GB2309002A

GB2309002A - Forming signs by moulding process

Info

Publication number: GB2309002A
Application number: GB9600752A
Authority: GB
Inventors: Shaughan Martyn Bingham
Original assignee: Individual
Current assignee: Individual
Priority date: 1996-01-15
Filing date: 1996-01-15
Publication date: 1997-07-16
Anticipated expiration: 2016-01-15
Also published as: GB2309002B; GB9600752D0

Abstract

A method of forming a sign e.g. for a house, using a kit, comprises providing a transparent flexible mould 10, forming a layer of transparent material in the bottom of the mould 10, arranging one or more symbols 14 face down on the material in the bottom of the mould 10. The appearance of the sign can then be checked before proceeding any further by looking through the transparent mould 10 from the underside. The symbols 14 are then covered with a layer of thermosetting plastics, which has been mixed with a catalyst. Once the mixture has set, the sign 16 can be removed from the mould 10 and drilled ready for mounting on a wall or the like.

Description

SIGNS This invention relates to signs, such as house signs.

House signs are generally made to order from metal or wood by specialised manufacturers. A disadvantage of this is that the signs are expensive, and often do not appear quite as the purchaser had intended.

I have now devised a method of forming a sign which alleviates the above-mentioned problems.

In accordance with this invention there is provided a method of forming a sign, the method comprising providing a mould, arranging one or more symbols on the bottom of the mould, introducing a thermosetting plastics material into the mould to cover the symbol or symbols, and removing the sign from the mould once the plastics has set.

It is relatively easy to form cheap and attractive signs using the method in accordance with this invention.

Furthermore, the layout of the sign can be checked prior to introducing the thermosetting plastics into the mould.

A thermosetting plastic is a liquid polymer material in which chemical reactions, including cross-linking, take place while the material is being moulded, such that the material sets under applied heat.

Generally, the sign is moulded at room temperature, and thus most thermosetting plastics will take a considerable amount of time to set under this low heat. Thus, preferably a catalyst is mixed with the thermosetting plastics material prior to introducing it into the mould.

In order to facilitate removal of the sign from the mould, the internal surface of the mould is preferably coated with a release agent prior to arranging the symbol or symbols therein.

Preferably a layer of transparent material is applied to cover at least the bottom of the mould to form a protective layer in front of the symbols.

Preferably an aperture is drilled in the sign once it has been removed from the mould, to enable it to be mounted to a wall or the like.

Also, in accordance with this invention there is provided a kit for forming a sign, the kit comprising a mould, a plurality of symbols for arranging on the bottom of the mould and a quantity of thermosetting plastics for introducing into the mould.

Preferably the mould is flexible to facilitate removal of the sign from the mould.

Preferably the mould is formed from a transparent material, so that the visual appearance of the sign can be checked through the bottom of the mould before the plastics is introduced.

Preferably the symbols comprise letters and/or numbers.

Motifs, such as flowers or scrolls may also be provided.

Preferably the thermosetting plastics comprises a polyester, an epoxy-resin or a phenolic-resin.

Preferably the kit includes a catalyst for mixing with the plastics.

Preferably the kit comprises a pigment for adding to the plastics.

The pigment may comprise particles of a material such as metal, which become suspended in the plastics to give the appearance that the sign is made from that material.

Preferably the letters and/or numbers are formed from a light-emitting (illuminous) material, so that the signs can be seen in the dark.

An embodiment of this invention will now be described by way of example only and with reference to the accompanying drawings1 in which: Figures 1 to 7 show the successive stages of forming a house sign in accordance with this invention.

Referring to Figure 1 of the drawings, there is shown a transparent mould 10 of plastics material in the form of a shallow tray. The mould has a flat octagonal bottom wall 11 with upstanding side walls 12 extending around its periphery.

Prior to using the mould, the inside surface thereof is sprayed with a clear lacquer 13, which will form a transparent protective layer for the front of the sign and also acts as a release agent for the mould.

Referring to Figure 2 of the drawings, symbols 14 such as letters, numbers and motifs are then laid face-down in the bottom of the mould 10. The symbols 14 may be formed on a clear plastics background and protected by a protective covering 15, which can be peeled off prior to use, as shown in the drawing. The appearance of the sign can then be checked before proceeding any further by looking through the transparent mould 10 from its underside.

Referring to Figures 3 and 4 of the drawings, once the desired layout of the symbols is achieved, a liquid thermosetting plastics material is thoroughly mixed with a catalyst and a pigment in a container. The mixture is then introduced into the mould 10 to cover the symbols 14.

Referring to Figure 5 of the drawings, the sign 16 can be removed from the mould once the mixture has set.

Referring to Figures 6 and 7 of the drawings, apertures 17 are then drilled in the sign 16, so that it can be mounted on a wall by passing screws through the apertures.

A sign made in accordance with this invention is cheap and simple to manufacture, and is as attractive as professionally-made signs.

Claims

1. A method of forming a sign, the method comprising providing a mould, arranging one or more symbols on the bottom of the mould, introducing a thermosetting plastics material into the mould to cover the symbol or symbols, and removing the sign from the mould once the plastics has set.

2. A method as claimed in claim 1, in which a catalyst is mixed with the thermosetting plastics material prior to introducing the plastics into the mould.

3. A method as claimed in claims 1 or 2, in which the internal surface of the mould is coated with a release agent prior to arranging the symbol or symbols therein.

4. A method as claimed in any preceding claim, in which a layer of transparent material is applied to cover at least the bottom of the mould.

5. A method as claimed in any preceding claim, in which an aperture is drilled in the plastics material once it has set and after it has been removed from the mould.

6. A method of forming a sign, the method being substantially as herein described with reference to the accompanying drawings.

7. A kit for forming a sign, the kit comprising a mould, a plurality of symbols for arranging on the bottom of the mould and a quantity of thermosetting plastics for introducing into the mould.

8. A kit as claimed in claim 7, in which the mould is flexible.

9. A kit as claimed in claims 7 or 8, in which the mould is formed a transparent material.

10. A kit as claimed in any of claims 7 to 9, in which the symbols comprise letters.

11. A kit as claimed in any of claims 7 to 10, in which the symbols comprise numbers.

12. A kit as claimed in any of claims 7 to 11, in which the symbols comprise motifs.

13. A kit as claimed in any of claims 7 to 12, in which the thermosetting plastics comprises a polyester.

14. A kit as claimed in any of claims 7 to 12, in which the thermosetting plastics comprises an epoxy resin.

15. A kit as claimed in any of claims 7 to 12, in which the thermosetting plastics comprises a phenolic-resin.

16. A kit as claimed in any of claims 7 to 15, including a catalyst for mixing with the plastics.

17. A kit as claimed in any of claims 7 to 11, including a pigment for adding to the plastics.

18. A kit as claimed in claim 17, in which the pigment comprises particles of a material, which become suspended in the plastics such that the plastics resembles a body of the material of the plastics.

19. A kit as claimed in claims 10 or 11, in which the symbols are formed from a light-emitting material.

20. A sign substantially as herein described with reference to the accompanying drawings.