SYSTEM FOR FORMING LEAF LAMINATES

• US 20070295448A1
• Filed: 06/22/2007
• Published: 12/27/2007
• Est. Priority Date: 06/23/2006
• Status: Abandoned Application

• Current Assignee: Ishwar R. Mansukhani
• Original Assignee: Ishwar R. Mansukhani
• Inventors: Mansukhani, Ishwar R.
• Application Number:
  US11/767,285
• Publication Number:
  US 20070295448A1
• Time in Patent Office: Days
• US Class Current: 156/277
• CPC Class Codes: B44C 1/1712 Decalcomanias applied under heat and pressure, e.g. provided with a heat activable adhesive

Abstract

A method of forming a laminate including a very thin leaf layer. In a first step an image corresponding to a desired pattern is printed in a conventional manner on said substrate using an ink having adhesive properties. The substrate and image are then covered with a very thin, frangible leaf material such a very thin metal foil. The leaf material is then laminated onto said image by applying pressure to said leaf, image and substrate. Mechanical agitation is then used to remove excess leaf outside the boundaries of the image by flaking off the excess leaf from the substrate.

Claims

1. A method of forming a laminate including a leaf characterized by a pattern on a substrate, comprising the steps of:

a) printing an image corresponding to said pattern on said substrate using an ink having adhesive properties;

b) covering said substrate including said image with a thin frangible leaf;

c) laminating said leaf onto said image by applying pressure to said leaf, image and substrate; and

d) mechanically agitating said leaf in order to remove excess leaf outside the boundaries of the image by flaking the excess leaf off the substrate.

2. The method of claim 1, further including the steps of:

drying said image until said ink is substantially cured, and wherein;

said step of laminating also includes applying heat to said leaf and printed image.

3. The method of claim 1, further including the step of:

allowing said image to dry until said ink is partially cured but still retains substantial tackiness.

4. The method of claim 1, wherein:

said planar substrate comprises paper.

5. The method of claim 1, wherein:

said frangible leaf comprises a silver leaf of about 0.4 cm thickness.

6. The method of claim 5, wherein:

said ink includes resinous components providing adhesive properties.

7. The method of claim 1, wherein:

said frangible leaf comprises a aluminum leaf.

8. The method of claim 1, wherein:

said step of agitating includes using brushes to provide mechanical abrasion to said leaf.

9. The method of claim 7, wherein:

said step of agitating includes using compressed air to provide mechanical abrasion to said leaf.

10. The method of claim 1, wherein:

said step of printing is performed using an ink-jet printer.

11. The method of claim 1, wherein:

said step of printing is performed using a letterpress printer.

12. The method of claim 1, wherein:

said step of printing is performed using a planographic printer.

13. The method of claim 1, wherein:

said step of printing is performed using flexographic printer.

14. The method of claim 1, wherein:

said step of printing is performed using a silk-screen printing process.

15. A method of forming a laminate having a thin metal leaf layer in order to fabricate an electrical circuit or decorative element on the surface of the laminate, comprising the steps of:

a) printing a pattern for said circuit on a planar substrate using an ink having adhesive properties;

b) covering said substrate including said pattern with a thin frangible metal leaf;

c) laminating said metal leaf onto said pattern by applying pressure to said leaf, pattern and substrate; and

d) flaking the metal leaf off of said substrate outside of the boundaries of said pattern.

16. The method of claim 15, further including:

drying said pattern until said ink is substantially cured, and wherein;

said step of laminating also includes applying heat to said leaf and printed pattern.

17. The method of claim 15, wherein:

said planar substrate comprises paper.

18. The method of claim 15, wherein:

said planar substrate comprises a food item.

19. The method of claim 15, wherein:

said frangible leaf comprises a silver leaf.

20. The method of claim 15, wherein:

said frangible leaf comprises a copper leaf.

21. The method of claim 15, wherein:

said frangible leaf comprises aluminum leaf.

22. The method of claim 15, wherein:

said step of flaking includes using mechanical abrasion to remove said leaf outside the boundaries of said image.

23. The method of claim 22, wherein:

said step of flaking includes using a brush to provide said mechanical abrasion.

24. The method of claim 15, wherein:

said step of printing is performed using an ink-jet printer.

25. The method of claim 15, wherein:

said ink includes resinous materials providing adhesive properties.