IE960126A1 - A method for laminating a sheet of fabric to a panel - Google Patents

Abstract

A method for forming a lampshade (1) which comprises a composite panel (2) secured to upper and lower wire frames (12) and (13) comprises laminating a sheet of silk fabric (7) to a PVC panel (6) to form the composite panel (2). The fabric (7) is laid over an adhesive coated surface (14) of the panel (6), and is lightly moistened to facilitate stretching of the fabric (7). The fabric (7) is then lightly stretched over the panel (6) by the use of a roller and is allowed to dry. The composite panel (2) is then formed into a frusto-conical shape in a jig, and end edges (15,16,20 and 21) are secured together by adhesive along a seam (22). The composite panel is then secured to the upper and lower frames (12) and (13) by wrapping side edge portions (8) and (9) of the fabric (7) around the upper and lower frames (12) and (13). <Fig.2>

Description

The present invention relates to a method for forming a composite panel by laminating a sheet of fabric, for example, a sheet of hydrophillic fabric such as silk to a panel, typically, a panel of semi-rigid material, for example, a semi-rigid plastics material for minimising subsequent blistering of the fabric from the panel. The invention also relates to the composite panel and to a method for forming a lampshade, which comprises the composite panel, and the invention also relates to a lampshade formed according to the method.

It is well known to laminate fabric materials to panels of semi-rigid or rigid plastics material, cardboard, timber, steel and the like. In general, such fabrics which would be laminated to such panels are relatively dimensionally stable type fabric materials, for example, cotton, linen, and the like. Laminates of fabric and sheet plastics material, for example, sheet PVC material which is semi-rigid and slightly resilient are typically used in the manufacture of lampshades. A typical example of such a laminated panel is disclosed in British Patent Specification No. GB-A-2,240,388. The lampshade of this British Specification is formed by . ,i^jui^ting»f^bric material to a sheet PVC material to « S ;. ' :... : t SECTION 28 AND RULE 23 JNL No. .1.7.33 OF 5.|.3.(3^/ form a composite panel, which when formed into a frustoconical formation is substantially self-supporting. The fabric material is cut larger than the panel of PVC material, and edge portions of the fabric material extending over top and bottom edges of the sheet PVC material when formed into a frusto-cone are wrapped onto and secured by adhesive to top and bottom wire frames to form the lampshade. The PVC panel is pre-coated with a contact adhesive for receiving the fabric material. In general, the fabric used in the construction of lampshades of this type is linen or cotton.

Silk is a particularly desirable material, and it is desirable to produce lampshades with silk material. However, due to the fact that silk is a relatively dimensionally unstable material, it is unsuitable for laminating to a panel using known techniques. In general, silk when laminated to a panel of, for example, plastics material begins to blister from the panel after a relatively short time. This is undesirable, and for this reason, in general, silk is not used as a fabric for laminating to a panel of plastics material in the manufacture of lampshades. In general, silk is only suitable for use in lampshades of the type which comprise a frame which supports the fabric unlaminated, for example, where the fabric is stretched or draped loosely over the frame. » r».

There is therefore a need for a method for laminating a sheet of silk or any other dimensionally unstable fabric material, and in particular, a dimensionally unstable material which is hydrophillic to a panel of, for example, a semi-rigid plastics material for minimising blistering of the fabric from the panel.

The present invention is directed towards providing such a method, and also to providing a composite panel prepared according to the method, and a lampshade manufactured using the composite panel, as well as a method for forming a lampshade.

According to the invention there is provided a method for forming a composite panel by laminating a sheet of fabric material to a panel of sheet material for minimising subsequent blistering of the fabric from the panel, the method comprising the steps of moistening the fabric, and bringing the fabric into contact with an adhesive coated surface of the panel, smoothing and lightly stretching the fabric material over the surface of the panel, and allowing the composite panel to dry, the steps of moistening the fabric and bringing the fabric into contact with the panel being carried out in any order, and the steps of moistening the fabric and lightly stretching the fabric over the surface of the panel being carried out in any order.

In one embodiment of the invention, the fabric is brought into contact with the panel prior to moistening of the fabric.

In another embodiment of the invention, the fabric is 5 smoothed and lightly stretched over the surface of the panel prior to moistening.

In an alternative embodiment of the invention, the fabric is smoothed and lightly stretched over the surface of the panel after moistening.

In one aspect of the invention, the fabric is lightly moistened. Preferably, the fabric is moistened with water. Advantageously, the fabric is moistened by a spray. Ideally, the fabric is moistened to an extent that the dimensions of the fabric increase.

In one aspect of the invention, the fabric is smoothed and lightly stretched over the adhesive coated surface of the panel using a roller. Preferably, the fabric is smoothed and lightly stretched over the adhesive coated surface by moving the roller with strokes from the centre of the fabric towards the edges thereof.

Ideally, substantially all air between the fabric and the panel is eliminated during smoothing and lightly stretching the fabric over the surface of the panel.

In one aspect of the invention, the composite panel is allowed to dry at room temperature. Alternatively, the composite panel is dried in a warm air stream.

In one aspect of the invention, the adhesive coated 5 surface of the panel is coated with a contact adhesive.

Preferably, the adhesive coated surface of the panel is precoated with the adhesive. Preferably, the adhesive is a water based adhesive.

In another aspect of the invention, the panel is of a 10 semi-rigid type sheet material, and preferably, the panel is of a slightly resilient sheet material. Ideally, the panel is of a bendable sheet material suitable for bending to form an arc.

In one aspect of the invention, the panel of sheet 15 material is of a plastics material.

In another aspect of the invention, the panel is of a PVC material.

In another aspect of the invention, the fabric is a hydrophillic fabric. In a further aspect of the invention, the fabric is silk.

In a still further aspect of the invention, the fabric is a woven fabric.

In one embodiment of the invention, the fabric is subjected to steam. Preferably, the steam is sprayed onto the fabric. Advantageously, the steam is applied to the fabric after the fabric has been moistened.

In a further embodiment of the invention, the method comprises the step of pressing the fabric and panel together. Preferably, the fabric is pressed onto the panel. Advantageously, the fabric is pressed onto the panel using a hot plate iron. Preferably, the temperature of the hot plate of the iron is maintained at a temperature insufficient to damage the panel.

Additionally, the invention provides a composite panel comprising a laminate of sheet fabric material and a panel of sheet material, the fabric and panel being formed using the method according to the invention.

The invention also provides a method for forming a lampshade from the composite panel according to the invention, the method comprising the step of securing the composite panel to a lampshade frame.

In one aspect of the invention, the lampshade frame comprises an upper frame and a lower frame, the :>ti,, β Ί composite panel being secured to the respective upper and lower frames. Preferably, the composite panel is secured to the respective upper and lower frames and forms a structural part therewith.

Advantageously, the composite panel is formed having side edge portions of the fabric extending beyond corresponding edges portions of the panel on two opposite side edges thereof, and the side edge portions of the fabric are secured to the respective upper and lower frames. Preferably, the side edge portions of the fabric are secured to the upper and lower frames by wrapping the side edge portions around the corresponding frames.

In another aspect of the invention, the respective upper and lower frames are formed by ring frames.

In one embodiment of the invention, the composite panel is secured to the lampshade frame prior to the step of moistening the fabric.

Further, the invention provides a lampshade comprising a frame and a composite panel according to the invention secured to the frame. Preferably, the composite panel is secured to the frame using the method according to the invention for forming a lampshade.

The invention will be more clearly understood from the following description of some preferred embodiments thereof which are given by way of example only, with reference to the accompanying drawings, in which: Fig. 1 is a perspective view of a lampshade according to the invention, Fig. 2 is a top plan view of a composite panel also according to the invention from which the lampshade according to the invention is made, Fig. 3 is an underneath plan view of the composite panel of Fig. 2, Fig. 4 is a plan view of one part of the composite panel of Fig. 2, Fig. 5 is a plan view of another part of the 15 composite panel of Fig. 2, Fig. 6 is a partly cut-away perspective view of the lampshade of Fig. 1, Fig. 7 is a perspective view of a portion of the lampshade of Fig. 1 being formed, Fig. 8 is a sectional end elevational view of a detail of the lampshade of Fig. 1 on the line VIIIVIII of Fig. 1, and Fig. 9 is a sectional plan view of another detail 5 of the lampshade of Fig. 1 on the line IX-IX of Fig. 1.

Referring to the drawings there is illustrated a lampshade according to the invention indicated generally by the reference numeral 1 constructed from a composite panel also according to the invention and indicated generally by the reference numeral 2, which is prepared using a method according to one embodiment of the invention. The lampshade 1 is of the type disclosed in British Patent Specification No. GB-A-2,240,388 and comprises an upper wire ring frame 12 and lower wire ring frame 13 to which the composite panel 2 is secured at upper and lower edges 4 and 5, respectively, of the composite panel 2. There are no structural connecting members between the upper frame 12 and the lower frame 13, and accordingly, the composite panel 2 acts as a structural component between the upper and lower frames and 13.

The composite panel 2 comprises a panel 6 of sheet PVC material laminated with a sheet of fabric material 7, ® | £ which in this case is woven silk. As can be seen in Figs. 2 and 3 the area of the fabric 7 is greater than the area of the panel 6, and side edge portions 8 and 9 of the fabric 7 extend beyond corresponding side edges 10 and 11 of the panel 6, which in turn form the top and bottom edges 4 and 5, respectively, of the lampshade 1. The fabric side edge portions 8 and 9 are wrapped around the respective top and bottom frames 12 and 13 for securing the composite panel 2 to the top and bottom frames 12 and 13 using a rotatable wheel carrying device 19, see Fig. 7, as described in British Patent Specification No. GB-A-2,240,388.

One surface 14 of the panel 6 to which the fabric 7 is laminated is pre-coated with a water based adhesive.

The fabric 7 is laminated to the panel 6 by bonding to the adhesive coated surface 14 using the method according to the invention which will now be described. The panel 6 is cut to size and a protective sheet (not shown) extending over the adhesive coated surface 14 is removed exposing the adhesive coating. The fabric 7 also cut to size is laid lightly over the surface 14 of the panel 6 as illustrated in Fig. 2 with the side edge portions 8 and 9 of the fabric 7 extending beyond the edges 10 and 11 of the panel 6. One end edge 20 of the fabric 7 co-incides with a corresponding end edge 21 of the panel 6. An end edge portion 15 of the fabric 7 extends beyond a corresponding end edge 16 of the panel 6 for folding around the end edge 16 for in turn concealing the end edge 16, which forms a seam 22 with the corresponding end edges 20 and 21 of the fabric 7 and the panel 6, respectively, when the composite panel 2 is shaped to form a frusto-conical shape prior to being secured to the upper and lower frames 12 and 13. This is described in detail in British Patent Specification No. GB-A-2,240,388.

Using an atomised water spray directed downwardly onto the fabric 7, the fabric 7 is lightly moistened with water. The fabric 7 is moistened sufficiently so as to dimensionally increase in its length and width. The fabric 7 is then smoothed and lightly stretched onto the panel 6 using a hand roller (not shown). The roller is operated with strokes which radiate outwardly from a centre 18 of the fabric 7 towards the side edge portions 8 and 9, and the end edge portion 15 and the end edge . Such radially outward strokes tend to expel air between the fabric 7 and the panel 6 in an outwardly direction thereby further minimising the possibility of the fabric 7 subsequently blistering from the panel 6.

When the fabric 7 has been smoothed onto and lightly stretched over the panel 6, the fabric 7 is then pressed onto the panel 6 using a hot plate iron. The hot plate ff 126 of the iron is maintained at a temperature which is sufficient to press the fabric 7, while at the same time insufficient to cause damage, deterioration or distortion of the panel 6. It is preferable that when ironing the fabric 7 onto the panel 6, the iron should be operated with radial strokes radiating from the centre 18 of the fabric 7 to the side and end edges similar to the radial strokes of the roller already described. This further facilitates in eliminating entrapped air between the fabric 7 and panel 8.

The composite panel 2 is then subjected to a warm air stream for finish drying of the fabric 7. As the fabric 7 dries it shrinks and is thus tightly stretched across the panel 6. This significantly reduces and in most cases eliminates subsequent blistering and bubbling of the silk fabric 7 from the panel 6.

The composite panel 2 is ready for forming into the frusto-conical shape prior to being secured to the upper and lower frames 12 and 13. The formation of the composite panel 2 into the frusto-conical shape is carried out as described in British Patent Specification No. GB-A-2,240,388. After the composite panel 2 has been formed into the frusto-conical shape, the frustoconical shaped composite panel 2 is then secured to the upper and lower frames 12 and 13 to form the lampshade f g g using the wheel device 19, see Fig. 7, in similar fashion as is described in British Patent Specification No. 2,240,388.

In this embodiment of the invention the panel 6 of PVC material is of thickness 0.3 mm, however, it is envisaged that the panel 6 may be of thickness in the range of 0.2 mm to 0.6 mm, and such a panel would be suitable for use in the preparation of a composite panel for a lampshade.

An alternative method also according to the invention for forming a lampshade identical to the lampshade 1 will now be described. The components used in the method according to this embodiment of the invention are identical to those used in the method for preparing the lampshade 1, and for convenience, similar components will be identified by the same reference numerals. The method according to this embodiment of the invention for forming the lampshade 1 is as follows. The panel 6 and fabric 7 are cut to size as already described, and the fabric 7 is laid lightly over the adhesive coated surface 14 of the panel 6. Side edge portions 8 and 9 and the end edge portion 15 extend respectively over the side edges 10 and 11 and the end edge 16 of the panel 6. The end edges 20 and 21 of the fabric 7 and panel 6 coincide. Before the fabric 7 is moistened, the fabric 7 is smoothed and lightly stretched onto the panel 6 using a hand roller (not shown). The hand roller is operated with strokes which radiate outwardly from the centre 18 of the fabric 7 as already described. Still without moistening the fabric 7, the laminated fabric 7 and panel 6 are formed into the frusto-conical shape as described in British Patent Specification No. GB-A2,240,388, and a seam 22 is formed and secured by adhesive along the end edges 16 and 21. The frustoconical shaped composite panel is then secured to the upper and lower frames 12 and 13 by wrapping the side edge portions 8 and 9 of the fabric 7 around the upper and lower frames 12 and 13 using the wheel device 19 as described in British Patent Specification No.

GB-A-2,240,388. After the composite panel 2 has been secured to the upper and lower end frames 12 and 13, the fabric 7 is then moistened using an atomised water spray directed onto the fabric 7. Only sufficient moisture is applied to the fabric 7 to increase its length and width dimensions. Additionally, after being moistened, the fabric 7 is then subjected to a light treatment of steam for a few seconds. This, it has been found, has the added advantage of accelerating the shrinking of the fabric 7 onto the panel 6. It is believed that the heat of the steam causes the accelerated shrinking.

The lampshade 1 is then allowed to dry at room ^9° 128 temperature, so that the fabric 7 is stretched tightly across the panel 6. If more rapid drying is required, the lampshade may be subjected to a stream of warm or hot air.

The advantages of the invention are many. The main and most important advantage of the invention is that it provides a method for forming a composite panel which includes a sheet of fabric, and in particular, silk, laminated to a panel in which there is virtually no danger of subsequent blistering or bubbling of the fabric sheet from the panel. Where the composite panel is used in the construction of a lampshade, and the fabric is silk, a particularly desirable lampshade is provided which is virtually entirely free from blistering or bubbling of the silk fabric from the panel. It is believed that by shrinking the fabric onto the panel as a result of moistening and then drying the panel in combination with lightly stretching the fabric over the panel causes the fabric to stretch tightly across the panel, and it is this which effectively eliminates subsequent blistering or bubbling of the fabric from the panel. The advantages of the invention appear to be achievable irrespective of whether the fabric is moistened before or after stretching of the fabric onto the panel.

It will be appreciated that while the method described first for preparing the composite panel has been described as comprising the step of lightly laying the fabric onto the panel and then moistening the fabric, these steps may be reversed. In other words, the fabric may be moistened prior to being laid on the panel. It is also envisaged that in the case of the first embodiment of the invention, the fabric may be lightly laid onto the panel, and then lightly stretched onto the panel using the roller as already described, and then subsequently moistened, rather than being moistened prior to stretching. It will also be appreciated that the step of ironing the fabric onto the panel, and then subsequently drying the fabric may also be reversed. Indeed, in certain cases, it is envisaged that the step of ironing the fabric onto the panel may be omitted, as it has been in the method described second for forming the composite panel and lampshade.

While the panel has been described as being pre-coated with an adhesive, in all cases, it is not essential that the panel be pre-coated with adhesive, although, needless to say, it is preferable. Additionally, while preferable, it is not essential that the adhesive be a contact adhesive, other suitable adhesives may be used, and while it is desirable that the adhesive be water based, a solvent based adhesive may be used, although, 129 in general, a water based adhesive tends to be easier to use. Liquids other than water may be used for moistening. While the fabric has been described as being moistened by an atomised spray, any other moistening means may be used, for example, the fabric either prior to being brought into contact with the panel, or after being brought into contact with the panel may be immersed in water or other suitable moistening liquid. It is also envisaged that the fabric may be moistened by the application of steam only to the panel. It is also envisaged that other suitable means for smoothing and lightly stretching the fabric onto the panel may be used besides using a roller.

It will also be appreciated that while a particular method for securing the composite panel to the upper and lower frames has been described, other suitable methods for securing the composite panel to the frames may be used.

While the composite panel has been described for use in a lampshade, it will of course be appreciated that the panel may be put to many other uses. Needless to say, while the panel of sheet material has been described as being of PVC material, the panel may be of any other plastics material, or indeed, any other suitable material, for example, timber, cardboard, masonry, steel, and the like. The fabric material may be any other fabric besides silk, although, in general, it is believed that the best results are achieved when the fabric material is a hydrophillic type material.

Claims (39)

1. A method for forming a composite panel by laminating a sheet of fabric material to a panel of sheet material for minimising subsequent blistering of 5 the fabric from the panel, the method comprising the steps of moistening the fabric, and bringing the fabric into contact with an adhesive coated surface of the panel, smoothing and lightly stretching the fabric material over the surface of the panel, and allowing the 10 composite panel to dry, the steps of moistening the fabric and bringing the fabric into contact with the panel being carried out in any order, and the steps of moistening the fabric and lightly stretching the fabric over the surface of the panel being carried out in any 15 order.

2. A method as claimed in Claim 1 in which the fabric is brought into contact with the panel prior to moistening of the fabric.

3. A method as claimed in Claim 1 or 2 in which the 20 fabric is smoothed and lightly stretched over the surface of the panel prior to moistening.

4. A method as claimed in Claim 1 or 2 in which the fabric is smoothed and lightly stretched over the surface of the panel after moistening.

5. A method as claimed in any preceding claim in which the fabric is lightly moistened.

6. A method as claimed in any preceding claim in which the fabric is moistened with water. 5

7. A method as claimed in any preceding claim in which the fabric is moistened by a spray.

8. A method as claimed in any preceding claim in which the fabric is moistened to an extent that the dimensions of the fabric increase.

9. 10 9. A method as claimed in any preceding claim in which the fabric is smoothed and lightly stretched over the adhesive coated surface of the panel using a roller. 10. A method as claimed in Claim 9 in which the fabric is smoothed and lightly stretched over the adhesive 15 coated surface by moving the roller with strokes from the centre of the fabric towards the edges thereof.

10. 11. A method as claimed in any preceding claim in which substantially all air between the fabric and the panel is eliminated during smoothing and lightly stretching 20 the fabric over the surface of the panel.

11. 12. A method as claimed in any preceding claim in which the composite panel is allowed to dry at room temperature.

12. 13. A method as claimed in any preceding claim in which 5 the composite panel is dried in a warm air stream.

13. 14. A method as claimed in any preceding claim in which the adhesive coated surface of the panel is coated with a contact adhesive.

14. 15. A method as claimed in any preceding claim in which 10 the adhesive coated surface of the panel is precoated with the adhesive.

15. 16. A method as claimed in any preceding claim in which the adhesive is a water based adhesive.

16. 17. A method as claimed in any preceding claim in which 15 the panel is of a semi-rigid type sheet material.

17. 18. A method as claimed in any preceding claim in which the panel is of a slightly resilient sheet material.

18. 19. A method as claimed in any preceding claim in which the panel is of a bendable sheet material suitable for

19. 20 bending to form an arc. 20. A method as claimed in any preceding claim in which the panel of sheet material is of a plastics material.

20. 21. A method as claimed in Claim 20 in which the panel is of a PVC material. 5 22. the A method as claimed in any preceding claim in which fabric is a hydrophillic fabric. 23. A method as claimed in any preceding claim in which the fabric is silk. 24. A method as claimed in any preceding claim in which 10 the fabric is a woven fabric. 25. A method as claimed in any preceding claim in which the fabric is subjected to steam.

21. 26. A method as claimed in Claim 25 in which the steam is sprayed onto the fabric. 15

22. 27. A method as claimed in Claim 25 or 26 in which the steam is applied to the fabric after the fabric has been moistened.

23. 28. A method as claimed in any preceding claim in which the method comprises the step of pressing the fabric and panel together.

24. 29. A method as claimed in Claim 28 in which the fabric is pressed onto the panel.

25. 30. A method as claimed in Claim 28 or 29 in which the fabric is pressed onto the panel using a hot plate iron.

26. 31. A method as claimed in Claim 30 in which the temperature of the hot plate of the iron is maintained at a temperature insufficient to damage the panel.

27. 32. A method for forming a composite panel by laminating a sheet of fabric material to a panel of sheet material, the method being substantially as described herein with reference to and as illustrated in the accompanying drawings.

28. 33. A composite panel comprising a laminate of sheet fabric material and a panel of sheet material, the fabric and panel being formed using the method as claimed in any preceding claim.

29. 34. A composite panel comprising a laminate of a sheet fabric material and a panel of sheet material, the composite panel being substantially as described herein with reference to and as illustrated in the accompanying drawings .

30. 35. A method for forming a lampshade from the composite panel as claimed in Claim 33 or 34, the method comprising the step of securing the composite panel to a 5 lampshade frame.

31. 36. A method as claimed in Claim 35 in which the lampshade frame comprises an upper frame and a lower frame, the composite panel being secured to the respective upper and lower frames. 10

32. 37. A method as claimed in Claim 36 in which the composite panel is secured to the respective upper and lower frames and forms a structural part therewith.

33. 38. A method as claimed in Claim 36 or 37 in which the composite panel is formed having side edge portions of 15 the fabric extending beyond corresponding edges portions of the panel on two opposite side edges thereof, and the side edge portions of the fabric are secured to the respective upper and lower frames.

34. 39. A method as claimed in Claim 38 in which the side 20 edge portions of the fabric are secured to the upper and lower frames by wrapping the side edge portions around the corresponding frames.

35. 40. A method as claimed in any of Claims 36 to 39 in which the respective upper and lower frames are formed by ring frames.

36. 41. A method as claimed in any of Claims 35 to 40 in 5 which the composite panel is secured to the lampshade frame prior to the step of moistening the fabric.

37. 42. A method for forming a lampshade, the method being substantially as described herein with reference to and as illustrated in the accompanying drawings. 10

38. 43. A lampshade comprising a frame and a composite panel as claimed in Claim 33 or 34 secured to the frame.

39. 44. A lampshade as claimed in Claim 43 in which the composite panel is secured to the frame using the method of any of Claims 35 to 42. 15 45. A lampshade substantially as described herein with reference to and as illustrated in the accompanying drawings.