Image-bearing composite element and method of making same

• US 6,939,827 B2
• Filed: 05/01/2002
• Issued: 09/06/2005
• Est. Priority Date: 05/01/2002
• Status: Expired due to Fees

• Current Assignee: Saeed Shariat
• Original Assignee: Saeed Shariat
• Inventors: Shariat, Saeed
• Primary Examiner(s): Hess, Bruce H.
• Application Number:
  US10/137,610
• Publication Number:
  US 20030207763A1
• Time in Patent Office: 1,224 Days
• Field of Search: 847/1, 428/480, 503/227
• US Class Current: 503/227
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B41M 5/38214 Structural details, e.g. multilayer systems composition of individual layers B41M5/42
• CPC Class Codes: B41M 7/0072 using mechanical wave energy, e.g. ultrasonics; using magnetic or electric fields, e.g. electric discharge, plasma
• CPC Class Codes: Y10T 428/31786 Of polyester [e.g., alkyd, etc.]

Abstract

A composite article includes a plurality of plies of composite material arranged atop one another in a stack and bonded together with a resin material, in which the stack includes a layer disposed on at least one outer surface of the stack, the layer bearing an image applied, prior to curing of the composite article, by a sublimation printing process. The layer preferably comprises a polyester material. The image preferably comprises a logo, identification information or any other representation of information or image depiction desired. The application of the image to the layer via sublimation printing results in the image having no height above said sheet. A process for fabricating the composite material article of the present invention includes a first step of forming a stack of plies made from “conventional” composite materials and a “conventional” resin material, a second step of disposing a layer of non-composite material over at least one surface of the stack of plies and incorporating the layer into the stack using the “conventional” resin material, the layer having an image formed on a surface thereof using sublimation printing facing away from said stack, and a third step of curing said stack.

Claims

1. A composite article, comprising:

a plurality of plies of composite material arranged atop one another in a stack and bonded together with a resin material,

said stack including a layer disposed on at least one outer surface of said stack, said layer bearing an image, said image having been applied by a sublimation printing process prior to curing of the resin material in said stack of layers.

2. The composite article of claim 1, wherein said layer comprises a polyester material.

3. The composite article of claim 1, wherein each of said plies exhibit unique mechanical properties.

4. The composite article of claim 1, wherein said image comprises a logo.

5. The composite article of claim 1, wherein said image comprises alphanumeric information.

6. The composite article of claim 1, wherein said stack forms an article comprising sporting equipment.

7. The composite article of claim 1, wherein said stack comprises a sheet and said image covers the entire outer surface of said sheet.

8. The composite article of claim 7, wherein said sheet is non-planar.

9. A process for fabricating an article of composite material, comprising:

a first step of forming a stack of plies made from composite materials and an uncured resin material, a second step of disposing a layer of non-composite material over at least one surface of said stack of plies and incorporating said layer into said stack using said uncured resin material, said layer having an image previously applied to a surface thereof using sublimation printing, said image facing away from said stack, and a third step of curing the resin in said stack.

10. The process of claim 9, and further including the step of disposing a sealing material about said stack and said layer prior to curing of the resin in said stack.

11. The process of claim 9, wherein said layer comprises a polyester material and said image consitutes a graphic.

12. The process of claim 9, wherein said layer comprises a polyester material and said image constitutes alphanumeric information.

13. An uncured composite assemblage which when cured forms a composite element, said composite assemblage comprising:

a plurality of plies of composite material arranged atop one another and an uncured curable resin material surrounding and infiltrating said plies, said plies and resin material forming a stack, and

a fabric layer disposed on at least one outer surface of said stack, said layer bearing an image formed by sublimation printing, said curable resin also surrounding and infiltrating said layer.

14. The composite article of claim 13, wherein said layer comprises a polyester material.

15. The composite article of claim 13, wherein each of said plies exhibit unique mechanical properties.

16. The composite article of claim 13, wherein said image comprises a logo.

17. The composite article of claim 13, wherein said image comprises alphanumeric information.

18. The composite article of claim 13, wherein said stack is shaped as an article of sporting equipment.

19. The composite article of claim 13, wherein said outer sheet comprises a woven polyester material.