MXPA96004125A - Method and apparatus for recoating articu - Google Patents

Abstract

The present invention relates to a method for altering the appearance of an article formed of a material having the appearance of at least one other material, the method being characterized in that it comprises: forming a plurality of grooves on a surface of an article, the grooves define a surface texture on the article, apply a surfactant solution on the surface of the article so that the grooves have a greater amount of surfactant solution than a remaining portion of the surface of the article, apply at least one color solution on the surface of the article so that the grooves have a greater amount of a mixture of the surfactant solution and the color solution compared to the remaining portion of the surface of the article, and saturate the surfactant solution, the color solution and the color of the substrate to obtain a desired concentration through the texture of the surface and obtain a grain, tint or tone and texture desired

Description

METHOD AND APPARATUS FOR RECOVERING R-rims FIELD IÉCHICQ OF THE mVENCTON The present invention relates to techniques for coating an article, such as a plastic (synthetic) article, to have an altered appearance, such as the appearance of naturally occurring materials, such as wood, leather, and the like. In the following main part, a coating of a plastic article is discussed so that it has the appearance of wood.

Consumers generally rely on the aesthetic appearance of a product to evaluate its quality and value. The aesthetic properties can be used as means to induce consumers a superior value and / or quality. Real wood, for example, represents something genuine and authentic. Simulated wood finishes (eg coatings) on non-wood products try to take advantage of this consumer attraction. Industries that use real wood include the automotive industry (for example, REF: 23186 recreation, luxury vehicles, sports vehicles, conversions of cargo vans (van) and trucks), in the marine industry, construction, interior decoration, furniture, sporting goods for entertainment, for example, The automotive and marine industries usually use real wood, such as walnut, maple, oak, cherry, teak, mahogany, birch or crawled oak, for various items such as flooring and decoration components. The sale of a product that uses real wood provides a pleasant aesthetic appearance, suggests quality and is perceived as something of high value. However, the real wood components generate the following problems - limited flexibility in design and assembly, slow manufacturing and installation process, high costs, lack of flexibility (ie, most woods are relatively rigid) , are unsafe in certain applications, splinter on impact, are not fire resistant and result in environmental waste. From the commercial and economic point of view, the manufacture of "synthetic" (simulated) wood articles has superior aesthetic appearance, strength and durability, which becomes more desirable. Synthetic plastic wood is an alternative for real wood. It is desirable to have plastic synthetic wood that (1) provides viable alternatives to real wood as a means of transporting value to the consumer and / or quality in a product or service "(2) reduce or solve the problems mentioned in the above, to the use of real wood. The following North American patents, incorporated by reference herein, are examples of the prior art methods for manufacturing synthetic wood: (1) North American patent No.3.77? .. 110 ("Method for Construction of Plastic Enclosure" the construction of a plastic container)) - which belongs to phonographic consoles and a glossy finish (2) the American patent HCL, 4.1Q3.Q56 ("Resilient ood Replication") - belonging to tiles for the floor and dyeing coatings; (3) U.S. Patent No. 5,075,059 ("Method for Forming Panel Door With Simulated Wood Grains") (Which is a method of producing a door panel with simulated wood grains) - belonging to door panels and to molding by compression and dyeing; and (4) U.S. Patent No. 4,830,929 ("Molded Wooden Products" (Molded wood-like products)) - this invention pertains to wood products formed by compression molded fibers - conventional molded wood products are manufactured by hot press forming methods in which a continuous or loose plate consisting of Wood fibers are pressed and conformed under heat. The US patent No.4.1O3.O56 mentioned in the foregoing describes a method for constructing phonographic consoles from a series of all plastic panels which have been injection molded to closely simulate the surfaces of master wood panels. In this patent "it is important that the initial stage required for the manufacture of the plastic panels, to obtain a wood-look panel can serve as a template. "In addition, this wood-like master panel will have a" wood grain which is aesthetically attractive and which the manufacturer wishes to reproduce in appearance on a plastic cabinet ". grain -in the master panel similar to defined wood (for example, it will limit) the appearance of the grain in the plastic panels which have been molded by injection.The outer surface of the plastic panel is sprayed with a varnish containing a filling material The "varnish" is removed from the panels in such a way that it leaves areas with bright and dark betas which simulate the brilliance or appearance of the real wood and also leave areas with dark grains in which the varnish has adhered in similar cracks to thin grains. "A disadvantage of the technique described in this patent includes restrictions on the appearance and texture of wood grain to that of maest wood panel. In addition, it is necessary to have a separate (different) mold for each desired wood grain. In addition, this technique requires that (1) the varnish contain a filler material to fill the molded plastic grain texture of the master panel in the form of wood, and (2) that the excess varnish is removed therefrom. Although attempts have been made to manufacture synthetic wood, several disadvantages and drawbacks of the prior art remain. Synthetic wood articles of the prior art generally have a high cost, inefficient manufacturing processes, require a panel in the form of "master" wood, are limited in grain control, texture and appearance of color; limited in their application, they tend to emphasize too much the appearance of real wood, appear artificial and / or use wood fibers. What is needed is a cheap, commercially useful and versatile process to manufacture synthetic wood with plastic and impart a pleasing aesthetic appearance to any desired grain, texture and coloration. In addition, it is desirable to have a process for making more than one grain, texture and color pattern, without the need for extensive changes. It is also desirable to obtain a synthetic plastic wood that has a favorable aesthetic appearance, adequate strength, impact resistance and flexibility. It is also desirable to have a synthetic plastic wood with design flexibility, ease of assembly and durability that exceed that of real wood. It is further desirable to have a synthetic plastic wood that has a desired aesthetic appearance that is suitable for indoor and / or outdoor applications. In addition, it is desirable to have a thin film (appearance or veneer) that has the appearance and / or texture of real wood.

BRIEF DESCRIPTION OF THE IMVB It is an object of the present invention to provide an improved technique for manufacturing a coating on an article, such as a plastic (synthetic) article, the coating imparts an altered appearance to one or more surfaces of the article, the altered appearance includes (1) the appearance of a material that occurs naturally, (such as wood or leather), and (2) an arbitrary and elegant (unnatural) appearance of one or more surfaces of the article.

It is another object of the present invention to present a process for manufacturing plastic articles that have the appearance of wood, leather or other materials that appear naturally. It is another object of the present invention to provide a process for manufacturing a plastic article having at least the desired wood grains, color and texture. It is a further object of the present invention to provide a process for manufacturing a plastic article having high impact strength and robustness, and having a relatively rigid to relatively flexible controllable rigidity. It is a further object of the present invention to provide a technique for manufacturing plastic articles that have the appearance of naturally occurring articles by utilizing a variety of processes including injection molding, profile extrusion molding, vacuum forming. , thermoforming, thermosetting, blow molding (including blow molding by extrusion and blow molding by injection), sheet extrusion, punching or casting and the like. In accordance with one embodiment of the present invention, a method for imparting an aesthetic appearance ~. desired (altered) to an article, comprises the steps of applying a surfactant solution (e.g. water or other suitable wetting or diluting agent) and a color solution to one or more textured surfaces of an article 5 (e.g., a plastic article) to obtain a desired grain, dye or shade and the texture on the surface or surfaces of the article (it is understood that the article has an underlying "inherent" color). In one embodiment of the present invention, a method for manufacturing synthetic plastic wood has the desired aesthetic appearance, and the method comprises the steps of: (1) preparing an article (eg, a plastic part) to have a surface texture 5 predetermined, a substrate color (inherent color of the article) and shape, the part having a desired hardness measurement "D" and a thickness "t"; (2) apply a surfactant solution on the surface of the part; "(3) apply at least one color solution on the surface of the part, (4) adjust the amount and color solutions on the surface, and cause the surfactant and color solutions to permeate the surface (especially the surface texture), when moving a saturating implement along the surface of the part at a speed and pressure sufficient to adequately saturate and synthesize the surfactant solution, the color solution and the substrate color, and the surface texture to generate a desired grain, tint or shade and / or texture. The mold can be used to define the shape and surface texture of a desired plastic part. A plastic part is, for example, injection molded so as to generate a predetermined surface texture, a substrate composition, a substrate color and a shape. The three-dimensional laser material processing can also be used to produce a predetermined surface texture and part shape. Etching techniques can also be used to produce a predetermined surface texture. The textured surface may have predetermined groove characteristics (area and spacing) so as to allow effective saturation (e.g. of surfactant and color solutions), produce the desired concentration and obtain a desired tint or shade. This is obtained by adequately controlling the pressure, speed and movement of the applicator implement, as well as the characteristics of the saturator and the groove.

The composition of an article (e.g., a plastic substrate) to be coated should be such that it is suitable for receiving and adhering a basecoating composition. The substrate has a predetermined color so as to generate a desired synthetic shade or dye. This shade or esthetic tint is obtained by properly applying and saturating the color solution, the surfactant solution and the substrate. The surface of the part will have a predetermined texture. This texture will provide irregularly spaced slots, each slot having a predetermined pattern. The texture of the plastic part, in addition to the color of the substrate, the color solution and the surfactant solution, facilitate the obtaining of any desired grain, color or texture. Preferably, the surfactant solution comprises distilled and deionized H20 mixed with a sufficient amount of methyl ethyl ketone peroxide (MEKP). The color solution is preferably water (or ink) based paint. The color solution can include coffee, red, black or any other color to obtain the desired effect. An applicator implement (tool, mechanism) is used to apply the surfactant and the color solutions to the surface texture of the part. The saturator implement (tool, mechanism) is used to saturate and synthesize the surfactant solution, the color solution, the substrate color and the surface texture; that generate the desired aesthetic appearance (for example grain, dye or tone and texture). The default color combination is (color solution and substrate color), with an appropriate surface texture and sufficient surfactant solution, facilitates the generation of any desired grain, tint or tone and texture. The applicator and the saturator are important mechanisms to obtain the desired aesthetic appearance. A means for controlling the pressure, speed, direction and pattern of the applicator and saturator implements is desirable. The applicator and the saturator can be controlled manually or automatically. In an automated processing system, a positioning mechanism, controlled by multiple axis computer, can be used. This mechanism will receive adequate parameters that generate a desired grain, tint, tone or texture. After the coating is finished, the substrate is placed in a curing station. After this phase, an upper cover (protective or decorative cover) can be applied. This top cover can provide a desired gloss (or a matte finish) on the completed part. The plastic part preferably includes means for attaching the part to another surface such as holes for screws or nails, snaps or hooks, double-sided tapes and staples. The automated techniques of the present invention allow the production of high volumes of coating on articles. It should be understood that the process can also be carried out manually. The techniques of the present invention allow combinations of surface appearances in different areas of an article. For example, one area of an article can be made to look similar to wood, while another area of the article can be manufactured to have a leather-like appearance, both of which are examples of naturally occurring materials. In the use of the techniques of the present invention, a coating can be applied to apply virtually to any article. For example, a plastic article, on one or more surfaces of the article, can be covered so that it has a wood, leather or similar appearance. However, the invention is not limited to coated plastic articles, nor is it limited to simulating the appearance of naturally occurring materials. For example, a metallic article (such as steel) can be coated to have an "unnatural" appearance (elegant and arbitrary) in which case the texture of the surface can be imparted by any suitable mechanism such as wet electrodeposition, dry electrodeposition, etc. Through the use of the appropriate implements, rugosities or undulations can also be coated, so that they have a natural or unnatural appearance (elegant and arbitrary). In this case, irregularities in the surface that occur naturally in the roughness can be used advantageously (for example, instead of carefully creating a surface texture in the article - in this case the roughness). According to one aspect of the invention, various modalities for creating a film are described (article similar to film) that has the appearance of wood, leather or other material that occurs naturally. Such films can be applied to articles to improve their appearance. Other objects, features and advantages of the invention will become apparent in light of the following description thereof.

BRIEF DESCRIPTION OF THE DTB8OS Figure 1 is a process flow diagram illustrating one embodiment of the technique of the present invention. Figure 2 is a partially schematic representation of a partially perspective view of one embodiment of a process for coating an article, in accordance with the present invention. Figure 3 is a schematic representation of a process for making a film-like article having an altered appearance, in accordance with the present invention. Figure 4 is a schematic representation of an alternative process for making a film-like article having an altered appearance according to the present invention.

DESCRIPTION ngriT.TAní pE LA IMVBNCIÓN The present invention describes a method and apparatus for manufacturing coated articles (such as synthetic plastic articles), which includes parts and films that have the appearance and / or texture of genuine materials, which occur naturally such as wood and / or leather or that have an arbitrary and elegant appearance. Generally, naturally occurring materials show a grain (observable surface irregularities, for example due to the cell structure) and / or a unique color that is not usually present in "usual" plasmic items (which tend to to have a relatively smooth surface that lacks granularity and which tends to show uniform coloration). In the main below, there are discussed - techniques for making plastic articles (for example parts and films) that have the appearance of wood. Figure 1 is a diagram showing an embodiment of the process steps for manufacturing plastic articles according to the present invention. In a first process step (step A), a plastic article (part) is manufactured, for example by molding or the like, so that it has a predetermined color, shape, durometer and / or thickness. The color of the part can be inherent (for example, the color of the plastic) or it can be a "base" color applied to the part, for example, with paint or with dye. In the manufacture of the part, or in post-manufacturing stages, at least one surface of the grooved part (surface regularities) is provided, which preferably imitates the granularity of a naturally occurring material (such as like wood or leather). This can be done on the front surface of a two-sided substrate, on one or more edges of the part, or on the walls of holes extending in or through the part. In the main, then the treatment (coating, alteration of the appearance of) the front surface of a substrate to simulate (imitate) the appearance of a material that occurs naturally is what is exposed. However, it should be understood that the technique of the present invention is applicable to any and all of the surfaces of an article (the part). As described in the following, different areas of the substrate can be provided with different (different) groove patterns, each of which mimics a particular material that occurs naturally. For example, one area of the substrate may be grooved to have a surface texture that imitates the wood grain (e.g., such as parallel lines or line segments), and another area of the substrate may be grooved to have a texture. surface that imitates leather grains (for example, such as irregular diamonds). In the next stage of the process (stage B) an applicator implement (tool) is used to apply a wetting agent (such as water), then "surfactant solution") in the front part (for example the groove) of the substrate surface. Generally this involves moving the moistened applicator implement across the front surface of the part, the appearance of which it is desired to alter. In the next stage of the process (step C), an applicator (or other implement) is used to apply at least one color solution to the front surface of the substrate. In a next stage of the process (stage D), a saturating implement is used to adequately eliminate and / or saturate the surfactant solution and at least one color solution, in a way that adapts to the substrate and synthesizes the surfactant solution, the solution with at least one color, the color of the substrate and the grooves in the front surface. After the coating is finished, the coated part is cured, for example by heat and / or air drying. This is indicated by the process step (stage E). Subsequently, in a process step (step F), a suitable top cover (a protective or decorative cover) can be applied to the part, so as to provide a desired finish (e.g., glossy, matt, etc.) to the part . Certain topcoat compositions will require curing in a process step (step G).

A suitable top cover includes a water-based or solvent-based coating, such as a urethane, epoxy and water-based acrylic, and can be applied in any suitable manner, for example with a brush, with a cloth, with a roller , by sprinkling on the substrate, etcetera. The completed plastic part (optionally coated with a base, coated and optionally with a top coating), has the appearance of a naturally occurring material, is useful for various applications including uses as a decorative article for automotive uses , sports equipment, furniture and the like. At the end of utilization of the completed plastic part as a decoration article, means are provided for joining the completed plastic part with another existing structure. These include through holes (or on the back of the unfinished side) of the completed part to receive screws, hooks integrated in the part, tape with glue on both sides, holes to receive nails or staples, and so on. Figure 2 is a block diagram of one embodiment of a system 200 for automated implementation of the techniques of the present invention. In an exemplary embodiment of the present invention, a method for manufacturing synthetic wood of plastic material having a desired aesthetic appearance comprises the steps of: (1) preparing a plastic part 202 having a determined surface texture 306 (indicated by the markings) ">" on the surface of the substrate), a color and shape, part 202 has a durometer "D" and a thickness "t"; (2) controlling the movement of an applicator implement 214 to apply a surfactant solution from a reservoir (of surfactant solution) 218 on the textured surface of part 202; (3) controlling the movement of the applicator implement 214 to apply at least one color solution of at least one deposit 220a..220n on the textured surface of part 202; (4) controlling the movement of saturating implement 216 to selectively move the fluid with color around the surface of part 202 and to control the thickness or density of color solutions on the surface of part 202, which include permeating the slots 206 and, if desired, lightening the non-slotted portion of the surface of surfactant and color; (4a) optionally, the saturator may be wetted with a catalyst or the like (not shown) before displacing the color solutions around the surface of part 202.

Generally, the saturating implement 216 is used to control the thickness, density and placement of the color solutions on the surface of the part 202 that it includes, but which is not limited to causing the color solutions to permeate the grooves on the surface of the surface. part 202 and / or remove color solutions from certain areas of part 202. Generally, saturating implement 216 is advanced (moved in a predefined path) along the surface of the part at a sufficient pressure rate to adequately saturate and synthesize the surfactant solution, the color solutions, the optional substrate base coat color, all face to face with the surface texture to generate a desired grain, tint or shade and / or surface texture of the part. A molding apparatus (not shown) or the like can be used to define the shape and texture of the surface of the plastic part 202. For example, the plastic part can be injection molded to define, in the process, the desired texture of the plastic part. the surface (for example 206), the composition, the color and the shape. Alternatively, the part can be molded (or similar) to have a smooth surface, and can be further processed to have a non-smooth surface texture. For example, three-dimensional laser material processing equipment (not shown) can also be used to produce a predetermined surface texture. Other examples for producing a predetermined surface texture include etching or die-cutting techniques. In other words, an initially smooth surface on a plastic part can be postprocessed (for example, after molding or the like) to show the desired surface texture. Preferably, the surface texture (e.g., 206) imparted to the surface of the part (e.g., 202) comprises a predetermined pattern of a plurality of grooves, in which dimensions (including depth, length and width) of each slot, as well as its separation and location on the surface of the part are controlled. The configuration of the grooves on the part surface plays an important role to allow an effective saturation of the color solution on the surface of the part, which include producing a desired concentration and obtaining a desired tint or shade. The interaction of the applicator and saturator implements on the surface of the part also play an important role in this important function. More particularly: (1) in a general sense, the applicator implement is caused to apply a desired amount of surfactant solution and color solution to the surface of the part; and i (2) in a more defined sense, the pressure, speed and movement of the applicator and saturator implements on the part surface are controlled to influence the application of the surfactant and color solutions to the surface of the part. Generally, the composition (material) of the plastic substrate of part 202 must be adequate to receive and adhere sufficiently with surfactant and color solutions (as well as the optional basecoat applied to the part). The coating or cover having a desired aesthetic shade or dye is obtained by suitably applying and saturating the surfactant solution, the color solutions and the inherent substrate 214 color (underlying). Preferably, the part substrate is provided with predetermined, irregularly spaced slots, each slot having a predetermined length, width and depth. The texture of the surface of the part, in addition, the color of the substrate and the color solutions, facilitate the generation of any desired aesthetic grain, color or texture (for example, walnut, oak, cherry, maple, birch and mahogany) on the surface of the part. Suitable surfactant solutions include distilled and dee-toned water (H20) preferably mixed with methyl ethyl ketone peroxide (MEKP). Suitable color solutions include water-based (or ink) based paints. Suitable colors for the color solutions include coffee, red and black or any other color that simulates the appearance (when applied to a substrate according to the techniques of the present invention) of a naturally occurring material. The applicator instrument (214) is used to apply the surfactant solution and the color solutions on the surface of the part (202). The saturator (216) is used to saturate and synthesize the surfactant solution, the color solution, the substrate color and a surface texture to generate the desired aesthetic appearance. The applicator (214) can be of any suitable form or material which is capable of, suitably (1) applying the surfactant solution and the color solution, and (2) directing the surfactant solution and the color solution to the surface and slots to generate the desired concentration or effect.

The saturator (216) can be of any suitable form or material, which serves to control the saturation and synthesis of the surfactant solution, the color solution and the substrate color. The saturator 206 may be of any material which (1) is capable of sufficiently saturating the surfactant solution, the color solution and the substrate color, and (2) generating a desired concentration of solutions through the part, and develop the desired aesthetic appearance. Preferably, the saturator is pre-wetted with sufficient surfactant solution to carry out these functions. The saturating implement can be applied to the surface of the part to remove most or all of the surfactant and color solutions from the surface of the substrate, while rendering the surfactant and color solutions permeable in the grooves within the surface of the substrate. substratum. However, preferably, instead of removing the color solution from the surface of the part, the saturator will be sufficiently integrated and will synthesize the surfactant solution, the color solution, the substrate color and the texture of the surface. Although the prior art techniques generally involve applying and removing a stain from a surface, the present invention involves effectively saturating and synthesizing a surfactant solution (e.g., 218) a color solution (e.g., 220a..n), and a color of substrate on a surface texture, to obtain the desired grain, dye or tone, texture and grain effect. The applicator 214 and the saturator 216 are important mechanisms to obtain the desired aesthetic appearance. Generally, the applicator and the saturator should be formed of a material having adequate pores to adequately saturate and synthesize the surfactant solution, solution color and substrate color, and the surface texture to generate the grain, tint or shade and / or desired texture. It has been found that both a polyester foam and a polyurethane foam are suitable materials for applicator implements and saturators. A mechanism to control the pressure, velocity, direction and pattern (across the surface of the substrate) of the implements applicator and saturator is necessary to automate the process. As shown in Figure 2, in an automated processing system, a multi-axis computer controlled positioning mechanism 222 can be used to control the movement and interaction (with the substrate) of the applicator and saturator implements. This mechanism 222 receives parameters programmed from a control system (e.g., a CNC system) 224 that generates a desired grain, dye or tone, or texture. The mechanism 222 can also be used to control a device 226 suitable for receiving the part 202. In this way, the mechanism 222 can be used to control the applicator 214, the saturator 216 and / or the device 236. A feature of this invention is that slots can be formed, and the applicator and saturator implements can be controlled, and the color solutions selected, in order to obtain virtually any desired appearance on the finished product.

This includes generating random grain and color patterns, repeated patterns, non-repeating patterns and the like on plastic parts produced in the same mold or having identical topographic features. A predetermined combination of colors (solutions of color and color of substrate) with an appropriate surface texture and with a surfactant solution, facilitates the generation of any grain, dye or tone and texture desired. The hue or dye generated in accordance with the present invention provides aesthetic appearance of substantially any desired wood including walnut, maple, oak, cherry, teak, mahogany or birch.

Exemplary uses of the completed plastic parts, manufactured in accordance with the present invention, include functional components and non-functional components. For example, non-functional synthetic plastic components for use in the conversion of a cargo truck (van) and in the truck industry include the following: the appearance or coating of the instrument panel, the appearance of the box of gloves, the appearance of the ashtray, the cover of the ashtray, the appearance of the radio and the decoration for the passenger. The completed plastic parts, manufactured in accordance with the techniques of the present invention, meet automotive standards for resistance to moisture, resistance to usual wear, exposure to an apparatus for producing artificial climate, exposure to an instrument to ascertain the strength to light, impact resistance, acid resistance, soap and water resistance, cyclic fracture resistance, naphtha resistance, flexibility and adhesion. The base cover (optional) of the present invention will firmly adhere to the part, and will not flake off, flake, fracture or form into powder to become detached or lose its color or luster.

The completed plastic parts, manufactured in accordance with the techniques of the present invention are useful for indoor or outdoor applications. As shown in Figure 2, the technique of the present invention is useful for coating one or more edges 204 of part 202, as well as for coating side walls 210 of a hole (or depression) 208 in part 202. Virtually any portion of any geometric part can be coated according to the techniques described herein, which include coating different portions of the parts in different ways. Exemplary uses include: 1. a plastic coating, which includes thermal plastic, elastomers, nylon, ABS and PVC, to have the appearance of walnut by creating irregularly separated grooves, optionally in a pattern, on a surface that is to be coated, starting with a base color (color of the substrate or a base coat applied to the substrate) of light yellow (for light walnut) or coffee (for dark walnut), and application of coffee color solutions (40%) and red (60%) for appearance of light walnut, or coffee (50%) and red (50%) (for appearance of dark walnut) by using an applicator (and saturator) of polyurethane foam (for appearance) light walnut or dark walnut); 2. form a simulated maple coating by using a color solution of 70% brown and 30% red; 3. Shaping, a simulated oak veneer using a light yellow substrate (for a light oak appearance) or a dark yellow substrate (for a dark oak appearance), and 50/50 brown / red (for light oak) or 70/30 coffee / red (for dark oak); 4. create an appearance similar to birch by using color solutions 75/20/5 coffee / red / black; and 5. create an appearance similar to mahogany by using color solutions 70/20/10 coffee / red / black. The completed article (for example a plastic part) can be in the form of a film (appearance or veneer), as well as in the form of a substrate, as described in the following, with respect to Figures 3 and 4. Figure 3 is a diagram of a system 300 for making a film 330 having a desired appearance and / or texture of real wood. The film 330 comprises an upper carrier film 320 and a removable or removable lower carrier film 326. The rotating wheels (drums) shown in the figure include: a texture wheel 302, a top carrier wheel 316, a bottom carrier wheel 324 and a fusion wheel 328. The coating implement 306 directs a spray or spray of base coat solution 307 on the textured surface 304 of the texture wheel 302, to produce a base cover 308 on the wheel 302. A heating implement 310 directs heat (shown as 311). ) on the base cover 308, on the surface 304 of the wheel 302. The heated base cover 308, on the surface 304 of the wheel 302, is marked as 312. The carrier wheel 316 supplies a film 318 to which, it adheres the base cover heated. In this way, the film 318 coated with base cover becomes the upper carrier film 320, which has the base cover on the upper side 320b thereof. An adhesive implement 322 directs spray 323 of adhesive on the rear side 320a of the upper carrier film 320. A supply of lower carrier film 326 is provided via a wheel 324. On the wheel 328, the upper carrier film 320 and the lower carrier film 326 are fused, with the lower carrier film 326 positioned against the support side 320 a coated with adhesive of the 320 upper carrier film. The wheel 328 provides sufficient pressure to cause the joining (melting) of the two films 326 and 320 to produce a two-layer film 330. In this way, when it is desired to apply the upper carrier film 318 * to an article, to improve the appearance thereof, the lower carrier portion 326 (release film) is simply peeled off and removed, and the upper part (modified appearance film) 320 is applied to the article by means of the adhesive (311) Mode 300 is not the preferred modality. It is within the scope of this invention that a separate film (318) is not used, and that the cured base coat (308) forms a sufficient carrier film (320). It should be understood that a cleaning or sweeping implement can be applied between the implements 306 and 310, to selectively remove areas of the base cover to produce the desired appearance (of the carrier film of the cured base cover). It should be understood that the coating implement 306 can be attached to the mixing head to obtain the appropriate color mixture and base coat viscosity. It is within the scope of the invention that the top cover can be applied and cured on the surface (320b) of the film (320).

A suitable adhesive used in the film systems of this invention is a vinyl adhesive. Figure 4 shows another preferred system 400 for a film and the development of a tape. A mixing head 402 supplies a base covering 404 (cf. 308) to the surface of a texture wheel (roller 406. The surface of the roller 406 is preferably textured with grooves (not shown), in the manner described above. A cleaning implement 408 mixes and divides the base cover, selectively removes the areas of the base cover to produce the desired appearance.The cleaning implement 408 is preferably in the form of a foam sponge. (The cleaner may also be used to establish a predetermined thickness for the base cover, in a manner similar to a "doctor blade".) The base cover for adjusted thickness is subsequently cured by a curing attachment 412 (compare 310). returns a 414 film (compare 318), which is "detached" from the drum at the position marked with 416. Subsequently a top cover is applied to the surface front 414a of the film 414, at station 418. The film 414 with the top cover subsequently advances and passes through another curing implement 422. Film 414, at this point in the process, has the desired appearance, and is ready to be "baked" with a release film. A release film 424 is supplied with adhesive, in any suitable manner, on the front surface 424a thereof, and is advanced on a freewheel (roll) 428. At this point, the film 424 advances in the process, list to be applied as a reinforcement or support to the film 414 coated on top. The two films 424 and 414 pass through a gap between a freewheel (roller) 432 and a jointing wheel (roller) 434, so that the surface 424a front coated with film adhesive 424 is urged against the support surface 414b of the film 414. This results in a two-layer film 436 which is taken over a rewind deposit 440 (catchment). When it is desired to improve the appearance of an article (not shown) the film 436 is removed from the rewind accumulation 440, cut to the desired length, the backing 424 is removed (and discarded) and the film 414 is applied to the article.

It is noted that in relation to this date, the best method known to the applicant to carry out the aforementioned invention, is that which is clear from the present description of the invention. Having described the invention as above, property is claimed as contained in the following:

Claims (50)

1. A method for altering the appearance of an article formed of a material that has the appearance of at least one other material, the method is characterized in that it comprises: forming a plurality of grooves on a surface of an article, the grooves defining a surface texture on Article; applying a surfactant solution on the surface of the article so that the grooves have a greater amount of surfactant solution than a remaining portion of the surface of the article; applying at least one color solution on the surface of the article so that the slots have a greater amount of a mixture of the surfactant solution and the color solution as compared to the remaining portion of the surface of the article; and saturating the surfactant solution, the color solution and the substrate color to obtain a desired concentration through the texture of the surface and obtain a desired grain, dye or tone and texture.

2. The method for altering the appearance of an article, according to claim 1, characterized in that it additionally comprises: applying, subsequently, a top cover on the surface of the article.

3. The method for altering the appearance of an article, according to claim 1, characterized in that it additionally comprises: before applying the surfactant solution, apply a base color to at least the surface of the article.

4. The method for altering the appearance of an article, according to claim 1, characterized in that it additionally comprises: forming a first portion of the plurality of grooves on a first selected area of the surface of the article; and forming a second portion of the plurality of grooves on a second selected area on the surface of the article.

5. The method for altering the appearance of an article, according to claim 4, characterized in that it additionally comprises: applying a first surfactant solution on the first selected area; and applying a second surface-active solution on a second selected area.

6. The method for altering the appearance of an article, according to claim 4, characterized in that it additionally comprises: applying a first color solution on the first selected area; and apply a second color solution on the second selected area.

7. The method for altering the appearance of an article, according to claim 1, characterized in that it additionally comprises: controlling the movement of an applicator implement on the surface of the article to control the application of the surfactant solution.

8. The method for altering the appearance of an article, according to claim 1, characterized in that it additionally comprises: controlling the movement of an applicator implement on the surface of the article to control the application of at least one color solution.

9. The method for altering the appearance of an article, according to claim 1, characterized in that it additionally comprises: controlling the movement of a saturating implement on the surface of the article to permeate the surfactant and color solutions in the grooves.

10. The method for altering the appearance of an article, according to claim 1, characterized in that: the altered appearance is that of a material that occurs naturally.

11. The method for altering the appearance of an article, according to claim 10, characterized in that: the material that occurs naturally is wood.

12. The method for altering the appearance of an article, according to claim 10, characterized in that: the material is presented naturally is leather.

13. The method for altering the appearance of an article, according to claim 1, characterized in that: the altered appearance is elegant and arbitrary.

14. A method for coating a substrate, characterized in that it comprises: applying surfactant and color solutions to a surface of the substrate having a color; adjust the amount of surfactant and color solutions on the surface; and causing the surfactant and color solutions to permeate the surface by moving a saturating implement along the surface of the substrate at a rate and pressure sufficient to adequately saturate and synthesize the surfactant solution, the color solution, the substrate color and the textures of the surface to generate at least one desired selected characteristic, of the group consisting of grain, ink, tone and texture on the surface of the substrate.

15. An apérate for manufacturing a plastic, synthetic, wood-like article having a desired aesthetic appearance, characterized in that it comprises: means for placing selected grooves on a surface of a plastic part, the grooves defining a surface texture, the plastic part has a selected substrate color; means for applying a sufficient amount of a surfactant solution on the surface texture, the grooves have a higher concentration of surfactant solution; means for applying a sufficient amount of a color solution on the surface texture, the slots having a greater concentration of a mixture of the surfactant solution and the color solution; means for saturating the surfactant solution, the color solution and the substrate color to obtain a desired concentration through the surface texture and obtain the desired grains, dyes or shades and texture.

16. The apparatus for manufacturing an article similar to synthetic wood, plastic having the desired aesthetic appearance, according to claim 15, characterized in that: the means for applying a sufficient amount of surfactant solution on the surface texture is an applicator.

17. The apparatus for manufacturing an article similar to wood, synthetic, plastic, having a desired aesthetic appearance, according to claim 15, characterized in that: the means for applying a sufficient amount of the color solution on the surface texture is an applicator .

18. The apparatus for manufacturing an article similar to wood, synthetic, plastic, having a desired aesthetic appearance, according to claim 15, characterized in that: the means for saturating the surfactant solution, the color solution and the substrate color is a saturator, the saturator has a sufficient amount of the surfactant solution therein.

19. The apparatus for manufacturing an article similar to wood, synthetic, plastic, having a desired aesthetic appearance, according to claim 16, characterized in that: means for controlling the pressure, speed and direction of the applicator.

20. The apparatus for manufacturing an article similar to wood, synthetic, plastic, having a desired aesthetic appearance, according to claim 18, characterized in that it additionally comprises: means for controlling the pressure, speed and direction of the saturator.

21. The apparatus for manufacturing an article similar to wood, synthetic, plastic, having a desired aesthetic appearance, according to claim 19, characterized in that: the means for controlling the pressure, speed and direction of the applicator is a multi-axis positioning mechanism .

22. The apparatus for manufacturing an article similar to wood, synthetic, plastic, having a desired aesthetic appearance, in accordance with claim 20, characterized in that: the means for controlling the pressure, speed and direction of the saturator is a multi-axis positioning mechanism .

The apparatus for manufacturing an article similar to wood, synthetic, plastic, having a desired aesthetic appearance, according to claim 15, characterized in that: the slots are irregularly separated and have a selected length, width and depth .

24. The apparatus for manufacturing an article similar to wood, synthetic, plastic, according to claim 17, characterized in that it additionally comprises: means for controlling the pressure, speed and direction of the applicator.

25. The apparatus for manufacturing an article similar to wood, synthetic, plastic, according to claim 24, characterized in that: the means for controlling the pressure, speed and direction of the applicator is a multi-axis positioning mechanism.

26. The apparatus for manufacturing an article similar to wood, synthetic, plastic, according to claim 15, characterized in that it additionally comprises: means for applying an upper cover on the surfactant solution and the color solution.

27. The method according to claim 14, characterized in that it additionally comprises: controlling the movement of the saturating implement along the surface of the substrate.

28. The method according to claim 27, characterized in that it additionally comprises: controlling the movement of the saturating implement with a multiple axis positioning mechanism.

29. The method according to claim 14, characterized in that it additionally comprises: causing the substrate, when it is coated, to have the appearance of a material that occurs naturally.

30. The method according to claim 29, characterized in that: the appearance is that of wood.

31. The method according to claim 29, characterized in that: the appearance is that of the leather.

32. The method according to claim 14, characterized in that it additionally comprises: causing the substrate, when coated, to have an elegant and arbitrary appearance.

33. The method according to claim 1, characterized in that: the article is formed of a plastic material.

34. A method for altering the appearance of an article formed of a first material that has an altered appearance of at least one different second material, the method is characterized in that it comprises: applying a surfactant solution on a surface of an article, the surface has a surface texture; apply at least one color solution on the surface; and saturating the surfactant solution and the color solution to obtain a desired concentration through the surface texture.

35. The method for altering the appearance of an article, according to claim 34, characterized in that it additionally comprises: subsequently applying a top cover on the surface.

36. The method for altering the appearance of an article, according to claim 34, characterized in that it additionally comprises: before application of the surfactant solution, apply a base color to the surface.

37. The method for altering the appearance of an article, according to claim 34, characterized in that it additionally comprises: applying the surfactant solution with an applicator implement that moves across the surface.

38. The method for altering the appearance of an article, according to claim 37, characterized in that it additionally comprises: controlling pressure, velocity and direction of the applicator implement as it moves across the surface.

39. The method for altering the appearance of an article, according to claim 38, characterized in that it additionally comprises: controlling the pressure, speed and direction of the applicator with a multi-axis positioning mechanism.

40. The method for altering the appearance of an article, according to claim 34, characterized in that it additionally comprises: applying at least one color solution with an applicator implement that moves across the surface.

41. The method for altering the appearance of an article, according to claim 40, characterized in that it additionally comprises: controlling the pressure, speed and direction of the applicator implement as it moves across the surface.

42. The method for altering the appearance of an article, according to claim 41, characterized in that it additionally comprises: controlling the pressure, speed and direction of the applicator with a multi-axis positioning mechanism.

43. The method for altering the appearance of an article, according to claim 34, characterized in that: the first material is plastic.

44. The method for altering the appearance of an article, according to claim 34, characterized in that: the altered appearance is that of a material that occurs naturally.

45. The method for altering the appearance of an article, according to claim 44, characterized in that: the material that occurs naturally is wood.

46. The method for altering the appearance of an article, according to claim 44, characterized in that: the material that occurs naturally is leather.

47. The method for altering the appearance of an article, according to claim 34, characterized in that: the altered appearance is arbitrary and elegant.

48. A method for manufacturing a film having an appearance of at least one different material, the method is characterized in that it comprises: applying a base covering to the surface of a texture roller; curing the base cover on the texture roller so that it becomes a top film; apply a top cover to the cured base cover; provide a support or backup film; and fusing the supporting film with the upper film.

49. The method according to claim 48, characterized in that it additionally comprises: storing the fused support film and the upper film on a pick-up coil.

50. A method for altering the appearance of an article, characterized in that it comprises: applying a base covering to the surface of a texture roller; curing the base cover on the texture roller so that it becomes a top film; apply a top cover to the cured base cover; provide a supporting film; merge the supporting film with the upper film; subsequently, remove the backing film from the upper film; and apply the upper film to the article.