EP0658447A1 - Process for manufacturing decorative products using reproductions of graphic representations - Google Patents

Abstract

Process for manufacturing decorative products, particularly for applying to walls or for use in advertising, in which the representation (work) to be reproduced is transferred by printing onto a planar support (1) consisting of a sheet (2) made from thermoformable plastic. According to the invention, this process is characterised in that it consists in producing, on the said support, in trompe l'oeil, the design of a frame (4) surrounding the reproduction (3) of the work, in thermoforming the plastic material of the support in line with the drawing of the frame in order to cause an embossing, constituting a lath or peripheral structure (5, 6), to appear in the plane of the support, in cutting out this support prior to or subsequent to the thermoforming operation, along the outer contour of the frame, in turning the support over in order to apply it on a support matrix (13), keeping it flat, in injecting or otherwise filling the hollowed-out profile made on the opposite side of the frame with a material (16) capable of becoming stiff, then in separating the support from the matrix in order to form a panel in a single piece including, on one face, the reproduction arranged in the centre of the drawing of the frame and, on the opposite face, a surround accommodated inside the frame and stiffening the latter. The invention also relates to the products obtained by means of this process.

Description

The present invention relates to a method for manufacturing decorative products, in particular for wall applications, of the kind of various reproductions of graphic works, such as drawings, sketches, sketches, photographs, tables or the like, if necessary of articles. the type of signs or objects to be applied against a wall, such as coat hooks, height rods, or similar articles, having in common the ability to be generally flat to allow to be disposed against this wall, vis-à-vis screw from which they are suspended or fixed at an appropriate height.

Numerous methods of reproducing works of various natures have been known for a very long time, for example by printing, photography, photocopying, screen printing, lithography or the like, on supports which vary from one production to another, the most characteristic of which general is to allow a replica in multiple identical copies of an original original creation, allowing a wide dissemination of these works for the cultural benefit and the pleasure of the public.

These reproductions are carried out in most constant rule on a rigid support, plan, paper, cardboard, material plastic, fabric possibly, without this list having by itself a limiting character, the only imperative being to be able to transpose and reproduce faithfully on such a support the original work with a sufficient reliability ensuring the suitable durability of the reproduction, that- these may further and where appropriate, include additions or decorative additions which may be made to the work reproduced, either because it is in the public domain, or by virtue of the Authorization of the Author.

An application of these well-known general principles is envisaged in US-A-3,289,193 or GB-A-1,572,324, which describe methods of reproduction, in particular of a work of painting, available in original, consisting of by means of a mold reproducing in relief the reliefs of this work, in obtaining a reproduction of the latter by pressing any support which will include the same reliefs as the initial work. After which, the reproduction can be painted by the buyer, who can also be guided in the work to be done.

Generally, these reproductions, once made on the chosen medium, are most often arranged inside a presentation and support frame, ensuring the flattening of the reproduced work, usually in the case of paintings, drawings or the like, with partial overlap of the edges of the support by means of a "pass everywhere" cover, plain or decorated, which surrounds the reproduction on its support and forms a transition with the border of the frame surrounding the set. Note that the aforementioned prior patents indicate that the framework of the work to be reproduced can be produced at the same time as the reproduction itself.

However, these conventional solutions, which, moreover, require the application of paints or inks, manually or by any other process, to achieve a framed finished product, have various drawbacks, the least of which is not the relatively high cost of l '' assembly, requiring for the user the purchase of the reproduction itself on its support but generally also of the frame, possibly of the intermediate peripheral cover, the assembly being sold assembled, if necessary in separate parts, the manufacturer in one case, the user in the other, mounting these various parts, having to realize their centering with respect to each other before their final assembly, the price of labor sometimes coming to burden important the cost of the final product and requiring in all cases a know-how which is not necessarily mastered by anyone.

In short, the framing of a reproduction involves significant costs, which sometimes put off the buying speed of the Customer.

The present invention relates to a method of manufacturing decorative products of the aforementioned kind, which avoids these drawbacks by eliminating, after prior production of the support on which the reproduction is postponed, the successive operations necessary to achieve its framing, with a separate cost but ultimately accumulated from these interventions.

The invention also relates to decorative products in the broadest sense, obtained by the implementation of the process considered.

To this end, this process in which the work to be reproduced is printed by any conventional means, on a flat support, in particular made of material thermoformable plastic, is characterized in that it consists in carrying out simultaneously or later on said support in trompe l'oeil the drawing of a frame surrounding the reproduction of the work, in thermoforming the plastic material of the support in line with the drawing of the frame to make appear in the plane of the support a boss constituting a rod or peripheral structure, continuous or not, extending according to the profile of the frame in relief towards the outside relative to the plane of the support, to cut this support before or after during the thermoforming operation, according to the external contour of the frame, to invert the support to apply it on a support matrix keeping it flat, to inject or otherwise fill the hollow profile formed on the opposite side of the frame by a material capable of stiffening, then separating the support from the matrix to form a panel in one piece, having on one side the reproduction arranged in the middle of u drawing of the frame and on the opposite face, an entourage housed inside the frame and stiffening it.

The method according to the invention therefore makes it possible, by a series of successive operations carried out on the medium of the reproduction itself, to directly incorporate therein the frame surrounding this reproduction and in total to provide a product eliminating any operation subsequent mounting and mutual centering of various independent elements, before carrying out their final assembly.

The transfer of the work, original or adapted, that is to say incorporating any desired or authorized addition or modification, on the thermoformable plastic support, in particular at the level of the frame, can be carried out by any printing process. conventional, in particular by photography, serigraphy, lithography, photoengraving, offset, decal or other transfer process, such process known per se having no direct impact on the present invention, from the moment when it makes it possible to reproduce the work on this medium under satisfactory conditions of fidelity and reliability.

In addition, the drawing of the trompe l'oeil frame around the reproduction can be made, either on a test used for the subsequent implementation of the reproduction and transfer process of the work on the thermoformable material support, or on the medium itself after the reproduction has been printed on it.

The frame can have any contrast effect with respect to the reproduction that it surrounds, by simulating by drawing any material, any texture, or any desired profile or dimensions, to integrate into or be reproduced from this reproduction. to distinguish. In particular, the drawing of the frame may include, interposed between the reproduction and the peripheral strip, an intermediate cover, or "pass everywhere", transferred simultaneously or successively to the support.

Depending on the case, the thermoformable plastic support is made of polyvinyl chloride, polyester, polypropylene, polycarbonate, ABS (acrylonitrile butadiene styrene), or any other equivalent material, having an appropriate relative rigidity and above all a good ability to serve as a printing medium for the reproduction to be transferred thereon. The thickness of the support can be variable from one plastic to another, of the order of 0.3 to 3 mm, or even more, depending on the resistance sought for the support, in particular in tearing or vis- against shocks or spikes. On the other hand, the reproduction on the support has a thickness which can be extremely limited, of the order of 0.2 to 0.8 mm, depending on the process. adopted printing, without these dimensions being in themselves limiting.

According to an advantageous additional characteristic, the support of thermoformable plastic material comprising the reproduction may be coated, before or after the thermoforming of the frame, with a thin layer of external protection. Preferably, such a thin protective layer can be produced in the form of a transparent plastic sheet, applied or bonded to the support, or else obtained by projection or passage through a bath, followed by a drying step.

According to another particular characteristic of the process considered, the thermoforming of the support for the production of the frame is carried out in a mold, comprising a raised rib, the profile of which corresponds to that of the rod or structure to be produced in the support, the pressure application of the latter against the rib of the mold causing in the support an indentation delimiting the outline of the frame.

Advantageously, the thermoforming mold comprises a rigid seat provided with the rib in relief in line with the location of the frame to be formed, the support being applied against the seat by means of a press plate, comprising, where appropriate, like the seat, heating means capable of ensuring the deformation of the support under the combined effect of pressure and temperature.

Optionally, the seat of the mold may include pneumatic suction means to perfect the application of the support against the frame-forming rib.

Preferably, the support matrix on which the support is applied comprising the frame after cutting according to the outer periphery thereof, has a hollow external imprint receiving the frame rod and a flat inner part in contact with the reproduction carried over to the support. Advantageously, this inner part includes a protective coating, to avoid any deterioration of the support in contact.

According to another characteristic, the filling of the frame after thermoforming, inside the rod received in the imprint of the support matrix, is carried out using a material chosen from polyurethane foam, an epoxy resin or plaster, or more generally a thermosetting material, preferably quick setting, neutral with respect to the plastic of the support.

Advantageously, a wall fastener of any type is placed or embedded in the filling material of the rod, before it hardens.

Finally and according to yet another characteristic of the process considered, the finishing of the product can be carried out by applying an external protective sheet against the face of the support opposite to that comprising the reproduction, this sheet being able to consist of a coating of plastic material, a sheet of paper, cardboard or other.

• La Figure 1 est une vue schématique en perspective d'un support en une matière plastique thermoformable sur lequel a été reportée une reproduction quelconque.
• La Figure 2 illustre une étape complémentaire de mise en place d'une feuille de protection sur le support de la Figure 1.
• La Figure 3 est une vue en coupe transversale du moule de thermoformage pour la réalisation de la baguette du cadre entourant la reproduction.
• La Figure 4 illustre le support après thermoformage et découpage à la périphérie du cadre.
• La Figure 5 est une vue en coupe transversale de la matrice d'appui du support permettant l'opération de remplissage de la baguette par un matériau de rigidification.
• La Figure 6 est une vue de côté du produit achevé.

Other characteristics of the manufacturing process under consideration, as well as of the decorative product obtained by this process, will become apparent from the following description of an exemplary embodiment, given by way of non-limiting example, with reference to the attached drawing in which :

• Figure 1 is a schematic perspective view of a support of a thermoformable plastic material on which has been transferred any reproduction.
• Figure 2 illustrates an additional step of placing a protective sheet on the support of Figure 1.
• Figure 3 is a cross-sectional view of the thermoforming mold for the production of the baguette of the frame surrounding the reproduction.
• Figure 4 illustrates the support after thermoforming and cutting at the periphery of the frame.
• Figure 5 is a cross-sectional view of the support matrix of the support for the operation of filling the rod with a stiffening material.
• Figure 6 is a side view of the finished product.

In Figure 1, the reference 1 designates a printing medium, consisting of a sheet 2 of a thermoformable plastic, of the polyvinyl chloride, polyethylene, polypropylene, polycarbonate, ABS or other type. This sheet has an appropriate thickness, which can be between 1 mm or less and 4 or 5 mm, depending on the nature of the plastic material and the printing process used to transfer onto the surface of the sheet 2 any reproduction 3 . This sheet has good resistance to tearing effects and to impact or attack by a sharp object.

The printing of the reproduction 3 on the support 1 can be carried out by any conventional method well known in the art, making it possible to transfer safely, reliably and faithfully, onto the surface of the sheet 2 a drawing, a sketch, a sketch, a photograph, a table, with in any case a report of the forms, dimensions and colors of the model, which can itself be an original work or a prior reproduction thereof.

If necessary, the reproduction of the reproduction on the sheet of the support can be carried out identically or on the contrary by making adaptations or modifications, desired and if necessary authorized. This reproduction can be made flat or include hollows or reliefs depending on the design itself and the effects to be manifested. As a general rule, the thickness of the reproduction thus reported on the support sheet is between 0.2 and 0.8 mm.

The next step consists in drawing or transferring onto sheet 2 the drawing of a frame 4 surrounding the reproduction 3, this drawing of the frame being able to be carried out prior to the postponement of the reproduction itself and in turn transposed onto the support, or be performed on the test to be reproduced before it is transferred to the sheet.

The frame 4 can have any suitable shape and in particular in the most general case include longitudinal parts, forming together around the reproduction the representation of a rod 5, the latter term being taken in the broad sense. In particular, the frame may itself include, in its longitudinal parts as well as in its corners 6, various extensions, decorations or modifications, the presence of which has no effect on the implementation of the method according to the invention.

Likewise, the frame 4 can be drawn in any color, preferably but not necessarily contrasting with the colors of the reproduction 3 as in a usual table. Inside the frame can be provided and drawn a neutral border (not shown on the drawings) simulating a cover of the "passe-partout" type, generally provided in tables or reproductions intended to be presented while hanging against the surface of a wall or the like.

In the next step, shown in Figure 2, there is arranged against the surface of the sheet 2, a protective layer 7, consisting of a thin film of a transparent plastic material, for example of the "Mylar" type or the like . Note, however, that this protective coating is not essential; as a variant, the thin film can be produced by spraying or spraying onto the surface of the support 1 carrying the reproduction 3 or alternatively by soaking or passing through a bath, followed by a drying step.

The support 1 thus prepared, with the transfer to sheet 2 of the reproduction 3 and of the drawing of the frame 4, then undergoes a thermoforming operation according to a process which is also well known in the art, Figure 3 therefore giving only '' a completely schematic representation of the adopted process. Note however that this thermoforming operation could be performed before the installation of the protective coating 7 described above.

Usually, a mold is used consisting of a solid seat 8 having a raised lateral rib 9, the profile of which is determined to ensure, in line with the frame 4, in particular in the longitudinal parts 5 thereof, a raised boss similarly, the thermoforming of the sheet 2 allowing it to closely match the profile of the rib 9 by pressing tightly against the seat 8. Advantageously, the application of the sheet 2 on the seat 8 is produced by means of the plate of a forming press 10, with an energetic suction of the sheet 2 through this seat in the direction of the arrows 11, the seat being for this purpose pierced with a plurality of channels (not shown). The seat 8 and the plate 10 of the press comprise heating means, for example electrical resistances and a regulation system, making it possible to bring the temperature of the sheet 2 to the level necessary to obtain its deformation.

Advantageously, the central part of the seat 8 against which the reproduction 3 produced on the sheet 2 is applied, may be coated with an appropriate protective layer, in order to avoid damaging it during the operation. thermoforming.

The next step, shown schematically in Figure 4, consists, after removing the sheet 2 thus conformed to the right of the frame 4 drawn around the reproduction, to cut the extreme edges of the sheet at the periphery of the frame, horizontally or vertically at by means of cutters schematically illustrated at 12 in this figure, which may be constituted by circular or band saws, or by any other similar means of the cutter, punch, laser or pressure jet cutting machine type , Or other.

The support 1 thus prepared and cut is then turned over on itself and put in place in a support matrix 13 (FIG. 5) comprising a hollow imprint 14, shaped in its lateral sides 15 so as to accommodate the boss forming the rod 5, 6 of the frame 4, strictly reproducing the shape of the rib 9 of the seat 8.

In this position, the hollow form delimited by the frame 4 is filled by means of a material 16, chosen to ensure proper stiffening of the latter. Preferably, this material can consist of polyurethane injected under pressure inside the frame, the matrix 13 being in this case covered with a cover (not shown) leaving only space, between itself and the matrix, the space in which the injection is to be carried out . As a variant, the frame can be filled with a thermosetting resin, of the epoxy resin type, or even with plaster or another quick-setting material, capable of solidifying by hardening, while being neutral with respect to the plastic material of the support which it cannot therefore affect.

Note, however, that one might as well plan to proceed in the reverse order, by filling the frame 4 before cutting it to the desired format, the operations illustrated in Figures 4 and 5 respectively being carried out one before the 'other.

The final step consists, after having embedded in the material 16 prior to its final hardening, a fastener 17 allowing the frame to be hooked subsequently against a wall or similar structure, to remove the product from the matrix 13, as shown in the Figure 6. Note that the clip 17 can be implemented in another way, for example using screws, gluing or any other means. Finally, there is advantageously behind the frame, a protective sheet 18, of paper, cardboard, plastic or other material.

Of course, it goes without saying that the invention is not limited to the example of implementation of the method described above, with reference to the accompanying drawing; on the contrary, it embraces all its variants.

In particular, if the process has been more particularly envisaged for the production of decorative wall panels, it is clear that its application cannot be thus limited, the provisions provided for being able to be adopted to manufacture other products of the height rods, hooks, signs or other type, comprising a central part and a frame, the latter ensuring the support of the assembly and requiring only to be stiffened, or even for producing decorative panels for advertising use, especially at points of sale.

Similarly, the method according to the invention can naturally be exploited, not only for producing the outline or the framing of the work during the thermoforming phase, but also part of the image or of the decorative patterns contained in this framing.

Whatever the variant used, the method according to the invention has the advantage which results from the simultaneous production of a reproduction and its setting, allowing a considerable reduction in costs vis-à-vis comparable products traditionally produced. . In addition, the possibility of making the frame directly around the design transferred to the support offers great creativity with regard to the shape, colors and structure of this frame.

Claims (19)

1 - Process for the manufacture of decorative products, in particular for wall applications, in which the work to be reproduced is printed by printing using any conventional means on a flat support (1), in particular consisting of a sheet (2) of thermoformable plastic material , characterized in that it consists in carrying out simultaneously or later on said support in trompe l'oeil the drawing of a frame (4) surrounding the reproduction (3) of the work, in thermoforming the plastic material of the support at right of the drawing of the frame to reveal in the plane of the support a boss constituting a rod or peripheral structure (5, 6), continuous or not, extending according to the profile of the frame in relief towards the outside relative to the plane of the support , to cut this support before or after the thermoforming operation, according to the external contour of the frame, to turn the support to apply it on a support matrix (13) maintaining it flat, to be injected or otherwise fill the hollow profile formed on the opposite side of the frame with a material (16) capable of stiffening, then separating the support from the matrix to form a panel in one piece, comprising on one side the reproduction arranged in the middle of the drawing of the frame and on the opposite face, an entourage housed inside the frame and stiffening the latter. 2 - Method according to claim 1, characterized in that the postponement of the reproduction is carried out by a printing process such as photography, screen printing, lithography, photoengraving, offset, decal or other transfer process. 3 - Method according to one of claims 1 or 2, characterized in that one carries out the drawing of the frame (4) trompe l'oeil around the reproduction (3), or directly on it, or on the support (1) after the reproduction has been printed there. 4 - Method according to any one of claims 1 to 3, characterized in that the frame (4) has any effect of contrast with respect to the reproduction (3) which it surrounds, simulating by drawing everything material, any texture, or any profile or dimensions desired, to integrate into or be distinguished from this reproduction. 5 - Method according to claim 4, characterized in that the drawing of the frame (4) comprises, interposed between the reproduction and the peripheral rod, an intermediate cover, transferred simultaneously or successively on the support. 6 - Method according to any one of claims 1 to 5, characterized in that the support (1) is made of thermoformable plastic material such as polyvinyl chloride, polyester, polypropylene, polycarbonate, ABS (acrylonitrile butadiene styrene) or any other equivalent material. 7 - Method according to any one of claims 1 to 6, characterized in that one realizes the thickness of the support (1) according to the resistance sought for this support to tearing or vis-à-vis shocks or cutting edge effects. 8 - Method according to any one of claims 1 to 7, characterized in that the reproduction (3) on the support (1) has a limited thickness, of the order in particular of 0.2 to 0.8 mm, in depending on the printing process adopted. 9 - Method according to any one of claims 1 to 8, characterized in that there is on the support material thermoformable plastic comprising the reproduction, before or after the thermoforming of the frame, a thin layer (7) of external protection. 10 - Process according to claim 9, characterized in that the protective thin layer (7) is produced in the form of a transparent plastic sheet, applied or bonded to the support, or also obtained by projection or passage through a bath. , followed by a drying step. 11 - Method according to any one of claims 1 to 10, characterized in that the thermoforming of the support (1) is carried out for the production of the frame (4) in a mold comprising a raised rib, the profile of which corresponds to that of the rod or structure to be produced in the support, the application under pressure of the latter against the rib of the mold causing in the support an indentation delimiting the outline of the frame. 12 - Process according to claim 11, characterized in that the thermoforming mold is constituted with a rigid seat (8) provided with the raised rib (9) in line with the location of the frame (4) to be formed, the support (1) being applied against the seat by means of a press plate (10), comprising, where appropriate as the seat, heating means capable of ensuring the deformation of the support under the combined effect of the pressure and temperature. 13 - Method according to claim 12, characterized in that the seat (8) of the mold comprises pneumatic suction means to perfect the application of the support (1) against the rib (9) for forming the frame (4) . 14 - Method according to claim 1, characterized in that one realizes on the support matrix (13) on which is applied the support (1) comprising the frame (4) after cutting along the outer periphery thereof, a hollow recess (15) receiving the strip (5, 6) of the frame and a flat inner part in contact with the reproduction carried over to the support. 15 - Method according to claim 14, characterized in that there is provided on the inner part of the matrix (13) a protective coating. 16 - Method according to any one of claims 1 to 15, characterized in that the filling of the frame (4) is carried out after thermoforming, inside the rod (5, 6) by means of a material ( 16) chosen from polyurethane foam, epoxy resin or plaster, or more generally still a thermosetting material, preferably quick setting, neutral with respect to the plastic of the support. 17 - Process according to claim 16, characterized in that a wall fastener (17) of any type is put in place or embedded in the filling material (16) of the rod, before it hardens . 18 - Method according to any one of claims 1 to 17, characterized in that the product is finished by applying an external protective sheet (18) against the face of the support (1) opposite to that comprising the reproduction ( 3), this sheet being constituted by a coating of plastic material, a sheet of paper, cardboard or the like. 19 - Decorative product, in particular for wall application, obtained by the process according to any one of Claims 1 to 18.

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