Decorative plaques and process

• US 4,125,655 A
• Filed: 02/22/1977
• Issued: 11/14/1978
• Est. Priority Date: 05/21/1975
• Status: Expired due to Term

• Current Assignee: Contemporary, Inc.
• Original Assignee: Contemporary, Inc.
• Inventors: Kanzelberger, James C.
• Primary Examiner(s): Dixon, Jr., William R.
• Application Number:
  US05/770,797
• Time in Patent Office: 630 Days
• Field of Search: 428/13, 428/14, 428/67, 428/172, 428/173, 428/199, 428/207, 156/219, 156/220, 156/230, 156/233, 156/235, 156/250, 156/251, 156/267, 156/268, 427/147, 427/148, 427/256, 427/270, 427/271, 427/275, 101/32, 40/135, 40/136, 40/160
• US Class Current: 428/67
• CPC Class Codes: B32B 2451/00 Decorative or ornamental articles wall paper B32B2607/02
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/304 comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/36 comprising polyesters
• CPC Class Codes: B32B 38/06 Embossing
• CPC Class Codes: B32B 38/14 Printing or colouring
• CPC Class Codes: B44C 1/1729 Hot stamping techniques
• CPC Class Codes: B44C 3/082 comprising a cutting out operation
• CPC Class Codes: B44C 5/0446 bearing graphical information
• CPC Class Codes: Y10T 156/1041 Subsequent to lamination
• CPC Class Codes: Y10T 156/1052 with cutting, punching, tearing or severing
• CPC Class Codes: Y10T 156/108 Flash, trim or excess removal
• CPC Class Codes: Y10T 428/22 Nonparticulate element embedded or inlaid in substrate and visible
• CPC Class Codes: Y10T 428/2462 with partial filling of valleys on outer surface
• CPC Class Codes: Y10T 428/24901 including coloring matter

Abstract

Low cost decorative award plaques are provided which use a plastic laminate article capable of being hot stamped with desired lettering or designs. The plaque is made by a process of repeatedly imprinting with different colors and surface effects. The process includes forming and cutting the plastic on a rigid backing, especially one simulating a fine, hardwood panel.

Claims

1. An article adapted to be imprinted by a hot-stamping process, said article being suitable for forming a wall plaque, comprising:

(a) a rigid board-like background support material having upper and lower surfaces, at least one of which surfaces has a discrete decorative appearance;

(b) a plastic laminated plate smaller than, and adhered to, the decorative surface of the support material, said laminate comprising a first relatively thick sheet of plastic material having heat deformable characteristics such that the material debosses under localized heat and pressure, and a second relatively thin sheet of a decorative plastic film coextensive therewith which conforms to said debossments when said first sheet is debossed; and

(c) a hot stamping foil positioned over said decorative film, said hot-stamping foil containing on the surface adjacent the plastic laminate coloring matter which transfers and adheres to said decorative plastic film in said debossments when said film is debossed under localized heat and pressure.

2. The article of claim 1 wherein more than one hot-stamping foil is provided, said foils having contrasting coloring matter thereon.

3. The article of claim 1 wherein the heat deformable material is rigid polyvinyl chloride which debosses under heat and pressure and the decorative film is a polyester film which does not respond to the heat and pressure required to form said debossment.

4. A decorative plaque adapted to be imprinted by a hot-stamping process comprising;

(a) a plaque blank of hard board-like material of predetermined area having at least one decorative surface with a desired size, shape and finish;

(b) a laminate of a plastic film and a plastic plate, said plate adhered to said decorative surface of said board-like material, said plate having a heat deformable characteristic such that the plastic material of the plate debosses under localized heat and pressure and said overlying plastic film having a characteristic such that it contains the plastic of the plate during deformation and conforms to said debossments;

(c) and a hot-stamping foil removably covering said laminate for forming a desired colored design on said laminate by applying heat and pressure to deboss said plastic material, said foil having coloring matter on the side thereof adjacent the plastic laminate which coloring matter is transferred to said debossments under said heat and pressure; and

(d) said plastic laminate having been trimmed to a final shape having an area smaller than said predetermined area to expose at least some of said decorative surface around the periphery of said trimmed plastic laminate.

5. The plaque of claim 4 wherein said one decorative surface of said hard board-like material of said plaque blank is a laminated plastic layer, and the edges of said plaque blank are covered by a finish coating.

6. The plaque of claim 5 wherein said plastic sheet has been die cut with a straight vertical edge on the selvage side of the trimming cut, and the non-selvage edge of said plastic sheet is rolled and inserted into a groove slit into said decorative plastic layer of said plaque blank.

7. The plaque of claim 6 wherein said plastic plate comprises a thermoplastic material with a polyester film laminated thereto, said film being inserted into said slit during said trimming step.

8. The plaque of claim 4 wherein said formed plastic laminate includes at least one patch of contrasting color on the surface of said plastic film and debossed and colored lines on the surface of said plastic film.

9. The plaque of claim 8 wherein said debossed lines are formed in contrasting color and at least partially overlaps said patches of contrasting color.

10. The plaque of claim 9 wherein said hard board surface finish has a wood grain vinyl plastic coating, the edges of said plaque blank having a finish coating, said plastic plate comprises a thermoplastic sheet of material having a covering decorative film, the thermoplastic sheet being cut with a straight edge on the selvage side of the cut and a rolling cut on the edge of the thermoplastic sheet on the plaque side of the cut, said rolling cut being inserted into a slit in the vinyl plastic coating film of the board.

11. The plaque of claim 4 wherein said plastic plate comprises a thermoplastic material with a polyester film laminated thereto.

12. A product made by the process of:

(a) forming a rigid background of substantial thickness, and a predetermined area;

(b) forming on one surface of said board a finish having decorative qualities;

(c) forming a laminate of a decorative plastic film covering a plastic plate, said laminate having an area which is smaller than said background board, said plastic plate having a heat deformable characteristic such that said plastic of said plate debosses under a predetermined localized heat and pressure, said plastic film laminated to said plate and being capable of conforming to the contours of said debossment while containing the flow of said plastic plate without said plastic film being damaged by said predetermined heat and pressure;

(d) adhering said laminated plastic plate to said one surface, whereby the background finish is displayed to view in those areas which are not covered by said plate;

(e) positioning over the laminated film on said plate an overlying, but separate, carrier film with a layer of coloring matter thereon and facing said laminated film, said covering matter being capable of transferring simultaneously with debossment to said decorative plastic film under said predetermined heat and pressure;

(f) hot-stamping said plate with a heated die to simultaneously (1) deboss the plastic of the plate and cause the plastic film to form itself into the contours of the debossed plastic plate, and (2) transfer said coloring matter from said carrier film onto said laminated film in the debossed portions of the plate; and

(g) removing the carrier film.