WO1999047951A1

WO1999047951A1 - Printable perforated vision control panel and method of fabricating

Info

Publication number: WO1999047951A1
Application number: PCT/CA1999/000211
Authority: WO
Inventors: Michael D. Andriash
Original assignee: Andriash Michael D
Priority date: 1998-03-17
Filing date: 1999-03-17
Publication date: 1999-09-23
Also published as: AU2708599A

Abstract

A vision control panel for application to a transparent surface includes a poly-coated adhesive release liner adhered to the underside of a vinyl or paper substrate, a primary coating overlying the opposite side of the substrate, a first ink receptor coating overlying the binder coating, a second ink receptor coating overlying the first ink receptor coating, a printed image on the second ink receptor coating and a protectant over-laminate. With the exception of the protectant over-laminate, the underlying layers are perforated to enable an observer on the inside of the transparent surface to see through the panel, i.e., through the perforations, while an observer on the opposite side of the panel sees only the image printed on the panel. Retroreflective material may be applied to the substrate to enhance the intensity of the image under nighttime conditions. To fabricate the panel, a non-perforated release liner is applied to the poly-coated liner prior to applying the second ink receptor coating and subsequent to perforating. Next, the second ink receptor coating is applied over the first ink receptor coating and onto the surface portions of the non-perforated liner in registration with the perforations to dry the ink subsequently applied during printing. The non-perforated liner is removed with the ink surface portions thereof and the protectant over-laminate is subsequently applied.

Description

Title: PRINTABLE PERFORATED VISION CONTROL PANEL AND METHOD OF FABRICATING

The present invention relates to vision control panels, i.e., light-permeable panels, formed such that a viewer on one side of the panel can see through the panel, whereas a viewer positioned on the other side of the panel cannot readily see through the panel but, rather, sees an image or a message printed on the panel and to methods of fabricating the panels.

BACKGROUND

In my prior U.S. Patent No. 5,679,435, issued October 21, 1997, incorporated herein by reference, there is disclosed a vision control panel of this type having a substrate formed of paper or vinyl sheet material (sheetstock) with retroreflective material on one side of the sheetstock and an opaque surface on its opposite side. The retroreflective material comprises glass beads, metallized or other retroreflective particles adhered to the substrate and has a printed overlay of light-permeable material such as inks defining an image on the retroreflective side of the substrate. An array of perforations, preferably laser-formed, are formed through the sheetstock, the retroreflective material and ink forming an open area through the substrate. Thus, an observer on the retroreflective side of the panel sees the printed image on the retroreflective material side. An observer on the opposite opaque side of the panel sees through the panel, i.e., through the perforations, without seeing the image. A release liner is preferably provided on the opaque side of the substrate whereby, upon removal of the release liner, the adhesive on the substrate releasably secures the vision panel to a surface, typically a transparent surface. The opposite retroreflective ink-printed side is also preferably overlaid with a sheet of protective laminate. While the 2

foregoing described laser-perforated vision control panels have proven satisfactory, they are difficult and expensive to fabricate.

DISCLOSURE OF THE INVENTION

According to the present invention, there is provided apparatus and methods for fabricating a unique vision control panel which preferably includes but need not include retroreflective material on the image side of the panel. Particularly, the present invention provides a series of layers of various materials applied in a specific sequence to form the vision control panel. First, an embodiment of the final vision control panel will be described, followed by a description of the method of fabricating the panel including an intermediate product. A substrate is formed which may comprise a preferably opaque white cast or calendar vinyl or paper sheetstock, and in a preferred form, has reflective or retroreflective material on one side. A poly-coated, preferably paper, liner is releasably adhesively secured to the opposite side of the vinyl or paper sheetstock. By poly-coated is meant that the liner is coated on one side with a plastic material such that a non-perforated adhesive liner attached thereto is easily removable at a later date by hand or machine. Preferably, the vinyl or paper sheetstock has an optically clear pressure-sensitive adhesive thereon for releasable securement of the poly-coated liner and sheetstock to one another on a side thereof opposite from the reflective or retroreflective side of the sheetstock, i.e., opposite the image side of the resulting vision control panel. Between the pressure-sensitive adhesive and the vinyl or paper sheetstock, there is provided a dark-colored flood coat. Alternatively, the pressure-sensitive adhesive on the vinyl or poly-coated sheetstock and the dark-colored flood coat may be combined as a dark-colored pigmented pressure-sensitive adhesive. The poly-coated paper has the 3

plastic coating on one side and a release coating on the opposite side, for reasons which will become clear.

It will be appreciated that the image formed on the vision control panel may be provided by any one of a number of different printing processes. For example, ink-jet printing, i.e., using thermal, piezo or crystal jet ink-jet printing heads may be used. Alternatively, other printing processes such as silk-screening, painting, airbrushing and electrostatic transfer may likewise be used. Further, the printing processes may use water-soluble inks or solvent or vinyl-based inks. Where water-soluble inks are employed on a paper substrate, ink-jet emulsion receptor coatings G and H (as described below) are used, whereas for a vinyl substrate, a primer coating and emulsion receptor coatings F, G and H, respectively (as described below), are used. Where solvent or vinyl-based inks are employed, primer and receptor coatings are not necessary.

On the image side, the vinyl or paper sheetstock may be coated with a primer coat, although for paper sheetstock, a primer coat is not necessary. Where there is a vinyl substrate, an acrylic or vinyl binder primer coat is applied to create a bond between the vinyl sheetstock and a subsequently applied ink receptor coating. The binder coat may be applied by conventional roller coating equipment. For use with water-soluble inks, the primer coating is overlaid with a conventional ink receptor coating which likewise may be applied by roller coating equipment. Where water-soluble inks of an ink-jet printer are contemplated for printing the image on the image side of the control panel, the receptor coating is an ink-jet emulsion receptor coating.

The sub-laminate thus formed from these various layers is then provided with a plurality of perforations. The perforations are preferably circular, have a hole diameter within a range of 0.03" to 0.25" and cover between 10-68% of the open area of the panel, defined by the perforations. Preferably, the perforations are formed by a laser, as set forth in my U.S. Patent No. 5,550,346, issued August 27, 1996, the 4

disclosure of which is incorporated by reference. Alternatively, the perforations may be formed mechanically as desired.

After perforating, a finish coat of ink receptor coating is provided over the previously applied receptor coating. This second or finish receptor coating repairs minor cracks or variations surrounding the perforations caused by the perforating process and is significant in the method of fabricating the vision control panel in conjunction with a seal liner, as described below. (The seal liner does not form part of the final vision control panel used by the consumer, as will become clear.) The panel is printed using any conventional printing process to form the image on the image side of the control panel. Preferably, ink-jet printing is provided and the first and second ink-jet emulsion coatings are receptive to the ink. Where retroreflective material is provided on the substrate, the ink comprises a light-permeable material overlying the retroreflective material and defining an image on the retroreflective side of the panel. After printing, a non-perforated over-laminate sheet is applied to the image side, e.g., when used in outside weather conditions. The vision control panel is then ready for use by the end user. As noted previously, the foregoing described vision control panel is fabricated in accordance with the present invention in a specific sequence of steps, with the above-described and other materials being applied in stages to form the panel. Particularly, the white cast or calendar vinyl or paper sheetstock, optionally with reflective or retroreflective material on the image side, and the poly-coated liner are secured to one another using pressure-sensitive adhesive with the dark-colored flood coating therebetween or by a dark-colored pigmented pressure-sensitive adhesive. The primer coating may then be applied to the substrate by conventional ink-jet bar coating equipment, first applying an optically clear primer (if retroreflective materials are used) or opaque white (if reflective material is not used) or other primer, followed by the first ink receptor coating, preferably an ink-jet receptor emulsion where ink-jet printing is contemplated.

At this stage in the fabrication process, there is provided a sub-laminate comprised of, from bottom to top, a poly-coated release liner, an optically clear pressure-sensitive adhesive, a dark-colored flood coat (alternatively, a dark color pigmented adhesive in lieu of the optically clear adhesive and dark-colored flood coat), the vinyl or paper sheetstock, a binder, e.g., an optically clear acrylic or vinyl binder primer and the first ink receptor coating. That sub-laminate is then perforated. For example, a rotary die, or step and repeat mechanical dies may be used to achieve a perforated structure. Where retroreflective material is provided the vinyl or paper sheetstock, laser perforations are preferably provided in accordance with the aforementioned patents. The perforations are sized and distributed to form an open area through the panel of between approximately 10-68% of the panel area, depending upon the applicable viewing requirements of the end user.

Next, and importantly, a non-perforated release or seal liner is applied to the perforated sub-laminate on the poly-coated side by passing the sub-laminate and non-perforated liner through a heated roller laminator, in which only one roller is heated. Particularly, a non-perforated seal liner is applied to overlie the first release liner (the poly-coated paper) with the non-perforated seal liner being exposed directly to the single heated roller during application. Heat-sensitive adhesive between the non-perforated seal liner and the poly-coated release liner is responsive to the low-temperature heated roller, e.g., a temperature of approximately 170-240°F such that the heat-sensitive adhesive on the seal liner will become tacky or sticky in that temperature range, binds to the plastic-coated side of the poly-coated liner and then, when cooled to room temperature immediately thereafter, become dry and non-tacky. At this stage of the fabrication process, the sub-laminate is no longer perforated between opposite 6 sides because of the application of the non-perforated seal liner to one side of the sub-laminate. It will also be appreciated that the nature of the seal liner adhesive is such that it can be removed by hand or machine from the poly-coated liner because the first liner has been poly-coated on the side receiving the heat-activated adhesive of the seal liner.

Following application of the seal liner to the sub-laminate and prior to printing on the image side of the panel using water-soluble inks, the opposite side of the sub-laminate is provided with a spray or mist coating of ink receptor, e.g., a diluted ink-jet emulsion receptor coating where ink-jet printing is contemplated. This spray coating recoats and repairs any damage caused the sub-laminate due to the formation of the perforations and adds a coating through the perforations to portions of the non-perforated seal liner in registration with the perforations. Additionally, the spray or mist receptor coating has chemical drying agents and absorption qualities which enables the receptor coating to dry subsequently applied ink when the substrate is printed and, importantly, to dry or otherwise avoid puddling of the ink in the perforations. Any puddling or non-drying of the ink in the perforations is a cause for potential ink splattering, and print contamination on the substrate, as well as on the printer and also during handling immediately after printing or upon re-rolling on take-up rewinders. The non-perforated seal liner prevents the ink from passing through the perforations, which would otherwise cause ink contamination of the ink-jet printer itself, causing further contamination of the print.

At this stage and prior to printing, an intermediate product has been formed. The intermediate product would typically be sold by the fabricator to a printer. The printer applies the image to the image side of the panel, removes the seal liner and also applies the protective laminate. The product is then ready to be sold to and applied by the end user. 7

After the printer prints an image on the receptor coated side of the sub-laminate, it is important that the seal liner be removed from the back side of the sub-laminate prior to applying a protective non-perforated, optically clear pressure-sensitive over-laminate, i.e., a protectant over-laminate, to the image side of the panel. The protectant over-laminate is used to prevent water or dirt from getting into the perforation holes during use. Thus, after printing and prior to applying the protectant over-laminate, the printer will remove the seal liner by hand or machine, typically by peeling away the seal liner, and taking away with it any dried ink deposited on the seal liner through the perforations. This is significant because the protectant over-laminate, when applied, has a tacky quality which would dip down during over-lamination into the perforations and pick up the dried inks deposited on the non-perforated seal liner. This would render outward visibility from the non-image side of the control panel unacceptable due to blurred vision caused by the dried ink deposits stuck on the protectant over-laminate in the areas of the perforations. The removal of the seal liner also prevents moist ink from contaminating the surface of the perforated first or poly-coated liner which would cause contamination of the lower roller or laminator during application of the protectant over-laminate. Once the protectant over-laminate is applied, the vision panel is ready for use by the end user.

To apply the vision control panel to a window, the end user removes the first poly-coated release liner, leaving the pressure-sensitive adhesive on the back side of the vinyl or paper sheetstock. This substrate may then be applied, e.g., directly to a window, the image side of the panel being protected by the protectant over-laminate. When viewed from the image side, the viewer will see the image provided by the ink applied to the substrate and, where retroreflective material is provided, an enhanced intense image, particularly during nighttime conditions. A viewer on the opposite 8

side of the panel will be able to see through the panel, i.e., through the perforations, without seeing the image, with only marginal little reduction in visibility.

In a preferred embodiment according to the present invention, there is provided a method of fabricating a vision control panel, comprising the steps of (a) providing a substrate of sheetstock having a poly-coated release liner releasably secured along one face thereof, (b) perforating the substrate, (c) subsequent to step (b), releasably adhesively securing a non-perforated liner along the poly-coated liner on a face thereof opposite the receptor coating, (d) subsequent to step (c), applying a receptor coating for receiving an image along a second face of the substrate, (e) subsequent to step (d), applying the image on the receptor coating applied in step (d), (f) removing the non-perforated liner from the poly-coated liner and (g) subsequent to step (f), applying a protective layer overlying the printed image applied in step (e).

In a further preferred embodiment according to the present invention, there is provided a method of fabricating an intermediate product for a vision control panel, comprising the steps of (a) providing a substrate of sheetstock having a poly-coated release liner releasably secured along one face thereof, (b) applying a receptor coating for receiving an image along a second face of the substrate forming a first sub-laminate, (c) perforating the sub-laminate, (d) subsequent to step (c), releasably adhesively securing a non-perforated liner along the poly-coated liner on a face thereof opposite the receptor coating and (e) subsequent to step (d), applying a second receptor coating for receiving an image overlying the receptor coating applied in step (b) with portions of the second receptor coating passing through the perforations onto portions of the non-perforated liner in registration with the perforations.

In a still further preferred embodiment according to the present invention, there is provided a method of fabricating an intermediate product for a vision control panel, comprising the steps of (a) providing a substrate of sheetstock having a release liner adhesively secured along one face of the sheetstock, with the release liner having a poly-coated surface on a side thereof remote from the sheetstock, (b) perforating the substrate, (c) subsequent to step (b), releasably adhesively securing a non-perforated release liner and the poly-coated liner to one another with the non-perforated release liner lying along the poly-coated surface and wherein the adhesive comprises a heat-sensitive adhesive and (d) performing step (c) by, in part, heating the heat-sensitive adhesive between the non-perforated liner and the poly-coated liner to activate the heat-sensitive adhesive to secure the non-perforated liner and the poly-coated liner to one another.

In a still further preferred embodiment according to the present invention, there is provided an intermediate product for forming a vision control panel, comprising a substrate of sheetstock, a poly-coated release liner releasably secured to the substrate along one side thereof, a first ink receptor coating overlying the substrate, a plurality of perforations through the substrate, poly-coated release liner and ink receptor coating, a non-perforated second release liner releasably secured to the poly-coated release liner along a side thereof remote from the substrate, thereby registering surface portions of the second release liner with the perforations and a second ink receptor coating overlying the first ink receptor coating with portions of the second ink receptor coating coating the registering surface portions of the second release liner.

In a still further preferred embodiment according to the present invention, there is provided a vision control panel, comprising a substrate of sheetstock, a poly-coated release liner releasably secured to the substrate along one side thereof, a first ink receptor coating overlying the substrate, a plurality of perforations through the substrate, poly-coated paper and ink receptor coating, a second ink receptor coating overlying the first ink receptor coating, ink on the 10

second ink receptor coating forming an image and a protective layer of non-perforated plastic material overlying the image.

In a still further preferred embodiment according to the present invention, there is provided an intermediate product for forming a vision control panel, comprising a substrate of sheetstock, a poly-coated release liner releasably secured to the substrate along one side thereof, a plurality of perforations through the substrate and the poly-coated release liner, pressure-sensitive adhesive between the poly-coated release liner and the substrate for releasably securing the poly-coated release liner and the substrate to one another, a non-perforated second release liner releasably secured to the poly-coated release liner along a side thereof remote from the substrate, with surface portions of the second release liner in registration with the perforations and a heat-sensitive adhesive between the non-perforated liner and the poly-coated liner for releasably securing the liners to one another.

Accordingly, it is a primary object of the present invention to provide a novel and improved printable perforated vision control panel, an intermediate product for fabricating the printable perforated vision control panel and methods of fabricating the panel and intermediate product, wherein the problems associated with the fabrication of a vision control panel, including smearing or blurring of ink on various layers of the panel during fabrication and blurred vision through the perforations caused by ink particles in the perforations in the final product are eliminated.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGURE 1 is an exploded perspective view illustrating various layers of different materials used in the fabrication of a vision control panel according to the present invention; 11

FIGURE 2 is a schematic illustration of the various steps of forming the vision control panel illustrated in Figure 3;

FIGURE 3 is a cross-sectional view of the completed vision control panel as applied to a transparent window; and

FIGURE 4 is a schematic illustration of an ink receptor coating spray or misting machine for use in fabricating the control panel of the present invention.

BEST MODE FOR CARRYING OUT THE INVENTION

Referring now to Figure 1, there is illustrated various layers used in the fabrication process to form a vision control panel according to the present invention. The various layers are designated A through J. The vision control panel 10 as supplied to the end user of the panel is comprised of layers B through J, whereas an intermediate product 12 used in the fabrication of the control panel 10 comprises layers A through H. As will become clear, certain layers are omitted depending on the nature of the substrate and whether water-soluble or solvent or vinyl-based inks are employed. In order from bottom to top, the various layers formed in the fabrication process when water-soluble inks are used are as follows:

A - A non-perforated over-laminate or seal liner with heat-activated adhesive

B - A poly-coated release liner

C - An optically clear pressure-sensitive adhesive

D - A dark-colored flood coat

E - A cast or calendared vinyl, polyester or paper sheetstock

E' - An optional retroreflective or reflective material on the layer E

F - A primer coat

G - A first ink receptor coating

H -- A second ink receptor coating 12

I -- An ink layer forming the image on the control panel

J A protectant over-laminate with optically clear pressure-sensitive adhesive

To form a vision control panel using solvent or vinyl-based inks on a paper or vinyl substrate, layers F, G and H are not included. Where the panel substrate is paper and water-soluble inks are used, the binder coating of layer F may be omitted (layer E' being optional). Where the panel substrate is vinyl and water-soluble inks are used, all of the above layers are required (layer E' again being optional).

Referring more particularly to the various layers, layer A comprises a non-perforated seal liner which employs a heat-activated adhesive for securement to the underside of the poly-coated release liner B. Layer A may be purchased commercially under brand names, such as Seal and GBC Pro-Tech. As noted below, layer A is laminated to layer B after the perforations are provided layers B-G and before the spray coating H. Layer B is a poly-coated release liner, preferably paper, which is releasably secured to layer D by the optically clear pressure-sensitive adhesive of layer C. The poly-coat layer B has a plastic material coating on its side adjacent layer A and a silicone release coating on its opposite side. The dark-colored flood coat of layer D, which is preferably dark gray or less preferably, black, is suitably adhered to the vinyl, polyester or paper sheetstock of layer E. In lieu of layers C and D, a dark-colored pigmented adhesive may be used to releasably secure the poly-coated paper liner of layer B to the vinyl, polyester or paper of layer E. The primer coat F may be an acrylic or vinyl binder and may be applied to the upper surface of the layer E by conventional roller coating equipment. For a paper substrate layer E, the primer coat F may be omitted. Layer E' is optional and comprises retroreflective or reflective material on the image side of the control panel as desired. Retroreflective material of layer E' may comprise glass beads, metallized, or other retroreflective particles which are suitably adhered to the underlying vinyl, polyester or paper 13 sheetstock of layer E. Other methods of forming retroreflective materials such as etching or causing diffractive properties within the substrate can be used. On top of layer E , E' or F, as applicable, and for use with water-soluble inks, is a first ink receptor coating G, preferably an ink-jet emulsion receptor coating where ink-jet printing is used to form the image on the resulting control panel. This receptor coating comprises well-known material and may be provided by similar roller coating equipment as used to apply the primer coating F. A second ink receptor coating H comprises the same material as the receptor coating of layer G, preferably in diluted form. The manner of application of coating H is by spraying or misting over the receptor coating G after perforations have been provided through layers B-G and layer A has been applied as described hereinafter. Layer I is the ink which is spray-printed, for example, during ink-jet printing, onto the ink receptor coating H to form the image on the panel. Ink layer I is preferably a water-soluble ink. Where layer I is a solvent or vinyl-based ink, coatings of layers F, G and H are not necessary. Layer J is an optically clear protectant non-perforated over-laminate applied using pressure-sensitive adhesive and may be formed from vinyl or polyester sheet material. The material of layer J is commercially sold under brand names from 3M 89-14, Avery DOL 4100 Perforated Window Film Overlaminate or MacTac IP-7000. This protective layer is applied after removal of the seal liner A as described below.

Referring now to Figure 2, the method of fabricating the final vision control panel is schematically illustrated. The layers B, C, D and E are commercially available from suitable suppliers. The primer coat of layer F may be applied to the non-perforated layers B, C, D and E by a conventional roller coating process schematically illustrated at 20. Next, the layer G, which is the first ink receptor coating, may be applied to the vinyl, polyester or paper sheetstock of layer E by a conventional roller coating process schematically illustrated at 22. For example, an acrylic or clear vinyl binder primer may be applied, 14

particularly when layer E comprises vinyl sheetstock. This sub-laminate is now ready for perforation.

Many different types of perforators may be used to perforate the sub-laminate, one of which is schematically illustrated at 24. For example, rotary die, step and repeat mechanical dies or laser perforation may be used. Where retroreflective material is provided in layer E¹ overlying the vinyl, polyester or paper sheetstock layer E, laser perforations are preferred in accordance with my U.S. Patent No. 5,550,346. The perforations 26 are preferably circular holes, although other geometrical configurations may be provided. Preferably, the circular holes have a hole diameter within a range of 0.03 to 0.25 inches and the distribution of the perforations is such that preferably 10-68% of the panel comprises open areas defined by the holes. A typical vision control panel may therefore have a hole diameter of 0.05" with 114-260 holes per square inch, providing an open area of 22-50%.

The perforated sub-laminate is then passed through a roller laminator comprised of a pair of rolls 28 and 30, only one of which is heated. The non-heated roller 28 overlies the layer G, while the heated roller 22 overlies the seal liner layer A. Preferably, a 1 or 2 ml non-perforated seal liner layer A with a heat-activated adhesive thereon is laminated to the surface of the poly-coated release liner layer B at a low adhesive activation temperature of about 170-240°F. The seal liner A should be as thin as possible in order that the overall thickness of the laminate prior to printing remains as small as possible. This precludes the formation of a relatively stiff laminate which is to be avoided to eliminate problems associated with passing the laminate through a printer. By applying heat only to one roller, heat damage to the coating on the ink receptor coated side of the construction is prevented or minimized. It will be appreciated that the adhesive used to apply the seal liner A to the poly-coated paper is such that the adhesive becomes tacky at the above temperature range and 15 binds to the poly-coated paper of layer B and then, when cooled to room temperature, becomes dry and non-tacky. If pressure-sensitive adhesive is used on seal liner A, the surface portions of liner A in registration with the perforations would be tacky and the ink-jet receptor coating H would not properly bind to it.

It will be appreciated from a review of Figure 2 that at this stage in the fabrication process, the perforations 26 through the sub-laminate do not extend through from one side to the other because of the addition of the non-perforated seal liner of layer A. As the next step, an additional ink receptor layer H is applied to overlie the first ink receptor coating of layer G. The second ink receptor coating of layer H is preferably, but need not be, the same composition as the first ink receptor coating of layer G but in diluted form to permit spraying or misting onto the first ink receptor coating by a machine M illustrated in Figure 4, described hereinafter. Consequently, this second coating is a dilution with water of the same composition as the first ink receptor coating, e.g., a dilution in a range of 3:1 to 20:1. Thus, the second or final ink receptor coating is not applied by conventional commercial roller coating equipment but, rather, by a mist or spray machine custom-designed as set forth below which sprays or lightly mists the second ink receptor coating onto the first ink receptor coating.

It will be appreciated that the second ink receptor coating of layer H during the application process is beneficially and advantageously applied in the perforations such that the second receptor coating is applied to portions 32 of the seal liner of layer A which lie in registration with the perforations 26. The purpose of the second ink receptor coating of layer H is twofold: (1) to recoat and repair any damage caused to the first ink receptor coating of layer G due to the perforating process which would cause a halo effect surrounding the perforations upon printing and (2) to add a coating to the portions 32 of the seal layer A in registry with the perforations 26. 16

The repair of the first ink receptor coating of layer G affords a better quality print as the second mist or spray ink receptor coating of layer H fills any small hairline cracks or damage to the surface of the first ink receptor coating of layer G caused by the perforations 26, which might otherwise cause a halo effect about the perforations. Also, during subsequent printing, the chemical drying agents and absorption qualities of the second ink receptor coating enables the ink from the printing process to dry quickly, particularly on the registering surface portions 32. Puddling of the ink in the perforations 26 is also avoided. Non-drying or puddling of the ink in the perforations 26 causes a potential for ink to splatter, as well as print contamination due to wet ink during handling immediately after printing or upon re-rolling on take-up winders. One of the beneficial aspects of providing a seal liner, i.e., layer A, during printing is that the ink is prevented from passing through the perforations 26, which would otherwise cause ink contamination of the printer and cause further contamination of the print.

A single ink receptor coating may be applied to the paper or vinyl substrate of layer E instead of two ink receptor coatings as described above. It is important, however, that any applied ink receptor coating penetrate the perforations onto the seal liner layer A for the purposes previously discussed, e.g., to prevent ink residue from residing in the perforations and on the tacky pressure-sensitive protectant over-laminate of layer J, which would then blur the image and visibility through the final control panel.

At this stage of fabrication, the intermediate product IP is ready for printing and over-laminating and for use by the end user. Consequently, the fabricator may rewind the sub-laminate and ship the rewound intermediate product to a printer, for example, a commercial ink-jet printing establishment. With the seal liner of layer A intact and underlying the perforation holes 26, the opposite exposed surface area of the intermediate product IP may receive the 17 ink of layer I. The second receptor coating of layer H enables the inks forming the printed image to dry quickly without puddling or splattering. After printing by printer P, and before the addition of the final protectant over-laminate layer J, the seal layer A is removed from the poly-coated paper layer B, e.g., by hand or machine. As the seal liner is being removed, the liner takes with it the dried ink deposited through the perforations 26 during the printing process onto portions 32. The removal of layer A is important. If left in place and the protectant over-laminate J is applied to the opposite side, the tacky quality of the pressure-sensitive non-perforated protectant over-laminate J would dip down during machine or hand over-lamination into the perforations 26 and have adhered thereto the dried inks deposited on the seal layer A. As will be recalled, the protectant over-laminate is an optically clear non-perforated plastic material having pressure-sensitive adhesive for adhering it to the sub-laminate. If the dried inks or other materials adhere to the adhesive of the over-laminate of layer J, vision through the panel from the non-image side, i.e., through the perforations, would be inhibited and obscured. When viewed from the image side, the image also would appear blurred and poorly defined. Additionally, the removal of the non-perforated seal liner of layer A prevents moist ink from contaminating the surface of the poly-coated liner which could cause contamination of the lower roller of the laminator during application of the protectant over-laminate by rollers 34 and 36. Consequently, the seal liner A is removed after printing and before the over-laminate of layer J is applied to the control panel.

At this stage, and with the protectant over-laminate of layer J applied, the control panel is complete and ready for use by an end user. Turning to Figures 2 and 3, the end user applies the vision control panel to a transparent substrate such as a window W by removing the poly-coated layer B (Figure 2). The pressure-sensitive adhesive between the poly-coated layer B and the vinyl, polyester or paper 18

sheetstock of layer E remains with the panel and enables the panel to be adhered to the transparent window W. Consequently, an individual viewing the panel from the outside of the window, as viewed from right to left in Figure 3, will see the image on the panel, whereas a viewer viewing the panel from the inside of the window, from left to right in Figure 3, will see through the panel, i.e., see through the perforations, without seeing the image. Where retroreflective material of layer E' is provided and transparent inks for layer I are used, a highly intense image will be seen from the outside of the window with only reflected ambient light.

As indicated previously, where solvent or vinyl-based inks are used, layers F, G and H are omitted. Where water-soluble inks are used on a paper substrate E, layer F can be omitted. Layers F, G and H, of course, are applied in conjunction with the other applicable layers, where a vinyl substrate layer E is used.

Referring now to Figure 4, there is illustrated an applicator for the mist or spray ink receptor coating of layer H. As illustrated, a roll of the various materials for forming the intermediate product, i.e., layers B through G, is provided. A web of the material is passed through a closed chamber 38 defined by a hood 40 connected to a suction blower 42 and overlying an over-spray catch pan 46. A spray nozzle 48 is provided for spraying the second ink receptor coating of layer H from a supply 50 thereof onto the first receptor coating layer G. Excess spray or mist is returned to the supply 50 via line 52. The web is then passed through a curing tunnel 52 in which are disposed a plurality of longitudinally spaced heat lamps 54. Additionally, a forced air blower 56 is provided for supplying air heated by heater 58 into the tunnel to cure the receptor coating. Once cured, the web is taken up on a rewinder 60 and provided to the printer in roll form. While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be 19

limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.

Claims

20I Claim

1. A method of fabricating a vision control panel, comprising the steps of:

(a) providing a substrate of sheetstock having a poly-coated release liner releasably secured along one face thereof;

(b) perforating the substrate;

(c) subsequent to step (b), releasably adhesively securing a non-perforated liner along said poly-coated liner on a face thereof opposite said receptor coating; (d) subsequent to step (c), applying a receptor coating for receiving an image along a second face of the substrate;

(e) subsequent to step (d), applying the image on the receptor coating applied in step (d);

(f) removing the non-perforated liner from the poly-coated liner; and

(g) subsequent to step (f), applying a protective layer overlying the printed image applied in step (e).

2. A method according to Claim 1 including applying a first receptor coating to the second face of the substrate prior to steps (b), (c), (d), (e), (f) and (g), the receptor coating of step (d) forming a second receptor coating overlying said first receptor coating.

3. A method according to Claim 2 including, before applying said first and second receptor coatings, applying a primer coating along the second face of said substrate, with the primer coating lying between said first receptor coating and said substrate, and applying a dark-colored flood coat along the one face of the substrate and between the substrate and the release liner.

4. A method according to Claim 1 including a pressure-sensitive adhesive between the poly-coated release liner and the substrate, and including the further step of releasably securing the poly-coated paper to the substrate by the pressure-sensitive adhesive. 21

5. A method according to Claim 1 including applying a first receptor coating to the second face of the substrate prior to steps (b), (c), (d), (e), (f) and (g), the receptor coating of step (d) forming a second receptor coating overlying said first receptor coating and applying the second receptor coating of step (d) with portions of the second receptor coating passing through the perforations onto portions of the non-perforated liner in registration with the perforations.

6. A method according to Claim 1 including applying a first receptor coating to the second face of the substrate prior to steps (b), (c), (d), (e), (f) and (g), the receptor coating of step (d) forming a second receptor coating overlying said first receptor coating and applying the second receptor coating of step (d) by spraying said second receptor coating onto the first receptor coating.

7. A method according to Claim 1 including a heat-sensitive adhesive between the non-perforated liner and the poly-coated release liner for securing the non-perforated liner to the poly-coated liner and including performing step (c) by passing the sub-laminate and non-perforated liner between a pair of rolls and heating the heat-sensitive adhesive between the non-perforated liner and the poly-coated liner to activate the heat-sensitive adhesive.

8. A method according to Claim 1 including applying a first receptor coating to the second face of the substrate prior to steps (b), (c), (d), (e), (f) and (g), the receptor coating of step (d) forming a second receptor coating overlying said first receptor coating and wherein step (e) includes printing the image on the second receptor coating using water-soluble ink, and wherein a heat-sensitive adhesive lies between said poly-coated release liner and said non-perforated liner for releasably securing the liners to one another, the step (c) including passing the sub-laminate and the non-perforated liner between a pair of rolls and heating the heat-sensitive adhesive of the non-perforated liner to activate the adhesive. 22

9. A method of fabricating an intermediate product for a vision control panel, comprising the steps of:

(a) providing a substrate of sheetstock having a poly-coated release liner releasably secured along one face thereof; (b) applying a receptor coating for receiving an image along a second face of the substrate forming a first sub-laminate;

(c) perforating the sub-laminate;

(d) subsequent to step (c), releasably adhesively securing a non-perforated liner along said poly-coated liner on a face thereof opposite said receptor coating; and

(e) subsequent to step (d), applying a second receptor coating for receiving an image overlying the receptor coating applied in step (b) with portions of the second receptor coating passing through the perforations onto portions of the non-perforated liner in registration with the perforations.

10. A method according to Claim 9 including, before step (b), applying a primer coating along the second face of said substrate, with the primer coating lying between said receptor coating of step (c) and said substrate.

11. A method according to Claim 9 including applying a dark-colored flood coat along the one face of the substrate and between the substrate and the release liner.

12. A method according to Claim 9 including a pressure-sensitive adhesive between the poly-coated release liner and the substrate and including the steps of releasably securing the poly-coated paper to the substrate by the pressure-sensitive adhesive and applying the second receptor coating of step (e) by spraying the second receptor coating onto the receptor coating applied in step (b).

13. A method according to Claim 9 including a heat-sensitive adhesive between the non-perforated liner and the poly-coated release liner for securing the non-perforated liner to the poly-coated liner and including performing step (d) by passing the sub-laminate and 23

non-perforated liner between a pair of rolls and heating the heat-sensitive adhesive between the non-perforated liner and the poly-coated liner to activate the heat-sensitive adhesive.

14. A method of fabricating an intermediate product for a vision control panel, comprising the steps of:

(a) providing a substrate of sheetstock having a release liner adhesively secured along one face of said sheetstock, with the release liner having a poly-coated surface on a side thereof remote from said sheetstock; (b) perforating the substrate;

(c) subsequent to step (b), releasably adhesively securing a non-perforated release liner and said poly-coated liner to one another with the non-perforated release liner lying along the poly-coated surface and wherein the adhesive comprises a heat-sensitive adhesive; and

(d) performing step (c) by, in part, heating the heat-sensitive adhesive between the non-perforated liner and the poly-coated liner to activate the heat-sensitive adhesive to secure the non-perforated liner and the poly-coated liner to one another.

15. A method of fabricating an intermediate product according to Claim 14 including performing step (c) by passing the substrate and the non-perforated liner between a pair of rolls, and including the further steps of applying ink on said substrate on a side thereof remote from the poly-coated liner and subsequently removing the non-perforated release liner from the poly-coated release liner.

16. An intermediate product for forming a vision control panel, comprising: a substrate of sheetstock; a poly-coated release liner releasably secured to said substrate along one side thereof; a first ink receptor coating overlying said substrate; 24 a plurality of perforations through said substrate, poly-coated release liner and ink receptor coating; a non-perforated second release liner releasably secured to said poly-coated release liner along a side thereof remote from said substrate, thereby registering surface portions of said second release liner with said perforations; and a second ink receptor coating overlying said first ink receptor coating with portions of said second ink receptor coating coating said registering surface portions of said second release liner.

17. A intermediate product according to Claim 16 wherein said substrate is formed of one of vinyl or paper, said substrate having retroreflective material on a side of said sheetstock remote from said poly-coated release liner, said sheetstock having an opaque surface on an opposite side thereof.

18. An intermediate product according to Claim 16 including a flood coat between said substrate and said poly-coated release liner.

19. An intermediate product according to Claim 16 including a pressure-sensitive adhesive between said poly-coated release liner and said substrate and a heat-sensitive adhesive between said non-perforated liner and said poly-coated liner for releasably securing said liners to one another.

20. An intermediate product according to Claim 16 wherein said substrate is formed of one of vinyl or paper, said substrate having retroreflective material on a side of said sheetstock remote from said poly-coated release liner, said sheetstock having an opaque surface on an opposite side thereof, a pressure-sensitive adhesive for releasably adhering said poly-coated release liner and said substrate to one another and a heat-sensitive adhesive between said non-perforated liner and said poly-coated liner for releasably securing said liners to one another.

21. A vision control panel, comprising: a substrate of sheetstock; 25 a poly-coated release liner releasably secured to said substrate along one side thereof; a first ink receptor coating overlying said substrate; a plurality of perforations through said substrate, poly-coated paper and ink receptor coating; a second ink receptor coating overlying said first ink receptor coating; ink on said second ink receptor coating forming an image; and a protective layer of non-perforated plastic material overlying said image.

22. A vision control panel according to Claim 21 wherein said substrate comprises sheetstock having retroreflective material on a side thereof remote from said poly-coated release liner and having an opaque surface on an opposite side thereof.

23. A vision control panel according to Claim 21 wherein said sheetstock is formed of one of vinyl or paper, said substrate having retroreflective material on a side of said sheetstock remote from said poly-coated release liner, said sheetstock having an opaque surface on an opposite side thereof, a pressure-sensitive adhesive between said poly-coated release liner and said sheetstock for releasably adhering said poly-coated release liner and said substrate to one another.

24. An intermediate product for forming a vision control panel, comprising: a substrate of sheetstock; a poly-coated release liner releasably secured to said substrate along one side thereof; a plurality of perforations through said substrate and said poly-coated release liner; pressure-sensitive adhesive between said poly-coated release liner and said substrate for releasably securing said poly-coated release liner and said substrate to one another; 26 a non-perforated second release liner releasably secured to said poly-coated release liner along a side thereof remote from said substrate, with surface portions of said second release liner in registration with said perforations; and a heat-sensitive adhesive between said non-perforated liner and said poly-coated liner for releasably securing said liners to one another.