GB2306404A - Visual display and patterned foil products - Google Patents

Abstract

The visual display product 10, which may be internally-illuminated, comprises transparent or translucent sheets 16,18 which carry visually related images 24 which interact to produce a three-dimensional effect eg a ball. The sheets are slotted 22 so as to interlock in the form of a cubic structure. Patterned holographic foils are applied to textiles or tiles by utilising the foil laminate as the substrate. Textiles are patterned by adhesively-bonding a holographic foil to a fabric having sheer or transparent (burnt-out) patterned regions so that the foil is visible therethrough. Floor or wall tiles are patterned by bonding the foil to the tile using a laminating sheet.

Description

MAKING FOIL AND OTHER VISUAL DISPLAY PRODUCTS This invention relates to a method of making foil and other visual display products, for example patterned foiled products in which a pattern or design of foil comprises areas of foil-effect on a substrate.

A more specific but non-limiting example of a product to which the invention relates is a woven textile product having foil-effect patterns thereon. The invention also provides laminated products in which the patterned foil-effect forms part of a decorative pattern in, for example, a floor tiling product. A particular but non-limiting example of the metallic foil to which the invention relates is that which is known ad available as holographic foil, available

under thettrade mark Holofoil from Astor Universal of Salford, England.

Holographic foil is an extremely attractive form of foil from the visual point of view, though the invention is applicable also to other types of foil.

It has the capability of producing extremely eyecatching rainbow and other effects which would be extremely useful in the textile industry, and particularly the garment industry, if these effects could be satisfactorily applied to a garment surface as a decoration, or indeed to a portion of a garment such as a tie or belt.

However, holographic foil is available as a laminar construction comprising an outer polyester carrier followed by a release coat, a colour/lacquer coat, the aluminium coat or foil itself and a final coat of size or adhesive. Such a unified laminar product does not lend itself readily to application in the form of patterns to a fabric surface in accordance with techniques which have been used in the past in relation to other or similar foil materials.

Moreover, the manufacturer's disclosed technique for the application of this foil to other surfaces states that the only way to add this product to paper, board or hard plastics and other surfaces is often by hot stamping. This involves the use of heated metal die or cliche which allows the metallic foil layer to become detached from the polyester film and to be transferred to the relevant surface. The manufacturers state that the surface to which the foil is to be transferred should be as smooth as possible and heavy grain and like surface finishes are to be avoided at all costs. This is understood to be due to the construction of the foil as an iridescent diffraction foil including microscopic grooves at intervals corresponding to approximately 1500 grooves or lines per inch.This structure in the foil is produced by dies which emboss a polyester film 0.0002 inches thick and which has a reflective metallic coating of thickness less than one millionth of an inch.

Accordingly, it is clear that the manufacturer's recommended hot stamping technique is inapplicable in the case of applying the foil to the relatively rough and irregular surface of a textile fabric, even before one has considered the practical implications of the application of the hot die almost directly to a fabric surface. Therefore, some alternative approach is clearly required.

An object of the present invention is to provide a method of making a patterned foil product offering improvements in relation to one or more of the matters mentioned above, or generally.

Accordingly to the invention there is provided a method of making a patterned foil product as defined in the accompanying claims.

In an embodiment described below the substrate sheet which is to carry the foil in the foil product is provided as the foil sheet itself and the patternapplying step comprises applying to the substrate sheet a pattern or design of foil-exposing and foilobscuring areas to enable the foil to be observed in the foil exposing areas.

In this way, what is achieved is that the need for hot stamping of the foil is avoided. The process of the conventional system for foil transfer or printing is reversed and the foil itself, for example in laminate form, serves as the substrate to which the pattern is applied. Accordingly, the need for a smooth and even and ungrained surface for foil transfer is avoided. The fabric or textile is adhered to the foil. In those areas where the foil effect is not required, the fabric or textile serves to cover or obscure the foil and in those areas where the foil is required to be seen as part of the intended pattern, the fabric or textile is provided in sheer or semisheer form, for example by the use in those areas of the sheer portion of a devour fabric.

Thus, it can now be seen that by the use of the method of the invention there can be achieved the production of a patterned foiled product, using a foil such as holographic foil, which does not require the use of the conventional hot stamping technique, and thus is not limited in its application to textile surfaces by the physical requirements of that process, and yet which enables the production of sophisticated patterns in a straightforward manner.

Thus, for example, in an embodiment, a devote fabric printed with a desired pattern comprising sheer or semi-sheer areas and plain fabric areas is adhered to a substrate of holographic foil to produce a laminar assembly in which the device pattern is enhanced in its sheer areas by the holographic foil and the foil effect is rendered more subtle by the moderating effect of the sheer or semi-sheer portions of the fabric which cover the foil in those areas. To put it another way, the invention enables the production of foil-effect fabrics and textiles by the use of a radical simplification of the production process in which the foil is mounted on the reverse side of the textile or fabric as compared with conventional techniques, and moreover the foil effect has the added subtlety of use in combination with a sheer or semi sheer fabric.

A significant feature of the method as applied to textile fabrics is the application of colour to the reverse or inside face of the textile which will be applied to the substrate or foil. This has two effects. Firstly, it enables (by choice of appropriate colour) the sheer or semi-sheer portions of the textile to be coloured in a colour complementary to that of the foil itself so that the sheer or semi-sheer fabric cannot be seen as such when assembled with the foil. Secondly, the colour applied to these areas can be so chosen as to co-operate with the colour of the foil to influence it, at least slightly, in a desired manner. Because the colour is applied to the reverse side of the fabric, its visible effect is only upon the sheer or semi-sheer areas.

In the embodiments of the invention utilising a printing technique, the substrate remains the laminar foil construction and the pattern applying step comprises printing on the substrate the pattern or design of foil-exposing and foil-covering or obscuring areas so that the foil can be observed in the foil exposing areas.

In this embodiment also the scope for variation in the printing step enables that step to simulate closely the steps in the above-described fabric or textile embodiment. Accordingly, the printing technique used produces areas corresponding not only to the full fabric or textile presence (in which the foil itself is completely obscured, but also areas corresponding to the sheer or semi-sheer regions of the devote fabric, in which the printing simulates that sheer effect and cooperates with the holographic foil in producing a subtle modification of the foil effect in which the metallic and rainbow and other effects of the foil are moderated to a degree corresponding to the requirements of the usage in question. Of course, the printing technique enables any desired pattern to be produced with completed ease and versatility.

In the case of this embodiment, the printed foil substrate is well adapted to be subsequently subjected to a laminating process employing protective transparent polymeric sheets. These can be applied so as to build up a relatively thick laminar assembly in which the patterned foil substrate provides its visually and optically attractive facets in the format of a tile suitable for decorative floor and wall tiling purposes.

In such usage, the tiles have the same ability to produce moderated rainbow and semi-holographic effects, in which a change of ambient lighting can produce dramatic changes in the colour effect presented by the product.

EXAMPLE 1 In this example a patterned foil product is produced comprising a textile fabric and a holographic foil material.

In this embodiment, the holographic foil comprises Holofoil obtainable from Astor Universal.

As described above, the holographic foil forms the substrate in the manufacturing process and to it is applied a devour fabric comprising sheer and/or semisheer areas.

The manufacturing process commences with the production of the devote fabric utilising a plain white 50 : 50 polyester; cotton fabric. This fabric is silk-screen printed with a burn-out paste in the required pattern and is then allowed to dry.

This is followed by the step of burning the thusprinted pattern by application of heat, for example by a contact heating iron or roller. The burnt-out fabric is then immersed in water to remove the burntout fibres.

The thus-treated fabric can now be dyed to the required colour, or this step can be carried out prior to commencing the process. In either case, direct dyes are used.

An additional printing step may be carried out at this stage in order to add to the complexity or interest of the design.

This completes the preparation of the devote fabric for application to the foil substrate.

For this purpose, the reverse side of the thusproduced fabric is sprayed with any suitable spray paint in order to produce a colour effect on the burnt out areas of the devour fabric.

Finally, the holographic foil substrate and the textile fabric layer are spray-coated with an adhesive suitable for fabrics, and bonded together.

Summarising, in this embodiment a combined cotton/polymeric fabric (50:50 or other ratios) is silk-screen printed, dried, the patterned fabric component burnt out and removed, and dyed to the required colour. The reverse side of the fabric, which is now semi-sheer or sheer in selected pattern areas is then sprayed on the reverse side with colour so that these areas allow the holographic foil to show through effectively in due course. In the combined foil/fabric product the integration of the sheer or semi-sheer fabric portions with the foil in the relevant areas is important. The colour-treatment of the fabric to avoid these areas clashing or standing out from the foil is therefore also important.

Accordingly, the reverse side of the fabric (which will be face-to-face with the foil in due course) is colour-treated so that its remaining textile constituent after the burn-out step serves simply to moderate the foil-effect.

EXAMPLE 2 In this embodiment, instead of applying a devour fabric to the holographic foil substrate, what is done is to apply a printing technique to the foil to simulate the textile fabric effect.

Accordingly, in this embodiment the holographic foil is silk screen printed with a desired pattern using as the printing medium a pigmented pva binder.

Alternative compatible pigmented media will be known to persons skilled in the art.

After printing of the pattern on the holographic foil, the latter is then ready for the lamination stage which is carried out by applying self-adhesive layers of transparent polymeric laminating sheet material. The result is the production of a protected product, suitable for use as a decorative floor or wall tile having a patterned foil finish combining the effect of holographic foil with a readily printed pattern which confines the foil-effect to chosen areas and adds subtlety and moderation to it elsewhere. For use in locations requiring resistance to wear, appropriate hardwearing laminate materials are used.

A second aspect of the invention relates to the provision of a method and a corresponding product in which, in a way related to the method of the first aspect of the invention, a visually distinctive and appealing effect is created by interactions between visually and/or spatially and/or structurally and/or optically related elements are employed to produce visual effects in association with, optionally related mechanical effects, in order to create visually pleasing and/or mechanically useful results.

An example of an application of this aspect of the invention is to the production of display articles of the kind which find application in the business environment such as corporate identity display devices and the like. Many other applications of this aspect of the invention are envisaged including purely artistic creative articles in which a design is embodied for display purposes in accordance with the principles of the invention.

Prior proposals in relation to corporate identity visual display devices have included the use of icons and insignia embedded in transparent and/or translucent materials including glass and acrylic plastic materials. Such devices have their merits but they are subject to inherent limitations arising from the system of construction. These limitations include the fact that the visual impact depends entirely upon the three-dimensional form of the embedded icon or other device, this being presented, in the finished article, merely as itself, the only enhancement of its visual impact being provided by its encasement in the acrylic or other material.

There is a need for a product and a method offering more versatility of approach and/or an ability to vary the visual impact without the necessity to create such variation as a pre-existent three-dimensional object and/or to accommodate a requirement for an ability to present the device in very substantial sizes if required for particular purposes - and without attendant prohibitive costs.

An object of the invention is to provide a method and a corresponding product offering improvements in relation to one or more of these matters or improvements generally.

According to this aspect of the present invention there is provided a method and a corresponding product as defined in the accompanying claims.

In the described embodiments, the method and the corresponding product provide substrates with visual interaction between related differing images provided on transparent and/or translucent substrates.

In the embodiments, the relationship between the visually interacting images include relationships by size, and/or colour and/or text and/or the form or format of the devices or designs provided thereon. An important aspect of the embodiments relate to visual interaction arising from gradation of images in sequence. In one embodiment such gradation in sequence is provided by gradation in size of the image provided and also in this embodiment there are provided two sets of substrates, each set providing its own gradation in sequence. These sets are interrelated by their mechanical relationship which is that of two interlocking sets of planar substrates. These co-operate to form a three-dimensional interlocked grid-like mechanical structure as a result of slotted interaction between the planar elements of the construction. Due to the spaced and parallel relationship of the planar elements of each set, the design printed on each of these co-operates with those of the adjacent elements to produce a complementary three-dimensional effect.

The structural relationship between the designcarrying elements of the construction, and their forms may be such that convenient provision may be made for related mechanical and optical and other functions.

These include the provision for mechanical lodgement of related articles in or on the structure of the device. For example, there may be provision for storage of clerical sundries in the case of a desk top decorative storage device, or the provision of a light source within the device, for example a small incandescent or mercury vapour lamp in the case of an illuminated display device.

In the principal described embodiment, the threedimensional relationship of the planar design-carrying elements and their interlocking mechanical relationship, together with their visual/optical relationship due to the overlapping images which they can cause, and their ability to define a space to receive a related structural or optical element enables the provision of a new article having both visual and practical mechanical practical applications and which is applicable to the fields of decorative articles, amusement articles, display articles, and so-called executive toys and children's toys.

Embodiments of the invention will now be described by way of example with reference to the accompanying drawings in which: Fig 1 shows a perspective view of an assembly of transparent or translucent substrates to carry visually related images; Figs 2 to 7 show plan views of six such substrates which are shown carrying visually related images for the purpose of the invention; and Fig 8 shows a three-quarter perspective view of a visual display product comprising an assembly of transparent substrates generally similar to those of Figs 1 to 7 and showing the resulting threedimensional effect which is created.

In the embodiment of Fig 1 there is shown a visual display product 10 of generally rectangular format and in transparent form and comprising an assembly of two sets of transparent substrates 12,14 respectively.

First set of transparent substrates 12 comprises six individual substrates 16, and second set of transparent substrates 14 comprises six individual substrates 18.

The individual substrates 16 and 18 are each in the form of a rectangle of transparent plastics sheet material, for example the material known as "acetate".

In this embodiment there is a need for a degree of mechanical stiffness, but not extending to actual rigidity, in the sheet material of the substrate, in order that they will satisfactorily mechanically interact for the purpose of producing the selfsupporting structure 10 shown in Fig 1. The degree of stiffness required will vary with the use intended.

In the case of a mere lightweight desk-top display product, then little more stiffness is required than is sufficient for the product to be self-supporting and in this particular case the particular degree of stiffness needed may be little more than that which would commonly be found in transparent plastic sheet material used for stationery purposes to provide storage wallets of the kind used to provide a modestly stiff product format. In other embodiments, where the structure required has to have mechanical strength of a defined level, then the stiffness of the material, or even its rigidity, will be chosen accordingly.

As Fig 1 shows, the substrates 16 and 18 mechanically interact and interlock to form the generally cuboid structure of the visual display product 10. The manner of interaction and interlocking will be described below. At this point it is noted that the spacing of these substrates or planar elements 16,18 is such that there is defined between the four innermost substrates 18,18 and 16,16 a generally rectangular void or space 20 in which may be received a variety of means or structures according to the intended purpose of the visual display product 10. For example, the space 20 may accommodate a light source such as a mercury vapour lamp so that the visual display product itself is self-illuminating and such a light source then serves to highlight and enhance the display of the visual images produced by the device.Those skilled in the art will be well able to provide the constructional details relative to the installation of lighting units, mounting means or the like within the space 20, or indeed otherwise in relation to the device 10.

Turning now to the construction of the substrates 16,18, these will now be considered further in relation to the substrates shown in Figs 2 to 7.

As can be readily seen from Figs 2 to 7, these figures show two sets of three substrates or planar elements (Figs 2, 3 and 4, and Figs 5, 6 and 7).

In Figs 2 to 7, the substrates are identified by reference numerals 16 and 18 to correspond to the substrates of Fig 1 - though in this embodiment each set comprises only three such substrates. Each of the substrates or elements 16,18 is formed with seven slots 22, each slot extending halfway across one dimension of the square substrate for the purpose of interlocking with complementary substrates or elements. In this embodiment, the provision of seven such slots permits the provision of an interlocking construction (generally on the lines shown in Fig 1) of two sets of seven such substrates or elements. If only three substrates per set were intended, then only three slots would be provided.

Each substrate or element 16,18 is transparent and planar in form and carries one image or device for visual display purposes. This image or device is indicated at 24.

As can readily be seen from a comparison of Figs 2 to 4 and Figs 5 to 7, the images 24 in the two series of substrates 16 and 18 are visually related between the images of each series. Thus, the image 24 in Fig 2 is slightly larger than that of Fig 3 and the latter is slightly larger than that of Fig 4. The same applies to those of Figs 5 to 7. The size relationship between these images corresponds to the size difference between sections through a threedimensional product at locations corresponding to the spacings of the substrates or elements 16,18 when assembled into the structure indicated generally in Fig 1. In other words, the image 24 in Fig 4 will be located in front of the image 24 of Fig 3, and latter in front of the image 24 of Fig 2 so that this graded sequence of images corresponds to the eye-perceived three-dimensional image of a ball or other circular device (to which the images 24 correspond) commencing with its perceived smaller dimension at the location nearest to the viewer's eye and increasing to the maximum dimension at the mid-point diameter (as seen from the viewer's position), and then the images can decrease again in dimensions back to the size of the image 24 of Fig 7 so that the substrates of Figs 2 to 7 could be used as a graded sequence, all mounted in parallel relationships in one series, commencing with Fig 4 followed by Figs 3, 2, 5, 6 and 7 in that order.

This would lead to a representation of a threedimensional ball-form structure which could be viewed from a number of different angles while presenting a convincing three-dimensional impression.

The selection of images and their visual sequential relationships need to be determined with care. Thus, for example, the images of Figs 2 to 7 could form a single series in a single sequence corresponding to those of the substrates 16 or 18 in Fig 1. The above-described interlocking mechanical relationships of the substrates of Figs 2 to 7 in terms of the series of substrates 16 and 18 illustrates merely the mechanical relationships between the substrates which are available by virtue of their interlocking facilities arising from the provision of the slots 22.

Generally, for the purposes of the present invention, the visual display device will often be provided with a single set of image-carrying transparent or translucent substrates which have visually related images which interact to produce, for example, a three-dimensional object within the display device. Thus, for example, in Fig 1 this series might be the first set of substrates 12 and the second set of substrates 14 might be mainly transparent or might carry images which are only partially or only indirectly related to those of the first series. This is the case in the embodiment of Fig 8, to be discussed below where the main three-dimensional product is conveyed by a single series of substrates and the image conveyed by the second set is a representation of a word such as "Swatch" (registered trade mark).Thus, for example, the relationship between the two sets of substrates could be that one set presents a corporate logo and the other set presents the corresponding corporate name or trading style whereby the entire three-dimensional product displays, according to the point of view, differing aspects of the corporate identity.

Thus, turning to the embodiment of Fig 8, it will be seen that the visual display product 30 is constructed generally along the lines shown in Fig 1 comprising interlocking sets of transparent substrates 32 and 34.

In this embodiment, the structure of the visual display product 30 is no longer cuboid as in Fig 1, but an elongated rectangular structure, and thus the set of substrates 32, which are spaced from each other in the lengthwise direction of product 30 are significantly greater in number than those of the other set 34.

The substrates 32 carry visual related images of a corporate identity logo. Each image is generally of circular profile, but the images differ in overall general size, and the resulting impression seen in Fig 8 is of a generally circular section corporate identity device. In practice, the device is printed in the relevant corporate identity colours.

The substrates 34 extending lengthwise of the visual display products 30 carry, in this embodiment, the corporate identity word mark, for example, the mark "Swatch" (registered trade mark) . Obviously, any other suitable corporate mark and device could be represented in a similar way.

It will be apparent from Fig 8 that not all the substrates 32 and 34 carry a visual image. This is a matter of design choice.

In Fig 8 reference numeral 36 identifies the generally circular-form images provided on the substrates 32 which convey the three-dimensional image of a corporate identity logo 38. Reference numeral 40 identifies the related word trade mark carried by the substrate 34.

Amongst other modifications which could be made in the above embodiments are the following.

Translucent or only semi-translucent substrates or elements 16, 18 could be used according to requirements and light source available in a particular situation. The substrate could be varied in spacing. In some cases they need not be planar.

An example would be a series of generally curved or of convex/concave format with, possibly, a graded sequence of changes in the radii of curvature, to produce enhanced or otherwise differing visual effects.

It is not essential that the spacing of the substrates be constant, nor that the spacing of one set be determined by corresponding substrates in another set. It is envisaged that an embodiment will provide simply spaces to mount a single series of substrates or elements. For example, a series of substrates could be mounted by one, two, three or preferably four rods extending through the series to define the relevant spaced relationship between the members of the series.

The visual display products may be employed for practical purposes. For example, such a product could readily be utilised as a table, or even as other articles of furniture such as chairs, desks or the like. The construction and materials would be modified accordingly.

So far as images are concerned, the related visual images need not always be elements of a device or logo. For example, the images could be simply interactive images which co-operate to give an overall visual effect.

Claims (25)

CLAIMS :

1 A method of making a visual display article or product comprising: a) providing at least two substrates; b) providing images on said substrates; and c) mounting said substrates in a defined relationship; characterised by d) providing said images in visually related form, and providing a defined spaced relationship of said substrates such that said images visually interact to produce a combined visual effect, as viewed from at least one defined direction, said visual effect differing from the visual effect of said substrates taken on their own, for example, a three-dimensional effect.

2 A method of making a visual display article or product characterised by providing images on transparent or translucent substrates which interact to produce a combined visual effect.

3 A method according to claim 1 or claim 2 characterised by providing said substrates in generally planar form.

4 A method according to any one of claims 1 to 3 characterised by providing said substrates in generally fixed positional relationships.

5 A method of making a visual display article or product substantially as described herein with reference to the accompanying drawings.

6 A visual display article or product comprising: a) at least two substrates; b) said substrates being provided with images thereon; and c) said substrates being mounted in a defined relationship; characterised by d) said images being in visually related form, and said substrates being in a defined spaced relationship such that said images visually interact to produce a combined visual effect as viewed from at least defined direction, such visual effect differing from that of the substrates taken on their own, for example a three-dimensional effect.

7 A visual display article or product characterised by transparent or translucent substrates having visually related images interacting to produce a combined visual effect.

8 A visual display product or article according to claim 6 or claim 7 characterised by said substrates being generally planar.

9 A visual display article or product according to any one of claims 6 to 8 characterised by said substrates being generally in fixed positional relationships.

10 A visual display article or product according to any one of claims 6 to 9 characterised by said visually related images being visually related by comprising elements of a representation of a three-dimensional object or design taken at spaced locations on said object or design.

11 A visual display article or product according to claim 10 when dependent on claim 9 and characterised by said fixed positional relationships of said substrates corresponding to the spacing of said spaced locations on said object or design.

12 A visual display article or product according to claim 10 or claim 11 characterised by said related images being related by comprising images corresponding generally to successive spaced sections through a three-dimensional product or design, or at least external portions of such sections.

13 A visual display article or product according to any one of claims 6 to 12 characterised by said spaced relationships of said substrates being defined by spacing elements which mechanically interact with said substrates.

14 A visual display article or product according to claim 13 characterised by said spacing elements comprising two or more transparent or translucent substrates carrying respective images.

15 A visual display article or product according to claim 13 characterised by said spacing elements comprising rod elements or the like.

16 A visual display article or product according to claim 14 characterised by said images on said further substrates being related to said images on said first set of substrates.

17 A visual display article or product substantially as described herein with reference to or as shown in the accompanying drawings.

18 A method of making a patterned foil product having a pattern or design of foil comprising areas of foil-effect on a substrate, the method comprising the steps of a) providing a substrate sheet material to carry said foil in the finished product; b) providing a pattern-applying means for application to said foil and causing same to produce said pattern or design of spaced foil-effect areas on said substrates; characterised by c) providing said substrate sheet as a sheet of said foil itself; and d) said pattern-applying step comprising applying to said substrate sheet a pattern or design of foil-exposing and foilobscuring areas to enable said foil to be observed in said foilexposing areas.

19 A method of making a patterned foil product characterised by providing a substrate foil sheet and applying a pattern of foil-exposing and foil-covering areas thereto.

20 A method according to claim 18 or claim 19 characterised by said step of causing said pattern-applying means to produce said pattern or design on said substrate comprises adhering said pattern to said substrate.

21 A method according to claim 18 or claim 19 characterised by said step of causing said pattern-applying means to produce said pattern or design comprising adhering printing ink or a pigmented binder or the like to said substrate.

22 A method according to any one of claims 18 to 20 characterised by the step of colour-treating the reverse side of said pattern by application of a colour which matches or complements the colour of said foil whereby sheer portions of said pattern are less visible against said foil itself.

23 A method according to any one of claims 18 to 20 and 22 characterised by said pattern of foil-obscuring and foilexposing areas comprises a devote fabric comprising said areas.

24 A method according to claim 23 characterised by the step of colour treating the reverse side of said device fabric in order to produce a visible colour effect in said foil-exposing areas to disguise said areas or to comlement the colour of said foil.

25 A method of making a patterned foil product substantially as described herein.