GB2333994A - Applying an image to a plastics material - Google Patents

Applying an image to a plastics material Download PDF

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Publication number
GB2333994A
GB2333994A GB9802521A GB9802521A GB2333994A GB 2333994 A GB2333994 A GB 2333994A GB 9802521 A GB9802521 A GB 9802521A GB 9802521 A GB9802521 A GB 9802521A GB 2333994 A GB2333994 A GB 2333994A
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GB
United Kingdom
Prior art keywords
sheet
image
layer
plastics material
sheet material
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.)
Granted
Application number
GB9802521A
Other versions
GB2333994B (en
GB9802521D0 (en
Inventor
Robin Jeffery
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.)
Hambleside Danelaw Ltd
Original Assignee
Hambleside Danelaw Ltd
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 Hambleside Danelaw Ltd filed Critical Hambleside Danelaw Ltd
Priority to GB9802521A priority Critical patent/GB2333994B/en
Publication of GB9802521D0 publication Critical patent/GB9802521D0/en
Publication of GB2333994A publication Critical patent/GB2333994A/en
Application granted granted Critical
Publication of GB2333994B publication Critical patent/GB2333994B/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/685—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks by laminating inserts between two plastic films or plates
    • B29C70/686—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks by laminating inserts between two plastic films or plates the inserts being sheets or documents, e.g. ID cards
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/86—Incorporated in coherent impregnated reinforcing layers, e.g. by winding
    • B29C70/865—Incorporated in coherent impregnated reinforcing layers, e.g. by winding completely encapsulated
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
    • B44C5/0423—Ornamental plaques, e.g. decorative panels, decorative veneers containing fibreglass elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
    • B44C5/0446—Ornamental plaques, e.g. decorative panels, decorative veneers bearing graphical information
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44F—SPECIAL DESIGNS OR PICTURES
    • B44F1/00—Designs or pictures characterised by special or unusual light effects
    • B44F1/06—Designs or pictures characterised by special or unusual light effects produced by transmitted light, e.g. transparencies, imitations of glass paintings
    • B44F1/066—Designs or pictures characterised by special or unusual light effects produced by transmitted light, e.g. transparencies, imitations of glass paintings comprising at least two transparent elements, e.g. sheets, layers
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D13/00—Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage; Sky-lights
    • E04D13/03—Sky-lights; Domes; Ventilating sky-lights
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
    • E04D3/24—Roof covering by making use of flat or curved slabs or stiff sheets with special cross-section, e.g. with corrugations on both sides, with ribs, flanges, or the like
    • E04D3/28—Roof covering by making use of flat or curved slabs or stiff sheets with special cross-section, e.g. with corrugations on both sides, with ribs, flanges, or the like of glass or other translucent material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/028—Paper layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/41—Opaque
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/414—Translucent

Abstract

A method of applying an image to the plastics material comprising a layer of resin (20) and a layer of glass fibre (14), which method comprises the steps of first applying an image (18) onto sheet material (16) and inserting the sheet material into the plastics material between said layers. The method may further comprise the steps of placing liquid resin (12) onto a first plastic film, inserting the sheet material into the liquid resin, applying glass fibres and optionally, applying a second plastics film to said glass fibre layer. Applications include roof lights, cladding or lining external or internal walls or for providing screening.

Description

PRINTING PROCESS The invention relates to a method of applying an image to a plastics material, for example glass reinforced polyester ("GRP").
It is known to print images using, for example, silk screening or lithography onto a surface of plastics material.
A problem associated with printing an image onto a surface, is that in certain conditions the printed image can be removed by scratching or through direct exposure to the elements which is undesirable and should be avoided, particularly when the images being displayed communicate warning symbols or messages.
It is also known to print images onto the surface of continuously formed GRP material. GRP sheets are commonly manufactured by laying a polyester film onto a table, then placing liquid resin onto the film. Thereafter, glass fibre in a mat form or rovings is applied to the liquid resin to form a sheet. The sheet is then cured and formed into profiles or flat sheets. If it is desired to display an image on GRP material, then commonly it is printed onto polyester film prior to the manufacturing process.
A problem associated with known printing processes is that the polyester film is required to undergo an additional printing process: the polyester film is unwound, the image is printed onto film and it is then rewound to be ready for the GRP manufacturing process. This additional process is costly and undesirable.
Other known processes print the polyester film directly prior to its application to the GRP production process which would also be costly requiring additional printing equipment operating in line with the production speeds of continual profiling process line, which can be variable depending upon the type of product being manufactured.
The present invention and its preferred embodiment seeks to overcome or at least mitigate the problems associated with the prior art.
According to one aspect of the invention, there is provided a method of applying an image to a plastics material comprising a layer of resin and a layer of glass fibre, which method comprises the steps of first applying an image onto sheet material and inserting the sheet material into the plastics material between said layers.
According to an optional feature of this aspect of the invention, the step of inserting the sheet material into the plastics material may further comprise the steps of placing the liquid resin onto a first plastics film and inserting the sheet material into the liquid resin, and optionally, applying a second plastics film to said glass fibre layer.
According to another optional feature, the sheet material is absorbed into the resin prior to curing the plastics material.
According to another optional feature, a second plastics film is applied to said glass fibre layer prior to curing the plastics material.
According to a further optional feature of this aspect of the invention, the step of inserting the sheet material into the plastics material may be carried out intermittently.
Preferably, the image is printed onto said sheet material using a polyester based ink.
More preferably, the plastics material and/or sheet material is translucent or, as the case may be, opaque.
Another aspect of the present invention provides a sheet of plastics material displaying an image comprising a layer of resin and a layer of glass fibre and a layer of sheet material including an image to be displayed in the plastics material, wherein the sheet material is disposed between said resin layer and said glass fibre layer.
According to an optional feature of this aspect of the invention, the image may be printed onto said sheet material using a polyester based ink.
Preferably, the plastics material and/or said sheet material is translucent or, as the case may be, opaque. In one class of embodiments, the sheet material comprises paper, or optionally, tissue.
In yet another embodiment of the present invention, there comprises a roof light having an image printed thereon using the process of the invention.
Another aspect of the invention includes the use of a sheet of plastics material to display an image on a profiled form of said sheet.
The invention includes the use of a sheet of plastics material to display an image on a flat form of said sheet.
An embodiment of the invention will now be described, by way of example, with reference to the accompanying drawings in which: FIGURE 1 is an exploded view of a layer of plastics material manufactured in accordance with the invention; and FIGURES 2 and 3 illustrate an example of a roof light, which can be formed from the material shown in Figure 1.
Turning to the drawings, and in particular, Figure 1, there comprises flexible plastics material which is desirably reinforced. It is most preferred, the material is glass reinforced polyester ("GRP") material, which is preferably formed by pultrusion or by continual profiling process into a sheet. Figure 1 illustrates a sheet 10 of GRP material manufactured in accordance with the invention which comprises a layer of resin 12, a layer of glass fibre 14 and a layer of sheet material 16 incorporating an image 18 to be displayed in the plastics material. In this embodiment, the sheet material layer 16 is disposed between the resin layer and the glass fibre layer.
In one class of embodiments, the invention can be incorporated into other GRP production processes, for example hand laying, by use of spray equipment or through a press technique, the sheet material being applied to the resin (or vice versa) so that it is absorbed into the resin.
In another class of embodiments described below, sheets of GRP material made in accordance with the invention are manufactured continuously by a continual profiling process, whereby a polyester film 20 or other suitable material is laid on a table and resin 12, for example an unsaturated polyester in liquid form is poured onto the polyester film 20.
Thereafter, a sheet 16 incorporating an image 18 to be displayed is laid on the liquid resin. The sheet 16 is desirably absorbent and more preferably can be fully absorbed into the resin. Examples of suitable sheet material 16 are paper or tissue, but other absorbent materials, for example cloth, may be used without departing from the scope of the invention. The sheet can be applied to the entire width of the resin layer or in thin strips. Alternatively, it can be applied to the resin as a series of spaced discrete panels, if so desired. A preferred weight of paper is used, which often depends upon the relationship of the overall resin/glass ratio governing the GRP thickness; usually up to 3 to 4mm. Commonly, the paper can be 16 to 18 grams and rising to about 175 grams for heavier weight product.
Once the paper sheet has been absorbed into the liquid resin, then suitable reinforcement material, for example, glass fibre rovings (or in the embodiment illustrated, a matt 14) is laid onto the resin, and the mix is consolidated into an homogenous composite.
Optionally, a second layer of polyester film (not shown) is applied onto the reinforcement material layer 14 and the laminate material is then cured into a flat sheet, or, where required, a particular profile. Thus, a sandwich of polyester film, the composite of resin glass and sheet, and then polyester film is formed.
Alternatively the sheet could be applied to the polyester film already on the table bed, with the resin being subsequently applied to it; or the sheet could be applied to the top of the resin surface after the resin has been poured onto the first polyester film surface, and prior to the optional application of the second layer of polyester film.
The image (or printed matter) 18 to be displayed can be applied to the sheet material 16 by a separate process. Commonly, screen printing or other known printing process is used to print the desired image onto the sheet. The inks used in this process should be capable of not reacting with the liquid resin when applied to it. One class of suitable inks are polyester based inks.
In certain cases, it is desired that either one or both of the polyester film surfaces can be removed as part of the production process. When inserting the sheet material incorporating the printed matter, which then becomes absorbed by the resin, it can remain as an integral part of the resin composite. This advantage is not present in the prior art where the polyester film is itself printed because if it is removed the printed message is also removed.
A further requirement of the sheet material and ink, is that it should, preferably, be capable of being absorbed into the liquid resin without the integrity of the image being affected. The preferred examples outlined above satisfy this requirement.
In order for the image to be displayed, the resin should preferably be transparent or translucent. The resin formed from the preferred polyester based compound possesses this quality. It is envisaged that the compounds used as the resin could be altered if so desired, and likewise, the choice of ink and/or sheet material can be changed to retain the qualities hereinabove described without departing from the scope of the invention.
Further, the positioning of the sheet material within the resin will to a certain degree govern the visibility of the product.
In another class of embodiments, the GRP material may be opaque by the addition of pigments to the resin. For example, the manufacturing process may be adapted such that the sheet may be laid on top of the glass mat/rovings which have already been saturated by the resin, rather than in the method outlined above where the paper is saturated prior to the application of glass mat/rovings. This type of production produces an opaque product where the printed matter is adjacent or juxtaposed the polyester film surface for visibility purposes.
A sheet made by the processes outlined above should be universal in its application, for example it can be used in flat sheet or profiled form.
One particular use is as part of a roofing system, where it is desired to carry messages in connection with safety issues and product information. The preferred translucent feature of the sheet material makes it ideal for use as a rooflight, when it is desired to warn persons not to step on it. Further uses include factory and warehouse constructions where there is a requirement for natural light. They may also be used for cladding or lining exterior or internal walls or for providing screening, for example, they may be used as anti-sight screen on airport perimeter roads.
Further or alternatively, the product will also allow incorporation within the product a trade mark or other identifying indicia or a design pattern.
In trials, it has been proved that the invention enables provision of a sheet incorporating an image which is displayed therefrom. The image cannot be removed inadvertently or otherwise and by including suitable ultra violet inhibitors in the resin, the image does not deteriorate significantly in sunlight. As the image is retained within the plastics material, it is suitably protected from the elements.
The present invention and its preferred embodiment can be applied to a continuous production process, or, where required, the sheet layer can be supplied separately and applied to the plastics material being formed in situ (often referred to as handlaying).
Further, the present invention and its preferred embodiments relate to a method of forming plastics material which minimises the production time required to apply an image to it.

Claims (18)

  1. CLBTMS 1. A method of applying an image to a plastics material comprising a layer of resin and a layer of glass fibre, which method comprises the steps of first applying an image onto sheet material and inserting the sheet material into the plastics material between said layers.
  2. 2. A method as claimed in claim 1, wherein the step of inserting the sheet material into the plastics material further comprises the steps of placing the liquid resin onto a first plastics film and inserting the sheet material into the liquid resin, and curing the plastics material
  3. 3. A method as claimed in claim 2 further comprising the step of allowing the sheet material to be absorbed into the resin prior to curing the plastics material.
  4. 4. A method as claimed in any of claims 1 to 3 wherein a second plastics film is applied to said glass fibre layer prior to curing the plastics material.
  5. 5. A method as claimed in any preceding claim, wherein the step of inserting the sheet material into the plastics material is carried out intermittently.
  6. 6. A method as claimed in any preceding claim, wherein the image is printed onto said sheet material with a polyester based ink.
  7. 7. A method as claimed in any preceding claim wherein the plastics material and/or said sheet material is translucent.
  8. 8. A method as claimed in any of claims 1 to 7 wherein the plastics material and/or said sheet material is opaque.
  9. 9. A method as claimed in any of claims 1 to 8, wherein the sheet material comprises paper or tissue.
  10. 10. A sheet of plastics material displaying an image comprising a layer of resin and a layer of glass fibre and a layer of sheet material including an image to be displayed in the plastics material, wherein the sheet material layer is disposed between said resin layer and said glass fibre layer.
  11. 11. A sheet as claimed in claim 10, wherein the image is printed onto said sheet material using a polyester based ink.
  12. 12. A sheet as claimed in claim 10 or claim 11 wherein the sheet material is absorbed within the resin layer.
  13. 13. A sheet as claimed in claim 10 or claim 12 wherein the plastics material and/or said sheet material is translucent.
  14. 14. A sheet as claimed in any of claim 10 or claim 12 wherein the plastics material is opaque.
  15. 15. A sheet as claimed in any of claims 10 to 14, wherein the sheet material comprises paper or tissue.
  16. 16. A roof light having an image printed thereon by the process according to any of claims 1 to 9.
  17. 17. Use of a sheet of plastics material of any of claims 10 to 15 to display an image on a profiled form of said sheet.
  18. 18. Use of a sheet of plastics material of any of claims 10 to 15 to display an image on a flat form of said sheet.
GB9802521A 1998-02-06 1998-02-06 Printing process Expired - Fee Related GB2333994B (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB9802521A GB2333994B (en) 1998-02-06 1998-02-06 Printing process

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB9802521A GB2333994B (en) 1998-02-06 1998-02-06 Printing process

Publications (3)

Publication Number Publication Date
GB9802521D0 GB9802521D0 (en) 1998-04-01
GB2333994A true GB2333994A (en) 1999-08-11
GB2333994B GB2333994B (en) 2002-10-16

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Family Applications (1)

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GB9802521A Expired - Fee Related GB2333994B (en) 1998-02-06 1998-02-06 Printing process

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB962869A (en) * 1962-01-22 1964-07-08 American Cyanamid Co Laminates
GB1020878A (en) * 1964-01-23 1966-02-23 Formica Corp Outdoor decorative laminate
GB1079835A (en) * 1963-10-11 1967-08-16 De La Rue Thomas & Co Ltd Improvements in or relating to the printing of plastics articles
GB1241742A (en) * 1969-07-14 1971-08-04 Resin Maps And Signs Improvements in and relating to panels
US4062711A (en) * 1975-12-03 1977-12-13 Davis R Elbert Method for forming fiberglass-resin laminate with permanent indicia pattern
GB2203691A (en) * 1987-04-24 1988-10-26 Hon Yee Looi Bath or shower panel

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB962869A (en) * 1962-01-22 1964-07-08 American Cyanamid Co Laminates
GB1079835A (en) * 1963-10-11 1967-08-16 De La Rue Thomas & Co Ltd Improvements in or relating to the printing of plastics articles
GB1020878A (en) * 1964-01-23 1966-02-23 Formica Corp Outdoor decorative laminate
GB1241742A (en) * 1969-07-14 1971-08-04 Resin Maps And Signs Improvements in and relating to panels
US4062711A (en) * 1975-12-03 1977-12-13 Davis R Elbert Method for forming fiberglass-resin laminate with permanent indicia pattern
GB2203691A (en) * 1987-04-24 1988-10-26 Hon Yee Looi Bath or shower panel

Also Published As

Publication number Publication date
GB2333994B (en) 2002-10-16
GB9802521D0 (en) 1998-04-01

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PCNP Patent ceased through non-payment of renewal fee

Effective date: 20090206