Background of the Invention
[0001] The present invention relates to a method for making decorative emblems, plaques,
panels, etc., which have a cured plastic layer over a decorative surface and, more
particularly, it relates to a method for flow coating a fluent plastic material onto
a decorative substrate to give a uniform thickness coated substrate from which emblems,
plaques, or panels are formed.
[0002] Decorative plaques and emblems are widely used throughout a number of industries,
including the automotive and appliance fields. In the past, a colored vitreous frit
was flowed into a bronze substrate and fired at 1250°F. The glass-like vitreous enamel
served to beautify the product and protect the decorative substrate from weathering
should the plaque or emblem - be exposed to the environment.
[0003] Today, plastics are primarily used for producing such plaques and emblems. For example,
in Loew (U. S. Patent No. 3,654,062), there is disclosed a process for injection molding
a decorative Mylar facing sheet over a vinyl plastic body. The plaque is coated with
a layer of protective varnish on the outer surface of the facing sheet. Gits, U. S.
Patent No. 3,246,066, is similar in that male and female molds are used to form a
cavity into which a decorative foil is placed and into which a clear plastic material
is injected. Prior to injecting a clear plastic material against the front face of
the foil, the foil is precoated. Other molding processes, such as compression molding
(either one or two shot), are also well known in the art. See for instance, U.S. Patents
No. 2,244, 565;2,931,119; 3,075,249; and 3,114,597.
[0004] In my copending application Serial No. 702,194, filed July 2, 1976, there is disclosed
an improved process for producing decorative emblems. That process involves casting
a plastic material onto decorative foil shapes to form a meniscus which when cured
gives a lens effect to the top surface of the foil shape. A problem with that process
is that despite an ability to vary the size and shape, it is not practical to later
conform the as-cast emblem to non-planar surfaces.
[0005] Another problem is that the foil shapes are cast individually and the manufacturing
process can as a result be too cumbersome and costly for some purposes. Accordingly,
the need exists for yet another improved process for producing decorative emblems
which is less expensive, more efficient and which yields a product which can be formed
to different three-dimensional shapes if desired.
[0006] The present invention meets that need by utilizing a flow coating process to apply
a clear plastic material to a decorative substrate from which individual emblems and
plaques may then be stamped and shaped. Of course, flow coating per se is known in
a number of areas. My copending application Serial No. 718,578, filed August 30, 1976,
discloses such a process for coating glass containers. As another example, U. S. Patents
No. 3,875,893 to Riley and 3,431,889 to Fraatz both disclose flow-coating processes
using multiple orifices to lay down a thin film onto a flat surface. But Fraatz and
Riley do not relate to emblem or plaque manufacturing processes where a clear plastic
is applied to a decorative substrate.
[0007] It should also be noted that Hansen in U.S. Patent No. 3,725,112 Mentions flow coating
as one of the possible methods for producing his coated or encapsu- substrates. That
patent discloses applying a protective low-glare, uniformly textured, transparent,
polymeric coating to a substrate such as wood, steel, hard- board, aluminum and the
like. Still, the intent of Hansen is to produce textured films having a low-glare
surface and not to produce decorative emblems of the type contemplated by the present
invention.
[0008] Therefore, the need still remains for a method for flow coating clear plastic materials
onto a decorative substrate to economically and efficiently produce decorative emblems,
plaques, panels, etc.
Summary of the Invention
[0009] The present invention utilizes such a flow coating process to produce decorative
emblems in a manner more conducive to mass production than the process of my copending
application Serial No. 702,194. Of course, the depth and beauty of the lens effect
achieved by the process of that copending application is not duplicated with the present
one. Still, it does have a number of other advantages. Principal among these is the
economical and efficient means of production and the ability to apply a smooth coating
to a decorated and embossed substrate which may be formed for application to non-planar
surfaces.
[0010] This latter feature is, in fact, possible because a high meniscus and lens effect
are not existent here. Rather, the plastic is of a more flexible variety and is applied
in a thinner film which will withstand subsequent shaping operations. And yet, because
it is possible with the instant flow coating process to deposit the plastic on the
decorative substrate uniformly to a thickness of .020 to .030 inches (.508 to .762
mm), an attractive emblem is still produced.
[0011] The substrate upon which the fluent plastic is coated may be a plastic or metal foil,
preferably an aluminium foil 0.003 to .020 inch (.0762 to .508 mm) thick. The foil
substrate is decorated with an appropriate design or series of designs. For example,
if a foil sheet or a substantial part of it is to be used as a panel with a minimum
amount of trimming after being coated, a single design might be used. More commonly,
a series of designs in the form of individual emblems or plaque shapes will be applied
to the foil sheet. With a metal foil, the series of designs is preferably applied
by silk screen or lithographic printing then the design is enhanced by embossing select
areas; although, other means for forming the decorative designs may also be used.
[0012] Likewise, it is desirable to prime the top surface of the substrate prior to printing.
Any suitable primer may be used such as a silane primer. The decorated-primed substrate
is then placed upon a vacuum mat which is situated upon a horizontal vacuum table
such as that shown in U.S. Patent No. 4,034,708, and assigned to the assignee of this
invention. Vacuum is drawn against the bottom surface of the foil through the mat
to hold the substrate flat and horizontal.
[0013] It is important that the substrate be held flat and horizontal during flow coating
because of the fact that the flow characteristics of the fluent plastic and the liquid
wettability of the substrate are used to control the spread of the plastic so that
it is contiguous with predetermined areas of the foil as well as being uniformly thick.
Another important factor in controlling'this is the existence of sharply defined peripheral
sides for the substrate or define areas of the substrate.
[0014] Thus, it is possible to limit the coated areas of a single foil sheet by forming
slits, embossed ridges, or other sharp edges in the sheet. When a predetermined amount
amount of fluent plastic is flow coated onto that area, then, it will spread only
to the sharply defined peripheral side. In this manner, it is possible to avoid waste
by coating only the path directly over the designs from which the emblems or plaques
are to be formed, and not wastefully on peripheral areas which are to be discarded.
[0015] In the present invention, the flow coating is a path- wise disposition. That is,
a multiple orifice nozzle (nor nozzles) is passed over the decorated-primed surface
of the foil at a steady speed as the substrate is held stationary. The number of orifices
used may vary depending on the width of the path to be laid down. As an example, a
2.1 inch (53. 34 mm) wide nozzle having 22 orifices of a .022 inch (.5588 mm) I.D.
and with a 0.10 inch (2.54 mm) spacing between the orifices, can be used to lay down
a path of 2.4 to 2.5 inches (60.96 to 63. 5 mm) in width.
[0016] As can be seen from this example, if such a nozzle is to be used to coat a sheet
of greater than 2.5 inches (63. 5 mm) width, then either several nozzles tracking
across the sheet in parallel paths must be used or the single nozzle must be programmed
to track back and forth across the sheet until the surface is covered with a uniform
thickness of the fluent plastic.
[0017] The thickness sought is between approximately .020 to .030 inch (.508 to .762 mm).
The plastic is preferably a fluent polyurethane of two component parts (polyol and
isocyanate) which are mixed immediately prior to coating and cure upon heating. A
polyurethane of this type is disclosed in my copending application Serial No. 702,194.
In formulating the particular plastic composition from among those disclosed in the
copending application, it is important to use a catalyst which results in a somewhat
slow curing time in order to allow the flow coated liquid plastic to flow to its full
extent, i.e., to the sharply defined peripheral sides, before curing is accomplished.
Otherwise, it may not be possible to obtain a uniform thickness, smooth coating.
[0018] Likewise, the polyurethane may be compounded from among the componentslisted in the
copending application as is known to give a more flexible cured plastic. As long as
the bond to the substrate remains strong, it is desirable in this invention to have
a somewhat flexible plastic coat so that the emblem, plaque, or panel may be conformed.
For example, some decorative automobile panels are applied to a curved surface. With
the present invention, it is possible to conform the cured plastic coated panel to
that surface.
[0019] For most of the types of plastic contemplated, curing will be by irradiation with
infra-red or ultraviolet light. The polyurethane compounds mentioned above are heat
curable and, thus, infra-red lamps are used; although, obviously other heat sources
may also be used. Still, it is desirable to get a through cure, i.e., heat from both
the top and bottom of the coated foil. The preferred vacuum table arrangement of U.
S. Patent No. 4,034,708 makes this possible because of a capability of heating or
cooling it. However, it has been found desirable to use the infra-red lamps themselves
as the heat source for both top and bottom heating. This may be done by using an I.
R. absorptive mat as the vacuum mat. The mat will, then, pick up heat from the infra-red
radiation and conduct it back from the bottom through the coated foil.
[0020] After curing, the coated substrate is cooled and removed from the vacuum table. It
may at this stage be further processed by cutting, trimming and forming. When individual
emblem or plaque shapes are contained on the single sheet, they are stamped out by
a cutting die around the particular emblem or plaque shape. It has been found that
by die cutting from the bottom surface of the coated foil, it is possible to impart
a slightly convex configuration when viewed from the top surface. The convex shape
helps give the appearance of a lens effect to the emblem; although, one does not actually
exist.
[0021] Still, the appearance of the coated emblem is superior to a non-coated one. The luster
and beauty of the clear plastic adds considerably to the appearance. It also serves
to protect the decorative surface from weathering, chipping, scratching, etc.
[0022] Accordingly, it is an object of the present invention to provide a method for making
decorative emblems, plaques and panels which have a cured plastic layer over a decorative
surface.
[0023] It is another object of the present invention to provide a flow coating process whereby
a clear plastic layer may be economically and efficiently laid down to a uniform thickness
on a decorative substrate from which the emblems, plaques, and panels may be formed.
[0024] Other objects and advantages of the present invention will be apparent from the following
description, the accompanying drawings and the appended claims.
Brief Description of the Drawings
[0025]
Fig. 1 is a perspective overall view of the preferred apparatus for performing the
method of the present invention;
Fig. 2 is a side view of the device;
Fig. 3 is a view illustrating the coating nozzle arrangement for performing the method
of the present invention;
-Fig. 4 is a perspective view of the coating arrangement for performing the method
of the present invention; and
Fig. 5 is a cross-sectional view of the coated sheet of Fig. 4.
Description of the Preferred Embodiments
[0026] The flow coating process of this invention may be performed with a modified form
of the device disclosed in U. S. Patent No. 4,034,708. An overall view of that device
is shown in Fig. 1. As seen there, a foil substrate 12 having a series of emblem design
shapes 82 decorated on its surface is positioned on vacuum table 14.
[0027] The coating operation utilizes a casting head (not shown in Figs. 1-2) in the form
of a multiple orifice nozzle or nozzles (see Figs. 3-4) for flow coating measured
amounts of a fluent plastic material, such as a fluent polyurethane, to the upper
surface of the substrate 12.
[0028] Preferred are approximately 100% solid polyurethane resin systems which are catalyzed
by mixing two components just prior to casting. In order to promote a rapid curing
of the fluent polyurethane system, an infrared radiation source means for supplying
infrared radiation may be provided to irradiate the polyurethane. Such a source is
included in member 20 which is shown extended in Fig. 1 in dashed lines.
[0029] In the arrangement illustrated in Figs. 1-2, the source of radiation is moved rather
than moving the substrate; although, the reverse situation can also be used. The extended
position of the member 20 is shown also in Fig. 2, along with lamps 23 which provide
the infrared radiation. Member 20 is moved by means of air cylinder 25. It should
be understood that an ultraviolet curable plastic may also be cast using the device
of the present invention; in such a case, lamps 23 would be ultraviolet radiation
sources.
[0030] While only very small amounts of volatiles will be given off by the plastic during
curing, an exhaust means including blower 29, exhaust duct 30, and associated motor
(not shown) are provided in order to insure that the operator of the machine does
not inhale fumes unnecessarily. As illustrated in Fig. 2, ambient air is drawn into
the cabinet 31 by fan 29. The air will be drawn over the top of the platen means 35.
The air will also be drawn past the lamps 23 preventing fumes from escaping upwardly
through member 20 and also cooling lamps 23.
[0031] It may be desirable to control the temperature of the substrate prior to and during
the casting and curing process. Under some circumstances, it may be desirable to maintain
the substrate at one temperature during casting and a portion of the curing process,
and then to maintain the substrate at a second temperature. Toward this end, water
inlets 36 and 37 and one or more outlets 38, are provided to receive and discharge
water supplied at more than one temperature.
[0032] It may also be desirable to irradiate the substrate prior to the casting process,
such that the substrates are heated and the viscosity of the cast plastic reduced
as it flows onto the substrates. This reduction in viscosity will cause the plastic
to flow more evenly over a larger foil substrate. Since it is desirable to be able
to change readily the sequence of steps and the order of these steps, a number of
timers and controls shown generally at 39 are provided. Vacuum pump 41 is also provided
to supply a vacuum platen 35 with a vacuum.
[0033] The use of a vacuum to hold substrate 12 flat and horizontal is better shown in Fig.
3. Thus, vacuum pump 41 draws a vacuum through holes 43 in platen 35. This serves
to hold vacuum mat 45 onto the platen since the holes in vacuum mat 45 are not aligned
with those in platen 35. The vacuum mat 45 may be a perforated one-fourth inch (6.35
mm) thick silicone rubber mat. Since it is perforated, the vacuum from platen 35 will
also be drawn through mat 45 against substrate 12.
[0034] Fig. 3 also shows in detail casting head 47 having two nozzles 49 and 50. Each nozzle
is fed a supply of fluent plastic such as a liquid polyurethane. Preferred is a mixture
of "A" and "B" components of the type disclosed in copending application Serial No.
702,194, filed July 2, 1976. Basically, that mixture is one of a polyether polyol
component ("A") which may be a difunctional, trifunctional and/or tetrafunctional
polypropylene glycol containing a suitable catalyst, and a diisocyanate component
("B") such as an aliphatic diisocyanate. A catalyst such as a lead material is used
since it promotes a slow cure at room temperature so as to allow time for full flow
of the liquid polyurethane before setting. As stated in application Serial No. 702,194,
which is specifically incorporated herein by reference, an example of the diisocyanate
is Hylene W from E. I. duPont de Nemours and Co., and the polyether polyol may be
one or more of the Pluracol materials (P-410 or TP-440) from BASF Wyandotte. It may
also be a polyether-polyester polyol combination, use of the polyester polyol making
the cured polyurethane more flexible. The ratio of components A:B is preferably 50-60:40-50.
A polyester polyol or polylactone polyol could be used in place of the polyether polyol.
[0035] The mixture of "A" and "B" components of this type cures, through catalytic action,
under heat such as produced by infrared radiation. Accordingly, this type of arrangement
will be disclosed as the preferred embodiment; although, single component, photocurable,
polyurethanes of known types could also be used.
[0036] Tanks (not shown) store the "A" and "B" material separately prior to mixing, then,
feeding to supply lines 51 and 52 for nozzles 49 and 50. Nozzles 49 and 50 are mounted
on carriage 54 which is slidably mounted on rods 57 and 58 for motion over the surface
of substrate 12 as indicated by the arrows in Fig. 4. Each nozzle has multiple orifices
in the form of tubes 61 and 62. Fittings 63 and 64 connect each of the multiple orifice
nozzles 49 and 50 to supply lines 51 and 52.
[0037] The number of tubes 61, 62 and the spacing between the tubes in an individual nozzle
will vary in dependence on the width of the portion of the substrate to be coated.
It has been found, however, that between 10 and 26 tubes, spaced apart approximately
1/8 to 1/10 inch (3.175 to 2.54 mm), may be used for each nozzle means in the present
embodiment. The tubes preferaby have .022 inch (.5588 mm) I.D. and a .039 inch (.9906
mm) O.D. Spacer bars 71 and 72 hold the tubes 61 and 62 spaced apart at desired distances,
preferably 0.10 inch (2.54 mm) For application of a uniform thickness coating across
each of the two zones of approximately 2.4 - 2.5 inches (60.96 - 63. 5 mm) in width
each, 22 tubes are used in each nozzle 49 and 50. The 22 tubes have a combined width
of approximately 2.1 inches (53.34 mm)
[0038] The operation of casting head 47 is better understood with reference to rig. 4. Pneumatic
or hydraulic controls (not shown) drive casting head along the length of stationary
substrate 12 as indicated by the arrows. A return movement, also as indicated, takes
place after completion of flow coating onto one decorative substrate and the casting
head is in position to repeat the process for another decorative substrate. As the
casting head 47 begins its initial track over substrate 12, starting at approximately
0.15 to 0.20 inch (3. 81 to 5.08 mm) from the edge 75, the liquid polyurethane flows
from tubes 61, 62 at a uniform flow rate. Since the movement of casting head 47 over
stationary substrate 12 is at a steady speed, there is laid down a uniformly distributed
amount of liquid polyurethane.
[0039] That fluent plastic then flows to complete the coverage of the portion of the surface
desired. A uniform thickness of plastic results. The speed of casting head movement
and coating rate for the plastic depend upon the area to be covered, the number of
tubes used, the viscosity of the fluent plastic, etc. Generally, however, it is possible
to easily adjust these variables in order to achieve a coating of the thickness desired.
The desired thickness is 0.020 to 0.030 inch (.508 to .762 mm).
[0040] As mentioned, an important feature in obtaining a uniform coating in this thickness
is that the fluent plastic on the surface of substrate 12 flows up to, but not beyond,
the sharply defined peripheral sides which intersect with the planar top surface.
[0041] Thus, the wettability characteristics of the fluent plastic are such that it only
partially wets the surface of substrate 12 and will flow on the surface of the substrate.
Under heating, the viscosity of the polyurethane becomes lower and flow slows. Upon
reaching a sharply defined peripheral side, this flow will be halted. If the edge
is verticle, the flowing liquid plastic wants to maintain a given contact angle at
that edge (specified by the interface properties of the plastic and the foil). As
long as the internal pressure (hydrostatic) of the plastic does not exceed the surface
tension at that contact angle, the liquid plastic will not overflow the side.
[0042] Accordingly, it is necessary to form sharply defined peripheral sides intersecting
with the top planar surface around each area to be coated. In Fig. 4, there are two
paths which are to be uniformly coated, one beneath nozzle 49 and one beneath nozzle
50. The line between these paths is slit 77 which forms sharp peripheral sides 79
and 80. The ordinary four edges of substrate 12, then, complete the formation of the
two paths. Of course, other arrangements may be used to form the sharply defined peripheral
sides, such as by embossing ridges in the sheet.
[0043] It is also possible to coat the whole surface of substrate 12 since its four edges
are sharply verticle. However, it may be advantageous in terms of eliminating excess
scrap and waste to form paths in the manner mentioned. Those paths, then, will be
over only those areas of the substrate from which emblems or plaques are to be formed.
[0044] In Figs. 4-5, those emblems are represented by emblem design shapes 82. It is desirable
to prime the substrate with a silane before printing. As an example, a mixture of
approximately 2% castor oil (Surfactol from The Baker Castor Oil Co.) and up to approximately
2% silane (Dow 6020, 6040, or 6075 from Dow Corning Corp., which are respectively,
3-(2-amino- ethylamine) propyltrimethoxysilane, glycidoxypropyltrimethoxysilane, and
vinyltriacetooxysilane) in a solvent (70% isopropyl alcohol and 30% octane) may be
used. Other known silane primers may also be used. The primers may be pre-applied
by spraying, dipping, or roller-coating, followed by drying to remove the solvent.
[0045] Next, the design shapes are decorated onto substrate 12. With a metal foil, silk-screen
printing and embossing are the usual methods. Thus, an aluminium foil from 0.003 to
0.020 inch (0.0762 to 0.508 mm) thick may be silk-screen printed and embossed in selected
areas to provide a series of emblem design shapes as at 82.
[0046] The fluent plastic is then flow coated onto the substrate 12 as described. Next,
the substrate is heated with infrared lamps 23, also as described, in order to cure
the plastic.
[0047] A feature of the present invention is the use of vacuum mat 45 to aid in that curing
process. That is, by using an infrared absorptive mat, such as a one-fourth inch (6.35
mm) thick silicone rubber mat, heat is absorbed by the mat and re-radiated back through
substrate 12 to give a through cure.
[0048] Once the curing is accomplished and the coated substrate cooled, plastic layer 84
is adhered to substrate 12 sufficiently to permit further processing. In the case
of panel production, that may involve only minor amounts of trimming, cutting and
forming. With emblem production as shown, a die is used to cut around each emblem
design shape 82 to form individual emblems. By die cutting from the bottom (uncoatcd)
side 86 of substrate 12, a slight convex shape is given to each emblem.
[0049] The emblems may then be adhesively applied into or onto the intended surface. They
may also be placed in a retaining frame which is used to affix the emblem onto the
surface. Finally, it is noted that since the fluent plastic may be compounded as described
to give a somewhat flexible material when cured, forming other than merely die cutting
may be undertaken. The emblem, and more often panels, may be conformed to non-planar
surfaces as long as the degree bending for the conformity required is not too severe.
[0050] While the preferred embodiment just discussed utilizes a two-nozzle casting head
as shown in Pigs. 3-4 which makes a single pass over substrate 12, it should be emphasized
that a single multiple orifice nozzle may be used for a narrower application path
or additional nozzles may be added to casting head 47 to give a wider application
path. Likewise, the number of tubes used with each nozzle may be varied to vary the
width of the application path.
[0051] Another embodiment involves use of a single nozzle of the type shown for coverage
of a substrate of varying widths. It is mounted on a carriage of the same width which
only tracks back and forth longitudinally over the length of substrate 12. Also, the
nozzle is movable laterally on the carriage. After each pass and on the return route,
the nozzle moves laterally one nozzle width (plus approximately 0.15 - 0.20 inch (3.81
- 5.08 mm). Another pass begins. This is repeated until the full expanse of the substrate
has been coated. In each dase, a timing mechanism is necessary to start and stop flow
of the liquid plastic during a single pass. A delay timer is provided to permit the
lateral movement of the nozzle after the plastic flow has stopped and prior to the
start of plastic flow after the lateral movement of the nozzle is completed.
EXAMPLE
[0052] In this example, a single nozzle having 22 tubes as described was used to flow coat
a substrate of approximately 2.5 inch x 24 inch (6.35 x 609.6 mm) in a single pass.
The substrate was 0.015 inch (0.381 mm) thick aluminium foil which had been cleaned,
primed, silk-screen printed and embossed with a series of circular emblem designs
approximately 1 1/8 inch (28.575 mm) in diameter.
[0053] The 22 tube nozzle had a width of approximately 2.1 inches (53. 34 mm) and was centered
over the 2.5 inches (63.5 mm) wide substrate to leave margins of approximately 0.20
inch (5.08 mm) Starting 0.20 inch (5.08 mm) from one end of the foil, it was passed
over the surface of the aluminium foil, which was held flat and horizontal on a vacuum
mat as described. A steady speed of 3.2 inches (81.28 mm) per second was used. Clear
liquid polyurethane was flowed from the nozzle at the uniform rate of 210 grams per
minute.
[0054] The liquid polyurethane was a mixture of "A" and "B" components and had a density
of 17.39 grams/cubic inch (441.706 grams per cubic millimetre). The "A" component
was itself a mixture of polyester polyol and polyether polyol and contained a lead
octoate catalyst. The "B" component was a mixture of polypropylene glycol and an aliphatic
diisocyanate. The ratio of "A" to "B" was 54. 5% to 45.5%.
[0055] It took the nozzle 7.43 seconds to transverse the 24 inch (60.96 mm) length of the
aluminium foil (stopping 0.20 inch (5.08 mm) from the end). In the process, 26 grams
of liquid polyurethane were deposited onto the foil at a uniform thickness of 0.025
inch ± .005 inch (0.635 mm ± 0.127 mm).
[0056] After flow coating, the coated foil was heated under four 1600 watt infrared lamps
at a distance of 12 inch (304.8 mm) for 10 minutes. This was followed by cooling the
vacuum table with 60°F (15.55°C) water for 2 minutes. After cooling, representative
ones of the emblem shapes were die cut from the foil by applying a die to the bottom
(uncoated) surface of the foil.
[0057] The emblems had a slightly convex shape when viewed from the front surface, and were
lustrous in appearance. The cured plastic was bound firmly to the decorative substrate
and provides a tough, resistant protective coating in addition to beautifying the
design.
[0058] While the method herein described constitutes a preferred embodiment of the invention,
it is to be understood that the invention is not limited to this precise method, and
that changes may be made therein without departing from the scope of the invention.
1. A method for producing decorative emblems, plaques and panels, comprising:
(a) providing a substrate (12) having a top surface and a bottom surface and a decorative
design or series of designs (82) applied to its top surface,
said substrate having sharply defined peripheral sides which intersect with said top
surface,
(b) holding said substrate flat and horizontal on a supported surface free from surrounding
side walls,
(c) flow coating a clear viscous fluent plastic onto said top surface of said substrate
from multiple orifices (62) so that said fluent plastic flows to said sharply defined
peripheral sides without flowing over said sharply defined peripheral sides, and forms
a uniform coating approximately .020 to .030 inch (.508 to .762 mm) thick,
(d) allowing said fluent plastic to cure while maintaining said substrate flat and
horizontal, and
(c) trimming, cutting and forming said substrate having said cured plastic (84) thereon
to produce the desired emblem, plaque or panel configuration.
2. The method of claim 1 wherein said substrate (12) is approximately 0.003 to 0.020
inch (0.0762 to .508 mm) thick metal foil.
3. The method of claim 2 wherein said metal foil is primed prior to being decorated
and coated with said fluent plastic.
4. The method of claim 3 wherein said fluent plastic is cured by heating under infrared
lamps (23).
5. The method of claim 4 wherein said substrate is held flat and horizontal on a vacuum
mat (45) which also serves as a heat sink during the heat curing of said fluent plastic.
6. The method of claim 3 wherein said metal foil substrate is silk-screen printed and
embossed to form a series of designs thereon.
7. The method of claim 6 wherein a number of individual emblems or plaques are formed
from said coated substrate by stamping out said emblem or plaque contiguous with each
individual design of said series of designs.
3. The method of claim 7 wherein said emblem or plaque is stamped out by application
of a cutting die to said bottom surface of said substrate so that each emblem or plaque
has a convex shape when viewed from said top surface.
9. The method of claim 1 wherein several sets of nozzles (49, 50) each having multiple
orifices (61, 62) are passed in a single pass at a steady speed over the top surface
of said substrate (12) while said substrate is held stationary.
10. The method of claim 1 wherein a single nozzle having multiple orifices is passed
at a steady speed back and forth in several passes over the top surface of said substrate
while said substrate is held stationary.
11. A method for producing a number of decorative emblems from a single sheet of aluminium
foil, comprising:
(a) providing an approximately 0.003 to 0.020 inch (0.0762 to .508 mm) inch thick
aluminium foil (12) having a top surface and a bottom surface,
(b) applying a primer to said top surface of said aluminium foil prior to screen printing,
(c) silk-screen printing and embossing said face to form a series of individual decorative
emblem shapes (82) thereon, said foil having sharply defined peripheral sides which
intersect with said top surface,
(d) allowing the decorations to set prior to placing the bottom side of said aluminium
foil on top of a vacuum mat (45) on a horizontal vacuum table (35),
(e) applying a vacuum draw to said bottom surface of said aluminium foil through a
vacuum mat (45) to hold said aluminium foil flat and horizontal,
(f) flow coating a clear viscous polyurethane in liquid form onto said top surface
of said aluminium foil by passing multiple orifices (61, 62) over said top surface
at a steady speed as said aluminium foil is held stationary and constantly ejecting
liquid polyurethane from each of said orifices during the passage so that said liquid
polyurethane flows to said sharply defined peripheral sides without flowing over said
sharply defined peripheral sides and forms a uniform coating of approximately .020
to .030 inch (.508 to .762 mm) thick,
(g) heating the coated aluminium foil under infrad- red lamps (23) while said aluminium
foil is maintained flat and horizontal to cure said liquid polyurethane,
(h) cooling and removing the coated aluminium foil from said vacuum mat, and
(i) stamping individual emblems from said aluminium foil by application of a cutting
die contiguous with each of said emblem shapes to the bottom surface of said aluminium
foil.