order to produce the graphics, a blade is used to cut the upper layer in the desired shape without cutting through the base. Once the desired shape has been cut, the unwanted portion of the upper layer surrounding the graphics is peeled off, thereby leaving only the graphics on the ~-base.
United States Patent No. 3,849,913 issued to Williams and United States Patent No. 4,864,755 issued to Owens both disclose methods for creating sign panels intended to be adhered to the windshields or windows of motor vehicle~. On the other hand, United States Patent No. 5,209,959 issued to McNaul discloses a sign for use on the side of trailer trucks. This outdoor signage includes: 1) a polyvinyl film having and exterior surface on which graphics can be printed, 2) an application tape, and 3) a carrier tape. The application tape is adhered to one surface of the plastic film using pressure ~ -sensitive adhesive. The carrier tape is then attached on top of the application tape, also using pressure sensitive adhesive. Therefore, the PVC film, application tape and carrier tape are joined together in a composite structure. ~he desired graphics are then printed on the other surface of the PVC iEilm in reverse image. Once the graphics have been printed, the transfer tape i8 laminated over the printed surface o~ the sheet material and the carrier tape can then be removed. The sign is attached to the side of a tractor trailer by removing the transfer tape and thereby exposing the layer of pressure sensitive transfer adhesive.
In addition to the methods and products disclosed in the patent art, there are other sign panels currently available in the marketplace. These sign panels, however, rely on the use of materials, processes and skills that are generally beyond the resources of a typical signage user. This has resulted in the creation ~ -~
of an industry which specializes in supplying signs to end users on an "as needed" basis, which is both costly and time consuming for the end user.
There have been attempts made to develop a sign making method which is easy and inexpensive so that end users can make the sign panels in-house. One such method ~
uses computerized vinyl cutters while another method uses -an "engraving" process. The~e methods, however, have the following disadvantages. Computerized vinyl cutters are relatively inexpensive, but production of graphics using these cutters is time consuming. Most importantly, the finished sign panel has poor durability, unless the product is applied to the rear surface of a clear material, which then must also have a background applied.
This approach is generally not undertaken by end users, as the background is created with either a solid layer of vinyl, being expensive and of undesirable appearance, or paint which is a process many users do not wish to undertake.
The engraving process is preferable to vinyl cutting because of the product's superior durability. However, engraving is a messy process, has relatively high material costs and has very limited graphics capabilities.
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Other processes that are somewhat relevant to sign making include "face-to-plastic" lamination. This is the lamination of a graphics panel, such as a photograph, onto the rear face of a sheet of clear plastic, typically acrylic, polycarbonate or other polymer. Face-to-plastic lamination is currently used mainly in the fine art or poster industries; it is rarely used for architectural signs. The graphics panel is attached to the plastic sheet using clear, pressure or heat sensitive adhesive, thereby allowing for visibility of the image through the plastic panel. In this process, however, the materials used cannot be reused if the graphics on ths panel are to be changed. Therefore the face-to-plastic process is costly over the long run. -The "fiber-glass embedment" process consists of creating graphics on a substrate, such as paper and/or structural mounting panels, and then coating them with a layer of transparent fiber-glass resin. The resin soaks into the substrate, thus creating a durable bond. This -process is like the "face-to-plastic" lamination process in that it achieves similar results and it does not have the characteristic of reusability of the structural components. It is therefore relatively costly to implement in the long run. Furthermore, this process involves the use of messy and potentially toxic substances (resins) which has prevented its use by anyone other than specialized fabricators.
There is, therefore, a need for a method of making sign panels that is inexpensive and easy to use.
Summary of the Invention It is, therefore, an object of one aspect of the present invention to provide a simple, quick and inexpensive method of making sign panels.
Accordingly, there iæ provided a method of fabricating a sign panel for displaying graphics and text, comprising: a) applying the graphics and text to a front surface of a graphics panel; b) releasably ' ,' ~ ' ' ' ' ' ' .' ' :;: ,' ,,: ` " " ., " ' " '. .' ' ' ' " ' ' ,~ ' ' - :' , ' attaching the rear surface of the graphics panel to a first side of a relatively rigid reusable structural mount with adhesive: and c) laminating the graphics panel with a clear, transparent laminate film, whereby the graphics and text can be changed by removing the graphics panel and laminate film from the reusable structural mount and repeating steps a) through c).
In another aspect of the present invention a method is provided for fabricating a sign panel for displaying graphics and text, comprising: a) applying the graphics and text to a front surface of a graphics panel: b) laminating the front surface of the graphics panel with a clear, flexible transparent laminate film; and c) releasably attaching a rear surface of the graphics panel to a first side of a relatively rigid, curved reusable structural mount with adhesive: whereby the graphics and ~ :
text can be changed by removing the graphic~ panel and laminate film from the curved reusable structural mount and repeating steps a) through c).
Brief Description of the Drawinqs Embodiments of the present invention are shown in the accompanying drawings in which like numerals denote like parts, and in which~
Figure 1 is a perspective exploded view of one embodiment of the present invention, having a flexible laminate film on a flat structural mount; --Figure 2 is a cross-sectional view taken along line 2-2 of the embodiment of Figure l;
Figure 3 is a perspective exploded view of a further embodiment of the present invention, having a rigid laminate film on a flat structural mount;
Figure 4 is a perspective exploded view of a further embodiment of the present invention, having a flexible laminate film on a curved structural mount;
Figure 5 is a perspective exploded view of a further embodiment of the present invention, having a rigid laminate film on a curved structural mount;
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Figure 6 is a perspective exploded view of yet a further embodiment of the present invention, having an encapsulating laminate film on a flat structural mount;
and Figure 7 is a perspective exploded view of yet a further embodiment of the present invention, having an sncapsulating laminate film on a curved structural mount.
Detailed Description of the Present_Invention Generally, the present invention is a method of easily and inexpensively making architectural sign panels that display graphics and text. The sign panels can also be readily and inexpensively changed should new graphics or text be required. A further aspect of the present invention is a method of fabricating sign panels that is clean, quiet and easy to use so that non-professional users can acquire and use the method, thereby providing in-house manufacturing capabilities.
The following description of the present invention is divided into three parts: first, a description of the equipment required to carry out the method; secondly, a description of the materials required; and thirdly a description of the method itself and the sign panels made by using the method.
EquiPment Generally, there are two main pieces of equipment required to carry out the method of the present invention. Firstly, a "graphics creation device" is required in order to create the graphics or text that is displayed on the sign panel. Throughout this disclosure, it will be understood that "graphics" includes both graphic images and/or text material. The sign's graphics can be created by a variety of graphics creation devices, including vinyl cutters, computer-driven devices, printers for oversized printing, and high resolution colour or black and white output devices.
Vinyl cutters are standard sign making equipment.
Essentially, a vinyl cutter cuts outlines of characters 4~l and graphics out of sheets of adhesive backed, coloured vinyl films. Typically, vinyl cutters are computer driven and they create graphics that are 3 or 5 mil thick. The graphics, however, have to be "weeded" once cut, which i5 the process of peeling away excess sheet material. The cut graphics must then be applied to a sign panel manually.
Computer-driven devices suitable for use in the method of the present invention include laser printers or ink jet printers. These are, essentially, any type of printer that is used in association with a personal computer. A personal computer, such as an Apple Macintosh or IBM PC computer is used to create the graphics and text material of the sign, and the printer is used to apply the graphics or text to paper or other substrate. Nost of the laser printers or ink jet printers currently available in the marketplace are, however, restricted to 8 1/2" X 14" output, although some printers can accommodate 11" X 17" output. Therefore, typical laser and ink jet printers may not accommodate some commonly required sign sizes.
A particular type of ink jet somputer-driven printer that can print oversized pages with an acceptable level of quality is the GCC Widewriter (a trade-mark~. The oversize capability of a GCC Widewriter is about 17" X
22" or 14.5" X 90" maximum. The GCC Widewriter uses a Canon Ink Jet "engine" which only works well with certain types of paper (as discussed more fully below). The GCC
Widewriter has been found to be the preferable graphics creation device for use with the method of the present invention because its large size graphics capability allows sign panels of almost all desired sizes to be made. As well, the GCC Widewriter is relatively inexpensive compared to other oversized printers currently on the market.
The method of the present invention may also include the use of high resolution colour or black and white , "~:è, ~ "
i'*~! ~lU~b~l output devices to create the graphics and text. The graphics created by these high resolution output devices result in higher quality sign panels, however, they are relatively more expensive than the other devices. High resolution colour output devices include printers such as the Canon Laser Copier and the Iris colour printed.
Although these output devices are relatively more expensive at present, it is likely that their cost will decrease substantially in the near future and therefore will make their use in the overall method more attractive.
The second major piece of equipment that is used in the method of the present invention is a lamination -press. A lamination press is not strictly required as ~-lamination may be done by hand application, although the quality of the finished product is generally much better when a press is used. The press can be either mechanically operated or vacuum operated. A mechanically operated lamination press includes one where a hand crank screws a flat plate down onto a support bed with the material in between, thus "sandwiching" it. Another type of mechanical press is a "roller" press where the material is run between rollers. On the other hand a vacuum operated lamination press is one where a vacuum is applied to force the laminate onto the substrate, thereby decreasing the possibility of air bubbles being entrapped. There are numerous lamination presses available in the marketplace that would be suitable for use in the method of the present invention. One such press that has been found to be suitable is the Model 2638 sold by Drytac Canada Inc.
Materials and Components There are essentially six components that can be ~
used in the method of the present invention: a structural ~ -fastener, a reusable structural mount, an adhesive layer, a disposable graphics panel, text and graphics,- and a protective laminate facing.
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The structural fastener is used in conjunction with a reusable structural mount or with a rigid laminate facing if no structural mount is used. Typical structural fasteners include mechanical tape or silicone or a custom designed double-sided fastener. In addition, any means for fastening the sign panel to a structure can be used, such as screws, clips, hooks, etc. The structural fastener should, but does not strictly have to allow easy removal of the sign panel from its site location, or allow easy access to change the sign panels on site. Structural fasteners are intended to be permanent components that attach assembled sign panels to permanent structures such as walls or to secondary mounts which are then permanently mounted to walls or ceilings.
The reusable structural mount may be made of any material that is "structural", that is, any material that holds its shape over time. Likely materials that can be used include steel, aluminum, stainless steel, plastic sheets such as acrylic, polycarbonate, polyvinyl chloride (PVC), expanded PVC foam, semi-rigid foam board, styrene, or acrylonitrile-butadiene-styrene (ABS). In addition, the reusable structural mount can be made of wood, glass, fiber-glass, etc. By "reusable", it is meant that the structural mount can: a~ be cleaned of previous graphics panels (to be discussed more fully below), and b) be either removed from its location or the graphics panel can be applied to it on site and a new sign panel created.
The adhesive layer is located between the structural 3~ mount and the disposable graphics panel. The adhesive should bond the surface of the structural mount to the rear surface of the disposable graphics panel. The adhesive may be available in any form, such as a spray on compound, a transfer film (preferable), or a layer preapplied to the disposable graphics panel (also preferable). The adhesive layer should bond permanently to the disposable graphics panel, but only temporarily to ~` ~lU4b~ 1 the structural mount. Therefore, a "low tack" adhesive is used on the side for bonding to the structural mount.
However, if no structural mount is used, that is only a structural fastener and a rigid laminate is used, then the bonding layer on both sides of the adhesive should be permanent. The disposable graphics panel either has the adhesive applied in a factory operation, or the adhesive is applied at the back of the panel as an assembly operation.
The graphics panel is where the graphics are applied. It is, but need not strictly have to be, a flexible material. Possible materials from which the graphics panel may be made are paper, some plastic films, acetate, textile fabric, or metal foil. The preferable material is paper as it is cheap and flexible. The graphics panel is disposable and usually coloured. It does not have to be a single uniform colour but may include a printed pattern or image that is applied to it in a preparatory manufactllring process. Individual sign-specific text or graphics are then applied to thesegraphics panels. If a GCC Widewriter is used as the graphics creation device, the graphics panel should be paper with specific porosity characteristics so that high quality yraphics can be created with the GCC Widewriter.
The graphics panel is typically provided in stock of standard sizes which can be trimmed to exact size in the assembly process. Since the panels are disposable, they are very inexpensive to use.
The graphics and text that are displayed by the sign panel are applied to the disposable graphics panel using one of the graphics creation devices described above.
The graphics are applied with material such as ink, vinyl, laser printer or photocopier toner, "ink jet" ink, paint, etc. The preferable material is "ink jet" ink used in the GCC Widewriter. The graphics are created by hand, or preferably with a computer and any suitable graphics software package. As mentioned earlier, other u ~
ll high resolution colour or black and white output devices can also be used to create full colour graphics.
The protective laminate facing used with the method of the present invention can be of 3 types: flexible protective laminate facing, rigid protective laminate facing, or encapsulating protective laminate facing. The laminate facing protects the disposable graphics panel from damage, and also provides a uniform and aesthetically pleasing surface and texture to the sign panel.
Flexible protective laminate facing is intended to wrap around the edges of the structural mount and to attach around the perimeter of the mount's rear surface.
As such, this reduces the possibility of the laminate film being picked apart at its edges, thereby providing a durable product. The flexible laminate film has adhesive on its rear surface so as to bond to the disposable graphics panel. The adhesive can be pressure or heat activated. The flexible laminate film is applied with a lamination press as described above, or by hand application, although the latter does not usually provide a quality product as air bubbles are difficult to remove.
Rigid protective laminate facings also protect the disposable graphics panel from damage and provide a uniform and aesthetically pleasing surface and texture.
Rigid laminate facings have a higher durability than the flexible laminate film, but they do not wrap around the edges of the mount, thus making them susceptible to peeling by vandalism or the like. A rigid laminate film also has pressure or heat-activated adhesive on its rear surface in order to bond to the disposable graphics panel. As was the case with the flexible laminate facing, the rigid laminate facing is applied with a lamination machine or by hand application, although the former is preferable.
The encapsulating protective laminate facing achieves the advantages of both the flexible laminate and ib~
the rigid laminate. It is, essentially, a rigid laminate facing with wrapped edges, thereby it provides maximum surface durability and reduces the possibility of picking the layers apart at the edges. The encapsulating laminate facing is applied to the disposable graphics panel by distorting the flat laminate material to wrap around the sign panel without creasing the laminate. One such method is vacuum forming, using heat to soften the laminate and suction to pull the film inward around the sign panel. Another method is shrink-wrapping, which uses heat only.
Method of the Present Invention With reference to Figure 1, there is shown an exploded view of one embodiment of a sign panel 10 made using the method of the present invention. The embodiment shown in Figure 1 includes a flexible laminate film 11 mounted on a flat structural mount 12. The graphics and text 13 displayed by the sign panel 10 are created using one of the graphics creation devices referred to above and printed or applied to a front surface of a disposable graphics panel 14. The size of the graphics panel 14 is slightly larger than required for the finished sign panel 10. Once the graphics 13 are applied to the graphics panel 14, an adhesive layer 15 is applied to the rear surface of the disposable graphics panel 14 unless the graphics panel 14 used already has preapplied adhesive to it. The oversized graphics panel 14 is then attached to a first side of a structural mount 12 and trimmed to size. An oversized piece of flexible laminate film 11 is then cut and applied to the top surface of the graphics panel 14. If a lamination press ;
is to be used, then the laminate film 11 is applied lightly to the surface of the graphics panel 14 and run in the press. However, if a press is not used, the laminate film must be applied firmly by hand.
once the laminate film 11 is applied to graphics panel 14, the corners 17 are notched out as shown in b ~ l Figure 1 and the four edges 18 of the laminate film 11 are foldsd over the back of the structural mount 12 and stuck to the second side of the structural mount 12.
Once this i9 done, a structural fastener 16 may 5 optionally be applied to the back of the structural mount 12 for easy attachment to a wall (not shown).
The sign panel 10 of Figuxe 1 can easily be altered by cutting and peeling away the graphics panel 14/laminate film 11 composite from the structural mount 10 12. The steps of the method described above are then repeated re~sing the structural mount 12 and the structural fastener 16. Alternatively, a new graphics panel/laminate composite may be applied directly on top of the existing laminate film 11, thereby avoiding the 15 necessity of cutting and peeling away. It will be appreciated that in sign panels using a flexible laminate film wrapped around the edges, it is not strictly necessary to have adhesive layer 15 between the graphics panel 14 and the structural mount 12. However, the use 20 of adhesive layer 15 is preferable to ensure complete attachment of the graphics panel 14 to the structural mount 12.
Figure 2 is a cross sectional view of sign panel 10.
Flexible laminate film 11 is attached to the front 25 surface 20 of graphics panel 14. The graphics and text appear on front surface 20 so that they are visible through laminate film 11. On the rear surface 21 of graphics panel 14 is applied adhesive layer 15, which in turn is applied to a first side 22 of structural mount 30 12. As mentioned above, adhesive layer 15 is, in a preferred embodiment, of "high tack" on rear surface 21 and of "low tack" on first side 22. Finally, in the embodiment shown in Figure 2, a structural fastener 16 is attached to second side 23 of structural mount 12. As 35 well, edges 18 of laminate film 11 are also attached to second side 23.
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With reference to Figure 3, there is shown a sign panel 30 in which a rigid laminate film 32 is used on a flat structural mount 34. The graphics and text 36 are applied to a front surface of an oversized disposable graphics panel 38 and the graphics panel 38 is attached to a first side of the structural mount 34 using adhesive layer 40. The graphics panel 38 is trimmed to size. An oversized rigid laminate film 32 is applied to the front surface of the graphics panel 38 using a lamination press or by hand application. The oversized rigid laminate film 32 is then trimmed to size. Optionally, a structural fastener 42 may be attached to the second side of the structural mount 34 for easy attachment to a wall (not shown).
As was the case with the sign panel 10 illustrated in Figure 1, in order to change the graphics panel 38 -when a rigid laminate 32 is used as in sign panel 30, the graphics panel 38/laminate film 32 composite is merely peeled away from the structural mount 34 and the steps ~ -described above repeated. Alternatively, a new graphics panel/laminate composite may be applied directly on top of the existing laminate film, thereby avoiding the necessity of peeling away.
In Figure 4, there is shown a sign panel 60 similar ~ -to sign panel 10 shown in Figure 1, except that the structural mount 62 is curved rather than flat. The first side of structural mount 62 can have a convex curve as shown in Figure 4 or a concave curve (not shown). As well, the curve may be oriented horizontally as shown in Figure 4, or vertically (not shown). The sign panel 60 of Figure 4 with its curved appearance may, in some cases, present a more attractive and desirable sign panel for the end user.
The method for making curved sign panel 60 is somewhat similar to the method for making the sign panel 10 of Figure 1, however, because the structural mount is curved, a slight variation is required. The graphics 64 a. ? ~ "
are created and applied to a front surface of an oversized disposable graphics panel 66 which is then trimmed to size. A flexible laminate film 68 is applied to the front face of graphics panel 66 using a lamination press or by hand application. The graphics panel 66/flexible laminate film 68 composite is then attached to a first side of the curved structural mount 62 using adhesive layer 76. The corners of the oversized laminate film 68 are notched out as shown in Figure 4 and the edges 72 are tightly folded over and adhered to the second side of structural mount 62. Optionally, a structural fastener 74 may be used for easy fastening to a wall (not shown).
Once the sign panel 60 of Figure 4 has been created, it is easy to change the graphic~ by simply cutting and peeling away the graphics panel 66/laminate film 68 composite from the structural mount 62 and repeating the steps of the method. Alternatively, a new graphics panel/laminate film composite may be applied directly on top of the existing laminate film 68, thereby eliminating the need of cutting and peeling.
Sign panel 80 of Figure 5 is an alternative to sign panel 30 of Figure 2, wherein a curved structural mount 82 is used. Here again, a first side of the structural mount 82 may have a convex curve as shown or a concave curve (not shown). As well, the curve may be oriented horizontally as shown in Figure 5, or vertically (not shown). The method for making sign panel 80 is similar to that for sign panel 30, except that a rigid laminate film 84 is applied to a disposable graphics panel 86 prior to the graphics panel 86/rigid laminate film 84 composite being attached to the first side of curved structural mount 82 using adhesive layer 88. A
structural fastener 90 may optionally be used. ~-once the sign panel 80 of Figure 5 has been created, it is easy to change by simply peeling away the graphics panel 86/laminate film 84 composite from the curved "'`' . ~llU~6 structural mount 82 and repeating the steps of the method. Alternatively, a new graphics panel/laminate film composite may be applied directly on top of the existing laminate film 84, thereby eliminating the need of peeling.
In Figure 6, there is shown a sign panel 100 made using an encapsulating laminate film 102. The method for making sign panel 100 includes creating the graphics 104 and applying them to a front surface of an oversized disposable graphics panel 106. The rear surface of the graphics panel 106 is coated with an adhesive layer 108 unless graphics panel 106 already has preapplied adhesive. The oversized graphics panel 106 is then attached to a first side of a structural mount 110 and trimmed to size. An oversized piece of encapsulating laminate film 102 is cut and the encapsulating film 102 and graphics panel 106/structural mount 110 composite are inserted into an encapsulating press (not shown). The encapsulating press operation causes the encapsulating laminate film 102 to adhere to the front surface of the disposable graphics panel 106 and causes the edges 112 of the laminate film 102 to be folded over and adhered to `~
the second side of structural mount 110. As will be appreciated, since the edges 112 of encapsulating laminate film 102 folds over to the rear of structural mount 110, the adhesive layer 108 is not strictly necessary, although preferable. Optionally, a structural -~
fastener 114 may be used for easy fastening to a structure (not shown).
As well, it will be appreciated that, although -Figure 6 illustrates a sign panel 100 having a flat structural mount 110, a curved structural mount similar to structural mount 82 shown in Figure 5 may also be used.
Figure 7 illustrates a sign panel 120 having a curved structural mount 122. The method of fabricating sign panel 120 is similar to the method for sign panel 100 described above. The same numerals are used in Figure 7 as in Figure 6 to denote the same parts.
Also, changing sign panel 120 is quick and easy by simply cutting and peeling away the graphics panel 106/encapsulating laminate film 102 composite from structural mount 122 and replacing it with a new one.
Alternatively, a new graphics panel/encapsulating aminate film is attached directly on the existing laminate film 102.
While embodiments of the present invention have been described hereinabove, it will be evident to a person skilled in the art that operations and modifications may be made from those embodiments without departing from the essence of this invention as set out in the claims appended hereto.
Claims (36)
1. A method of fabricating a sign panel for displaying graphics and text, comprising:
a) applying the graphics and text to a front surface of a graphics panel;
b) releasably attaching the rear surface of the graphics panel to a first side of a relatively rigid reusable structural mount with adhesive;
and c) laminating the graphics panel with a clear, transparent laminate film, whereby the graphics and text can be changed by removing the graphics panel and laminate film from the reusable structural mount and repeating steps a) through c).
a) applying the graphics and text to a front surface of a graphics panel;
b) releasably attaching the rear surface of the graphics panel to a first side of a relatively rigid reusable structural mount with adhesive;
and c) laminating the graphics panel with a clear, transparent laminate film, whereby the graphics and text can be changed by removing the graphics panel and laminate film from the reusable structural mount and repeating steps a) through c).
2. The method claimed in claim 1, wherein the laminate film is a flexible laminate film.
3. The method claimed in claim 1, wherein the laminate film is a rigid laminate film.
4. The method claimed in claim 1, wherein the laminate film is an encapsulating laminate film.
5. The method claimed in claim 2 or claim 4, wherein the laminate film is larger than the reusable structural mount such that portions of the laminate film are folded over the edges of the structural mount and attached to the second side thereof.
6. The method claimed in claim 1, wherein the graphics panel is made of a flexible material selected from the group consisting of: paper, plastic films, acetate, textile fabric and metal foil.
7. The method claimed in claim 6, wherein the graphics panel is paper.
8. The method claimed in claim 1, wherein the graphics and text are applied to the graphics panel using a graphics creation device.
9. The method claimed in claim 8, wherein the graphics creation device is a laser printer.
10. The method claimed in claim 8, wherein the graphics creation device is an ink jet printer.
11. The method claimed in claim 8, wherein the graphics creation device is an oversized printer.
12. The method claimed in claim 8, wherein the graphics creation device is a colour printer.
13. The method claimed in claim 1, wherein the reusable structural mount is made of a material selected from the group consisting of: wood, glass, fiber-glass, galvanized steel, aluminium, stainless steel, acrylic, polycarbonate, polyvinyl chloride, expanded polyvinyl chloride foam, semi-rigid foam board, styrene, and acrylonitrile-butadiene-styrene.
14. The method claimed in claim 1, further comprising the step of applying an adhesive layer to the rear surface of the graphics panel prior to step b), wherein the adhesive layer is high tack on the rear surface of the graphics panel and is low tack on the first side of the reusable structural mount.
15. The method claimed in claim 1, further comprising the step of attaching a structural fastener to a second side of the reusable structural mount for attachment of the sign panel to a permanent structure.
16. The method claimed in claim 15, wherein the structural fastener is double-sided tape and silicone.
17. The method claimed in claim 1, claim 2 or claim 3, wherein the laminate film is laminated onto the graphics panel using a lamination press.
18. A method of fabricating a sign panel for displaying graphics and text, comprising:
a) applying the graphics and text to a front surface of a graphics panel;
b) laminating the front surface of the graphics panel with a clear, flexible transparent laminate film; and c) releasably attaching a rear surface of the graphics panel to a first side of a relatively rigid, curved reusable structural mount with adhesive:
whereby the graphics and text can be changed by removing the graphics panel and laminate film from the curved reusable structural mount and repeating steps a) through c).
a) applying the graphics and text to a front surface of a graphics panel;
b) laminating the front surface of the graphics panel with a clear, flexible transparent laminate film; and c) releasably attaching a rear surface of the graphics panel to a first side of a relatively rigid, curved reusable structural mount with adhesive:
whereby the graphics and text can be changed by removing the graphics panel and laminate film from the curved reusable structural mount and repeating steps a) through c).
19. The method claimed in claim 18, wherein the laminate film is a flexible laminate film.
20. The method claimed in claim 18, wherein the laminate film is a rigid laminate film.
21. The method claimed in claim 18, wherein the laminate film is an encapsulating laminate film.
22. The method claimed in claim 19 or claim 21, wherein the laminate film is larger than the reusable structural mount such that portions of the laminate film are folded over the edges of the structural mount and attached to a second side thereof.
23. The method claimed in claim 18, wherein the graphics panel is made of a flexible material selected from the group consisting of: paper, plastic films, acetate, textile fabric and metal foil.
24. The method claimed in claim 23, wherein the graphics panel is paper.
25. The method claimed in claim 18, wherein the graphics and text are applied to the graphics panel using a graphics creation device.
26. The method claimed in claim 25, wherein the graphics creation device is a laser printer.
27. The method claimed in claim 25, wherein the graphics creation device is an ink jet printer.
28. The method claimed in claim 25, wherein the graphics creation device is an oversized printer.
29. The method claimed in claim 25, wherein the graphics creation device is a colour printer.
30. The method claimed in claim 18, wherein the reusable structural mount is made of a material selected from the group consisting of: wood, glass, fiber-glass, galvanized steel, aluminium, stainless steel, acrylic, polycarbonate, polyvinyl chloride, expanded polyvinyl chloride foam, semi-rigid foam board, styrene, and acrylonitrile-butadiene-styrene.
31. The method claimed in claim 18, further comprising the step of applying an adhesive layer to the rear surface of the graphics panel prior to step c), wherein the adhesive layer is high tack on the rear surface of the graphics panel and is low tack on the first side of the reusable structural mount.
32. The method claimed in claim 18, further comprising the step of attaching a structural fastener to a second side of the reusable structural mount for attachment of the sign panel to a permanent structure.
33. The method claimed in claim 32, wherein the structural fastener is double-sided tape or silicone.
34. The method claimed in claim 18, wherein the laminate film is laminated onto the graphics panel using a lamination press.
35. The method claimed in claim 18, wherein the first side of the curved structural mount is convex.
36. The method claimed in claim 18, wherein the first side of the curved structural mount is concave.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2104661 CA2104661A1 (en) | 1993-08-23 | 1993-08-23 | Method of fabricating sign panels |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2104661 CA2104661A1 (en) | 1993-08-23 | 1993-08-23 | Method of fabricating sign panels |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2104661A1 true CA2104661A1 (en) | 1995-02-24 |
Family
ID=4152197
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2104661 Abandoned CA2104661A1 (en) | 1993-08-23 | 1993-08-23 | Method of fabricating sign panels |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2104661A1 (en) |
-
1993
- 1993-08-23 CA CA 2104661 patent/CA2104661A1/en not_active Abandoned
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