Method for preparing a selectively decorated resin film

• US 4,720,315 A
• Filed: 09/05/1986
• Issued: 01/19/1988
• Est. Priority Date: 02/03/1984
• Status: Expired due to Fees

• Current Assignee: Illinois Tool Works Inc.
• Original Assignee: Transfer Print Foils
• Inventors: Greenman, Joseph
• Primary Examiner(s): Czaja, Donald E.
• Assistant Examiner(s): FALASCO, LOUIS V
• Application Number:
  US06/904,780
• Time in Patent Office: 501 Days
• Field of Search: 156/152, 156/230, 156/233, 156/234, 156/241, 156/240, 156/238, 156/239, 156/246, 156/249, 156/254, 156/250, 427/259, 427/272, 427/273
• US Class Current: 156/233
• CPC Class Codes: B44C 1/04 Producing precipitations producing precipitations by electrolysis C25D
• CPC Class Codes: B44C 1/10 Applying flat materials, e.g. leaflets, pieces of fabrics paperhanging B44C7/00
• CPC Class Codes: B44C 1/14 Metallic leaves or foils, e.g. gold leaf
• CPC Class Codes: B44C 3/046 using a modelling surface, e.g. plate
• CPC Class Codes: C23C 14/042 using masks
• CPC Class Codes: H05K 3/046 by selective transfer or selective detachment of a conductive layer
• CPC Class Codes: Y10T 156/1059 Splitting sheet lamina in plane intermediate of faces

Abstract

A method for the preparation of selectively decorated resin films comprises applying a first primer coat to the entire area of the base film, then applying either a masking coat alone or one or more color coats followed by the masking coat, the masking coat applied to an area of the base film that will define the final selective decoration. The masking coated surface is thereafter metalized and the resulting composite is joined to a mask-removing film bearing a pressure-sensitive adhesive having a limited peel strength known as "soft peel". The process is completed by the separation of the respective films, with the mask removing film withdrawing from the base film the unwanted portions of the metal coat and its underlying masking coat, to leave a crisp, patterned decoration.

The present process requires no solvents and is therefore environmentally preferred. In addition, the method may be easily and inexpensively practiced on a continuous basis and offers the reliable production of aesthetically superior decorations.

Claims

1. A method for the preparation of a directly decorated resin film having a selective decoration consisting essentially of:

A. providing and feeding a printable resin base film to serve as the base of said decorated resin film;

B. applying a primer coat over an entire broad surface of said base film;

C. applying over a portion of said primer coat a masking coat abhesive thereto, said masking coat applied in a predetermined pattern defining the outer border of said selective decoration;

D. applying a metal coat over the entire surface of the coated base film of Step C to completely cover said primer coat and said masking coat and to make direct interfacial contact therewith;

E. bonding the coated base film of Step D to a mask-removing resin film bearing a pressure-sensitive adhesive coat, with said adhesive coat positioned for contact with said metal coat; and

F. separating the coated base film of Step E from said mask removing film;

whereby the masking coat and the portions of the metal coat disposed thereover are removed from said base film and adhesively bound to said mask removing film, and

whereby said directly decorated resin film consists essentially of said base film bearing said selective decoration comprising said primer coat disposed against said base film and said metal coat disposed against said primer coat.

2. The method of claim 1 wherein subsequent to applying the primer coat of Step B, at least one color coat is applied to at least a part of said primer coat.

3. The method of claim 2 wherein said color coat is applied to the entire surface of said primer coat.

4. The method of claim 3 wherein said color coat is included within said primer coat.

5. The method of claim 2 wherein said color coat is applied to said primer coat in a predetermined pattern.

6. The method of claim 5 wherein said predetermined pattern has a surface area equal to and comprising the surface area of said primer coat to be left uncoated by said masking coat.

7. The method of claim 5 wherein said predetermined pattern has a surface area less than the surface area of said primer coat to be left uncoated by said masking coat.

8. The method of claim 5 wherein plural color coats are applied to said primer coat in mutually exclusive predetermined patterns.

9. The method of claim 8 wherein said predetermined patterns define a total surface area less than that of said primer coat to remain uncoated by said masking coat.

10. The method of claim 2 wherein said selective decoration comprises said primer coat disposed adjacent said base film, said color coat disposed over said primer coat, and said metalized coat disposed over said color coat.

11. The method of claim 1 wherein said masking coat is applied to said primer coat by a screen printing technique.

12. The method of claim 1 wherein said base film and said mask-removing film are laminated under pressure, by passage through pressure rollers.

13. The method of claim 8 wherein said plural color coats are applied consecutively.

14. The method of claim 8 wherein said plural color coats are applied simultaneously by multi-color gravure coating.