Patent Application
20070087164
1. Field of the Invention
This invention relates to a three-dimensional decorative article, methods for making such articles and more particularly to three-dimensional plastic articles with a predetermined configuration and a symmetrical cross section.
2. Background for the Invention
Transfer graphic articles with rounded and sealed edges and methods for making such articles are known. For example a U.S. Pat. No. 4,759,982 of Jensen et al. discloses a process for preparing a transfer article having a protective clear coat in precise registration with the graphic. The edges of underlying adhesive are sealed by a clear coat so that solvent resistance is achieved.
A more recent patent of Barthelman U.S. Pat. No. 5,622,587 discloses a method for producing a three-dimensional Laminated Decal Composite. The resulting composite has a predetermined configuration with top edges being curved or arcuate. As disclosed, the method includes providing a decal support for supporting a decal, and securing a decal to the decal support to produce a laminated decal composite. A thermal dye is produced with a dye base and at least one cutting ridge secured to the dye base. The cutting ridge in vertical cross section is essentially shaped as an isosceles triangle with a preferred height of about 0.09 inches. The laminated decal composite is die-cut with a cutting edge of the thermal dye having a cutting temperature, a cutting pressure and a cutting dwell time to produce a three-dimensional laminated decal composite having a predetermined configuration. A three-dimensional laminated decal composite produced in accordance with a method is also disclosed.
Molded articles of laminated/encapsulated substrates are also known. For example a Patent Application Publication of Julius U.S. 2004/0258889 discloses a process for applying an image to a permeable substrate and embedding the substrate in a resin. As disclosed by Julius, a digital image is applied to any of an infinite variety of substrates and sub sequentially embedded in a resin which is translucent/transparent and protective. Optionally, an image may be reproduced by a digital ink jet printer and applied to a substrate. The substrate may then be laminated, incorporated or bonded to a solid surface between layers of resin.
Not withstanding the above, it is presently believed that there may be a commercial market for a novel three-dimensional decorative article with a predetermined configuration and a symmetrical cross section and for methods to make such articles. There should be a demand for such articles because of a pleasing appearance, durability and availability with soft or hard surfaces. Further, such articles may be made in relatively ridged, firm or slightly flexible forms with complementary image profiles on both sides and forming a three-dimensional article. Further, the articles made by the process disclosed herein are applicable as key chains, toys, inexpensive jewelry, or other small articles in various shapes and sizes with various images.
In essence, the present invention contemplates a three-dimensional decorative plastic article including a thin sheet of flexible material having complementary image profiles on each side thereof. The articles also include a pair of superimposed arcuate domes with the flat sheet sandwiched between the domes. In one embodiment of the invention, the decorative articles include a passageway through both domes and the substrate and a key ring or other attachment means passes through the passageway.
The invention also contemplates a method for making a three-dimensional decorative article in accordance with the present invention including the steps of providing a thin flat sheet of flexible material such as a synthetic printing sheet. Complementary image profiles are printed on each side of the sheet and the printed sheet is placed on a low-tack paper. The printed sheet is die or precision cut around or along the image profile using care to avoid cutting the low-tack paper; and material outside of the image profile is removed to provide a relatively sharp edge surrounding the image. The low-tack paper is then fixed to a substrate as for example by means of a plurality of vacuum holes. In addition, a mass of liquid plastic such as a clear or transparent urethane resin is provided. The plastic resin is then added i.e. poured onto a first surface of the precision cut printed sheet until the resin is confined by an edge around the image profile due to surface tension to thereby form a first dome shaped cover. The dome on the first side of the printed sheet is then polymerized as for example dried in air at room temperature for a given time to thereby form a semi-finished article. The semi-finished article is then turned over and attached to a first or a second sheet of low-tack paper in the identical location with respect to one another as on the first piece of low-tack paper and liquid plastic is poured onto the second image surface until contained at the edge due to surface tension thus forming a second plastic dome. The second dome is polymerized as for example by air drying for about one day at room temperature or by the addition of hardener or dried at an elevated temperature to form a finished article. The article may have a passageway or hole drilled therethrough for a small ring or other attachment means. It is also contemplated that the article if used for a necklace will merely have a thin chain passing through the passageway.
The invention will now be described in connection with the following drawings.
A three-dimensional decorative article 2 in accordance with the present invention is shown in
It is also important that the micro porous synthetic printing sheet 14 is impermeable and prevents water or other fluid from penetrating into the sheet 14 from an outer edge thereof. In a preferred embodiment of the invention, the sheet 14 is TESLIN® sheet from PPG Industries, Inc. of Pittsburgh Pa.
The decorative article 2 also includes a pair of arcuate plastic domes 10 and 12 on each side of the sheet 14. The domes 10 and 12 are preferable made of a clear lensing resin. For example the domes 10 and 12 may be made from CHEM DEC 892 or 892F from CHEMIQUE, Inc. of Indianapolis, Ind. The resins are high quality, two component polyurethane resin systems that can be cured at room or elevated temperatures.
As illustrated in
A method for making decorative articles in accordance with the present invention will now be described in connection with
The excess material i.e. the portion of the printed sheet outside of the image profile are removed in step 28 and the low-tack paper is placed on a fixed substrate in step 30 and held in place thereon as for example by vacuum holes after positioning under an automatic mix-dispenser.
The clear lensing resin such as a 3 isocyanatomethyl-3,5,5-trimethylicyclohexyl isocyanate or other suitable plastic is dispensed onto each of the upper surfaces of the images to form a first plastic dome. The resin is added in a controlled amount and flows the edge of the image i.e. the edge formed in step 26. In forming elongated shapes such as a beverage bottle, the resin may be added at 2, 3, or more locations and allowed to flow together and outwardly to the edge until confined by the edge due to surface tension.
The first plastic dome is allowed to dry in step 34 as for example at room temperature for 8-24 hours to form a semi-finished article. Then, after drying the semi-finished articles are turned over in step 36 using care to position the semi-finished articles with respect to the plastic dispensers and with one another in the same location as previously placed. While the semi-finished articles can be turned over onto the same sheet of low-tack paper, it maybe more efficient to turn the low-tack paper with the semi-finished articles thereon and attach the semi-finished articles to a second sheet of low-tack paper and removing the first sheet leaving the semi-finished with the flat surface on an upper side thereof for receiving a second dome. The first low tack sheet may be removed by means of a thin roller to press down on the upper side and lifting up the first tack sheet behind the roller.
After turning the semi-finished article over in step 36, the clear lensing resin is dispensed onto the flat upper surface in step 38 in the same manner as in step 32. Also as in step 32, the low-tack paper is fixed to a substrate under a plurality of plastic dispensers. The second plastic domes are then dried or polymerized in step 40 and the finished articles removed from the low-tack paper in step 42.
The surface of the domes may be relatively soft or have a hard surface based on the composition of the dome and/or the amount of hardener as will be well understood by persons of ordinary skill in the art. Further, the domes may be of a compound with plastic memory so that an indentation by a fingernail will return to it's original form over time.
While the invention has been described in connection with the preferred embodiments, it should be recognized that changes and modifications may be made therein without departing from the scope of the appended claims.
