EP0028903A1 - Procédé de production d'emblèmes décoratifs pourvus d'un revêtement ultramince en matière plastique - Google Patents

Procédé de production d'emblèmes décoratifs pourvus d'un revêtement ultramince en matière plastique Download PDF

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Publication number
EP0028903A1
EP0028903A1 EP80303854A EP80303854A EP0028903A1 EP 0028903 A1 EP0028903 A1 EP 0028903A1 EP 80303854 A EP80303854 A EP 80303854A EP 80303854 A EP80303854 A EP 80303854A EP 0028903 A1 EP0028903 A1 EP 0028903A1
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EP
European Patent Office
Prior art keywords
substrate
coating
pressure
plastic material
onto
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.)
Withdrawn
Application number
EP80303854A
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German (de)
English (en)
Inventor
William A. Fielder
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
DL Auld Co
Original Assignee
DL Auld Co
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by DL Auld Co filed Critical DL Auld Co
Publication of EP0028903A1 publication Critical patent/EP0028903A1/fr
Withdrawn legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
    • B05D5/06—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain multicolour or other optical effects
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C1/00—Processes, not specifically provided for elsewhere, for producing decorative surface effects
    • B44C1/20—Applying plastic materials and superficially modelling the surface of these materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/40—Distributing applied liquids or other fluent materials by members moving relatively to surface
    • B05D1/42—Distributing applied liquids or other fluent materials by members moving relatively to surface by non-rotary members
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/12—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by mechanical means

Definitions

  • the present invention relates to a method for making decorative emblems, plaques, panels, and the like which have a cured plastic layer over a decorative surface, and more particularly to a method of flow coating a fluent plastic material onto a decorative substrate and applying pressure to yield an ultrathin coating.
  • Decorative plaques and emblems are widely used throughout a number of industries, including the appliance and automotive fields.
  • a colored vitreous frit was flowed into a bronze sub- strate and fired at/(1250 F).
  • the glass-like vitreous enamel served to beautify the product and protect the decorative substrate from weathering should the plaque or emblem be exposed to the environment.
  • materials and techniques have become prohibitively expensive today.
  • Alternative materials and processes are required which can produce a high gloss, non-yellowing, tough, weather-resistant coated emblem or plaque which can withstand the harsh environment an automotive exterior is subjected to and yet are low in cost.
  • U. S. patent No. 4,100,010 discloses a process for producing decorative emblems in which a viscous plastic material is cast onto individual decorative foil shapes to form a meniscus. This meniscus when cured gives a lens effect to the top surface of the foil shape.
  • a problem with that process is that despite an ability to vary the size and shape, it is not practical to later conform . the as-cast emblems to nonplanar surfaces. Additionally, since the emblems are individually cast, the manufacturing process can be too time consuming and costly for some purposes.
  • the present invention meets that need by utilizing a flow coating process to apply a viscous, clear plastic material to a decorative substrate and then applying pressure to the substrate to form an ultrathin yet tough coated layer.
  • a flow coating process to apply a viscous, clear plastic material to a decorative substrate and then applying pressure to the substrate to form an ultrathin yet tough coated layer.
  • pressure by a flat surface against a cast plastic material is per se known.
  • Frankenthal U. S. patent No. 2,294,865
  • Holden, U. S. patent No. 2,459,279 coats plywood surfaces by casting a resinous material onto a platen and then pressing the platen against the plywood substrate.
  • the resinous material has to be at least partially polymerized or "jelled" prior to being brought into contact with the substrate.
  • flow coating per se is also known in a number of different art areas.
  • Waugh, U. S. patent No. 4,092,953 discloses a process for flow coating glass containers. See also Suzuki patent No. 3,953,626.
  • Other examples include U. S. patents No. 3,875,893 to Riley et al and 3,431,889 to Fraatz which both disclose the use of multiple orifice applicators to lay down a film of material onto a flat surface.
  • Hansen U. S. patent No. 3,725,112 also mentions flow coating as one possible method for producing a protective, low-glare, uniformly textured coating on a substrate such as wood, steel, hardboard, aluminum, and the like. But Waugh, Suzuki, Fraatz, Hansen, and Riley do not relate to emblem or plaque manufacturing processes where a clear plastic is applied to a decorative substrate.
  • the present invention permits the manufacture of decorative emblems and plaques having even thinner coatings of clear plastic material than the U.S process disclosed in copending/application Serial No. 054,548.
  • the process of the present invention results in an ultrathin coating which is attractive, flexible, tough, and weather resistant and yet permits substantial savings in materials costs due to the small amount of coating material required.
  • Using the process of the present invention it is possible to deposit the plastic on the decorative substrate uniformly to a thickness of as little as 0.1 to 0.2mm and yet produce an attractive and weather resistant emblem.
  • decorative emblems, plaques, and panels are produced by providing a substrate having a series of decorative designs applied to its top surface and flow coating a clear, viscous, fluent plastic material over the top surface of the substrate to form a relatively uniform coating at least 0.1mm 0.004 inches)thick. Substantially uniform pressure is then applied to the coated substrate to reduce 0.1 to 0.2mm the thickness of the coating to/(0.004 to 0.008 inches)followed by curing and hardening the plastic material while maintaining pressure upon it. The pressure is then released, and individual emblems, plaques, or panels are formed by cutting the substrate contiguous with each design of the series of designs.
  • the substrate upon which the fluent plastic is coated may be a plastic foil such as a vinyl or Mylar foil, a metal foil, or a plastic laminated metal foil.
  • the substrate may be an aluminum foil 0.2 to 1.0mm thick, preferably 0.3 to 0.4mm thick.
  • the foil substrate is decorated with an appropriate design or series of designs. For example, if a foil sheet or a substantial part of it is to be used as a panel with a minumum amount of trimming after being coated, a single design might be used. More commonly, a series of designs in the form of individual emblems or plaque shapes will be applied to the foil sheet. With a metal foil, the series of designs is preferably applied by silk screen or lithographic printing then the design is enhanced by embossing select areas although other means for forming the decorative designs may also be used.
  • any suitable primer may be used such as a silane primer.
  • the decorated and primed substrate is then loaded onto a hinged pressure fixture.
  • the fixture has a flat lower portion onto which the substrate is positioned and an upper portion which is a highly polished metal plate or a metal plate faced with a non-stick material such as polytetrafluoroethylene or silicone rubber.
  • the upper and lower portions of the fixture are mounted on a base and are hinged in "clamshell" fashion so that as the upper portion is closed, any excess coating material on the substrate- is forced to flow uniformly across the substrate.
  • the fixture After the primed substrate has been loaded onto the open pressure fixture, the fixture is transferred to a casting station. At this station, a predetermined amount of a fluent curable plastic material is flow coated onto the substrate.
  • the plastic is preferably a fluent polyurethane of two component parts (polyol and isocyanate) which are mixed .immediately prior to the coating and cure upon heating.
  • a polyurethane of this type is disclosed in Waugh, U.S. Patent No. 4,100,010.
  • the pressure fixture After casting, the pressure fixture is closed and pressure applied. In closing the fixture, care must be taken that no air is entrapped. Thus, a slow and smooth closing motion is preferred.
  • the pressure may be applied uniformly over the entire surface of the substrate and plastic to produce an ultrathin coating or there may be stops located either on the fixture itself or embossed on the substrate to limit the downward movement of the fixture and produce a controlled but somewhat thicker coating.
  • the pressure required may range from as little as 0.7 Kg/cm 2 for flat substrates which have not been appreciably warped during embossing to up to 7.0 Kg/cm 2 .
  • Curing is accomplished by heating the fixture, directly or indirectly, for a predetermined period of time.
  • a suitable method of curing has been found to be heating the fixtures in an oven maintained at 82-110 0 C. for from 15 to 30 minutes.
  • the coating substrate is cooled and removed from the pressure fixture. It may at this stage be further processed by cutting, trimming, and forming.
  • individual emblem or plaque shapes are contained on the single sheet, they are stamped out by a cutting die around the particular emblem or plaque shape. It has been found that complex geometric contours can be imparted to a substrate which has an ultrathin coating. The contours can be formed prior to cutting, during cutting using a combined cut and form tool, or after cutting.
  • a decorated and/or embossed sheet is placed at loading station 10 onto an open pressure fixture 12 situated on conveyor 14. From loading station 10, the sheet is advanced to casting station 16 where a casting head (see Fig. 3) in the form of a multiple orifice nozzle or nozzles flow coats measured amounts of a fluent plastic material, such as a fluent polyurethane, onto the upper surface of the sheet.
  • a casting head in the form of a multiple orifice nozzle or nozzles flow coats measured amounts of a fluent plastic material, such as a fluent polyurethane
  • the upper surface of pressure fixture 12 is closed and supplemental pressure is applied by the use of additional clamps at station 18.
  • This clamping action squeezes out any excess plastic and results in a smooth, ultrathin coating of plastic on the decorated sheet.
  • the plastic is cured while being maintained in a clamped and level position by conveying the pressure fixtures through a curing oven 20.
  • Oven 20 may contain any suitable source of heat which is capable of maintaining the ambient air temperature inside the oven at 82-110 C.
  • the speed of conveyor 14 is such that the pressure fixtures 12 are in oven 20 for from 15 to 30 minutes.
  • the pressure fixtures are opened at station 22 and the coated sheets unloaded. From there, the sheets may be sent to a conventional stamping or die cutting operation to produce individual finished emblems, plaques, or panels.
  • the substrate may be a plastic foil such as vinyl or Mylar foil, a metal foil, or a plastic metal foil laminate.
  • a plastic foil such as vinyl or Mylar foil
  • a metal foil such as aluminum foil
  • a plastic metal foil laminate To prepare the substrate for decoration and/or embossing, it is first cleaned, cut to size, and pierced for accurate registration in subsequent handling steps.
  • an aluminum foil of from 0.2 to 1.0mm thick, and preferably.0.3 to 0.4mm, is utilized as the substrate.
  • the sheets are sized so that they can be formed into a multiplicity of individual emblems or the like. It is desirable to prime the substrate with a silane compound before printing to enhance the adherence of the printed decoration thereto.
  • silane primers may also be used. These primers may be applied by spraying, dipping, or roller-coating followed by drying or baking to remove the solvent.
  • the primed substrate is then decorated with designs and/or letters by known silk-screen printing techniques.
  • the substrate may be embossed to enhance certain design features. Typically, such embossments are approximately 0.15mm deep.
  • pressure fixture 12 has a base 24, a flat lower plate 26, and an upper plate 28 attached to the lower plate by means of hinges 29.
  • Decorated substrate 30, having a plurality of individual designs indicated by 31, and an optional embossed downstop 51, is positioned on pegs 32 lower plate 26 through holes 34 punched or drilled therein for that purpose. This insures that the substrate is accurately aligned when passing under the casting head.
  • Upper plate 28 also has a pair of clearance holes 36 therein positioned to be aligned over pegs 32 when the plate is closed onto lower plate 26.
  • Optional embossed downstop 51 serves to control the downward movement of plate 28 and produces a coating of controlled thickness.
  • Upper plate 28 has a highly polished surface so that it will not impart any texture or surface imperfections to the coating.
  • the plate may be coated with a smooth non-stick surface such as polytetrafluoroethylene or silicone rubber.
  • Upper plate 28 is constructed so that as it closes, excess coating material will be forced to flow in a uniform direction across the face of the substrate. The closing motion should be slow and smooth to prevent any air from being entrapped.
  • upper plate 28 is parallel to lower plate 26 resulting in a uniform coating on substrate 30.
  • Optional embossments on the substrate or on the fixture itself aid in maintaining the plates parallel by supporting the applied pressure plate over the surface of the substrate.
  • Base 24 onto which plates 26 and 28 are mounted, is adapted to be attached to conveyor 14 and maintain the substrates in alignment at each station.
  • a first actuator 38 which can be a projecting metal stud, passes a predetermined location and activates the casting operation by activating a magnetic sensor or proximity switch.
  • the passage of a second actuator 39 past the same location reactuates a sensor or switch and terminates the flow of casting material.
  • casting head 40 has a nozzle 42 having a plurality of orifices shown as tubes 44 arrayed across the face of substrate 30.
  • the nozzle is fed a supply of fluent plastic such as a liquid polyurethane.
  • fluent plastic such as a liquid polyurethane.
  • A polyether polyol component
  • B diisocyanate component
  • a catalyst such as a lead material is used since it promotes a slow cure at room temperature so as to allow time for full flow of the liquid polyurethane before setting.
  • the diisocyanate is Hylene W from E. I. dePont de Nemours and Co.
  • the polyether polyol may be one or more of the Pluracol materials (P-410 or TP-440) from BASF Wyandotte. It may also be a polyether-polyester polyol combination, use of the polyester polyol making the cured polyurethane more flexible.
  • the ratio of components A:B is preferably from 50-60% "A" to from 50-40% "B".
  • a polyester polyol or polylactone polyol could be used in place of the polyether polyol.
  • Tanks (not shown) store the "A" and "B” material separately prior to mixing, then, feeding to supply line 46 for nozzle 42.
  • Fitting 48 connects multiple orifice nozzle 42 to supply line 46.
  • the number of tubes 44 and the spacing between the tubes in an individual nozzle will vary in dependence on the width of the portion of the substrate to be coated. It has been found that the use of between 10 and 26 tubes, spaced apart approximately 2.5 to 3.25mm produce an even coating of plastic material across the face of the substrate.
  • the tubes preferably have a 0.56mm I.D. and a 1.0mm O.D. spacer bar 50 holds the tubes 44 spaced apart at desired distances, preferably 2.5mm.
  • the casting head 40 is in a fixed position while the substrate tracks beneath it on conveyor 14.
  • this arrangement may be modified even within the contents of a conveyor type system to provide for a moving casting head tracking over a temporarily fixed position substrate.
  • the fluent plastic material As the fluent plastic material is laid down, it flows over the substrate to complete the coverage of the surface. A uniform thickness of plastic results.
  • the speed of conveyor movement and coating rate for the plastic depend upon the area to be covered, the number of tubes needed, and the viscosity of the fluent plastic. Generally, however, it is possible to adjust easily these variables in order to achieve a coating of the thickness desired.
  • the final coated thickness will be only about 0.1 to 0.2mm. This thickness may be varied by varying the hinge clearance and spacing of the plates, by providing shims which maintain a slight spacing between plates or by embossments on substrate.
  • the amount of fluent plastic coated onto the substrate at the casting station is slightly in excess of the amount required to produce such a thickness, with excess material being squeezed out during the clamping operation.
  • the pressure fixture 12 is closed and clamped at station 18.
  • the pressure required may vary depending upon the particular substrate utilized and whether any significant warpage occurred during a preliminary embossing operation. It has been found that from between 0.7 and 7.0 Kg/cm 2 applied to the pressure fixture by means of external clamps is sufficient to produce the flat level surface necessary for a uniform coating.
  • the construction of the pressure fixture is such that the upper and lower plates remain parallel during clamping with the embossments on substrate 30 providing support for the upper plate.
  • the coated substrate is cured by passing it through a heated oven 20. As shown, the oven is elongated and the speed of conveyor 14 is regulated to produce a dwell time sufficient for a complete cure. It has been found that an ambient air temperature in the oven of from about 82 to 110°C. and a dwell time of from about 15 to 30 minutes produces a complete cure.
  • the cured, coated substrate is then unclamped and unloaded from pressure fixture 12 at station 22 and is ready for further processing steps. These steps may include cutting, forming, and trimming operations to form individual emblems, plaques, or panels. An adhesive layer and release liner may also be applied to the back of the substrate at this time.
  • emblems After individual emblems have been formed, they may be adhesively applied into or onto the intended surface of an automobile or appliance. They may also be placed in a retaining frame which is used to affix the emblem onto a surface. Since the finished product has an ultrathin coating and the fluent plastic material may be compounded as described above to give a somewhat flexible coating when cured, forming operations other than merely die cutting may be undertaken. The emblem, and more often panels, may be conformed to nonplanar surfaces as long as the degree of bending for the conformity required is not too severe.
EP80303854A 1979-11-09 1980-10-29 Procédé de production d'emblèmes décoratifs pourvus d'un revêtement ultramince en matière plastique Withdrawn EP0028903A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US9289579A 1979-11-09 1979-11-09
US92895 1979-11-09

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EP0028903A1 true EP0028903A1 (fr) 1981-05-20

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EP80303854A Withdrawn EP0028903A1 (fr) 1979-11-09 1980-10-29 Procédé de production d'emblèmes décoratifs pourvus d'un revêtement ultramince en matière plastique

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EP (1) EP0028903A1 (fr)
JP (1) JPS6050157B2 (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0060721A1 (fr) * 1981-03-16 1982-09-22 The D.L.Auld Company Emblèmes decoratifs et leur mode de fabrication
EP0285572A2 (fr) * 1987-03-31 1988-10-05 Società Italiana Vetro - SIV S.p.A. Dispositif et procédé pour la fabrication de vitres de verre de sécurité avec un revêtement superficiel de matière plastique
EP1247588A2 (fr) * 2001-04-06 2002-10-09 Illinois Tool Works Inc. Revêtement protecteur et procédé pour sa réalisation
EP3113946A4 (fr) * 2014-03-07 2017-12-13 University Of South Australia Revêtements décoratifs pour substrats en matière plastique

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4460429A (en) * 1982-08-25 1984-07-17 The D. L. Auld Company Apparatus for manufacturing foil shapes having a cast plastic cap
JP3022880U (ja) * 1995-08-21 1996-04-02 地平 澤田 ワンタッチ開封吸い口

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
USRE19549E (en) * 1922-06-30 1935-04-30 Decorated article and method of
AU462224B2 (en) * 1972-01-20 1975-06-19 Thams J-P B A process FOR PRODUCING SURFACES OF SPECIFIED TEXTURE
US4100010A (en) * 1974-06-12 1978-07-11 The D. L. Auld Company Method for making decorative emblems
DE2731081A1 (de) * 1974-06-12 1979-01-25 D L Verfahren zur herstellung dekorativer embleme
EP0005376A1 (fr) * 1978-05-08 1979-11-14 The D.L.Auld Company Procédé pour la production d'emblèmes décoratifs

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
USRE19549E (en) * 1922-06-30 1935-04-30 Decorated article and method of
AU462224B2 (en) * 1972-01-20 1975-06-19 Thams J-P B A process FOR PRODUCING SURFACES OF SPECIFIED TEXTURE
US4100010A (en) * 1974-06-12 1978-07-11 The D. L. Auld Company Method for making decorative emblems
DE2731081A1 (de) * 1974-06-12 1979-01-25 D L Verfahren zur herstellung dekorativer embleme
EP0005376A1 (fr) * 1978-05-08 1979-11-14 The D.L.Auld Company Procédé pour la production d'emblèmes décoratifs

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0060721A1 (fr) * 1981-03-16 1982-09-22 The D.L.Auld Company Emblèmes decoratifs et leur mode de fabrication
EP0285572A2 (fr) * 1987-03-31 1988-10-05 Società Italiana Vetro - SIV S.p.A. Dispositif et procédé pour la fabrication de vitres de verre de sécurité avec un revêtement superficiel de matière plastique
EP0285572A3 (en) * 1987-03-31 1989-08-09 Societa' Italiana Vetro-Siv-Spa Apparatus and process for the manufacturing of sheets of safety glass with a superficial coating of plastic material
EP1247588A2 (fr) * 2001-04-06 2002-10-09 Illinois Tool Works Inc. Revêtement protecteur et procédé pour sa réalisation
EP1247588A3 (fr) * 2001-04-06 2003-11-05 Illinois Tool Works Inc. Revêtement protecteur et procédé pour sa réalisation
US6770324B2 (en) 2001-04-06 2004-08-03 Kennedy Acquisition, Inc. Method of forming a non-uniform, protective coating on a flexible substrate
EP3113946A4 (fr) * 2014-03-07 2017-12-13 University Of South Australia Revêtements décoratifs pour substrats en matière plastique

Also Published As

Publication number Publication date
JPS5685000A (en) 1981-07-10
JPS6050157B2 (ja) 1985-11-07

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