HK1025078A - Process for decorating sections made of metal, plastic material or the like, and related apparatus - Google Patents

Description

Method for decorating a component made of metal, plastic or similar material and related device

The invention relates to a method for decorating elements made of metal, plastic, synthetic material or the like with one or more colors of geometric figures, motifs, wood-or marble-like patterns and the like.

The invention also relates to a device for implementing the method.

It is known that elements used as building elements, such as windows and doors, curtain walls, balconies, guardrails, urban installations and the like, must have a high resistance to ageing and pass various tests according to the national and international standards and/or quality marking regulations of the building products.

There is now a process for the manufacture of large-size, multi-decorative-pattern structures which is the subject of international patent application PCT/EP96/00656 filed by the same applicant as verniciata Industriale veneneta s.p.a. on 2.15.1996; the method comprises the following steps: winding the product which is subjected to surface treatment processes such as pre-painting, anodic oxidation and the like in advance on a transfer bearing layer with required decorations; covering the member wound in the carrier layer with a film made of rubber or the like; the vacuum forming is carried out through a proper conduit between the film and the component wound in the bearing layer, and the vacuum forming can lead the bearing layer to be tightly attached to the surface shape of the product due to the pre-embedding of other proper channels and outlets, and the pressure exerted by the film is uniform due to the adoption of a proper driven device; finally, the whole is heated to realize pattern transfer and color polymerization. This method is therefore very complex and delicate and requires a high expenditure of manpower, in particular the process of winding the product onto the transfer support, suitable means for ensuring the air outlet during the evacuation and permanent slaving means for achieving a uniform pressure.

It is an object of the present invention to provide a method for producing large-sized components which can be up to 20 m in length, are decorated in a multiplicity of ways, can be used in doors, windows and outdoor installations, meet quality requirements, are resistant to weathering and are subject to various international standards and quality marking regulations.

Another object of the present invention is to provide a method for manufacturing components, in particular components made of metal, aluminum and aluminum alloys, plastics, synthetic materials (for example carbon and/or glass fibre-reinforced resins), with one or more colors, such as geometric, floral, wood-or marble-like patterns, and also with decorations containing very complex patterns, in a highly mechanized and labor-intensive manner, without the occurrence of defects, such as edge deformations, soiling, blurring and overlapping of the patterns.

Another object of the invention is to provide a device to carry out the above decoration method of the above elements.

In order to make the above and other objects and the related advantages more clear, a method for the multi-modal decoration of elements made of metal, plastic, composite material or the like will be explained, which method according to the invention comprises the following steps:

pre-treatment, i.e. subjecting the component to at least one surface treatment, such as degreasing, cleaning, anodizing, neutralization, chromium plating, chromium phosphate treatment, phosphating, cobalt nitrate treatment, treatment with chromium-free articles or the like, mechanical polishing and the like,

-optionally pre-painting, i.e. applying at least one layer of paint, liquid or powder, to the surface of said pre-treated structure, so as to form a primer layer,

-optional preheating, i.e. heating said pre-painted component to 50-200 ℃,

decoration, i.e. the application of a decoration, delivered from a strip-like elastic support layer, produced from at least one first reel, to the surface of the above-mentioned pre-treated and possibly pre-painted and pre-heated element, by the action of temperature and/or pressure generated on at least one rotating press roller, which is made of an elastically driven, suitably shaped, heated and thermostated material,

-possible sublimation and fixation, i.e. heating and holding between 100 and 300 ℃ for 1 to 30 minutes of said component containing said decoration, so as to obtain the transfer of decoration and/or pattern and coloured polymer.

For components made of plastics, synthetic materials and the like, the above-mentioned pre-painting step is not always necessary, since the surface of the component may be provided with a pre-fixed colour as a primer for decorations.

By means of the above-described pre-painting, it is possible to obtain the desired base colour, if any, on the component, and in addition, it is possible to pre-apply one or more protective base layers on the component in order to prevent the occurrence of material or colour blurs, stains or the like during the decoration, in such a way that it is possible to achieve maximum definition of the pattern, to avoid colour blurs and overlaps, to ensure optimum quality and long-term durability of the decoration and to withstand the effects of various climates.

According to one embodiment of the invention, the decoration is attached to the surface of the pretreated and possibly pre-painted and preheated component by means of a thin layer of glue which, in cooperation with the action of the temperature and/or pressure, fixes the decoration.

According to another embodiment of the invention, a transparent decorative protective layer is also added to the decorations attached to the surface of the above-mentioned pretreated and possibly pre-painted and preheated components by the combined action of temperature and/or pressure.

After the possible sublimation and fixing steps described above, the decorated component according to the invention is subjected to a further protective treatment, i.e. an additional layer of transparent paint, which may be liquid paint, is then dried in an air, hot air, infrared or ultraviolet oven.

According to the invention, the above-mentioned strip-like elastic support layer is constituted by a continuous strip of paper, fabric, plastic or the like, which carries the pattern to be transferred on the side thereof intended to come into contact with the element to be decorated.

According to another embodiment of the invention, the above-mentioned strip-like elastic support layer is constituted by a continuous strip made of paper, fabric, plastic or the like, which carries, on its side intended to come into contact with the element to be decorated, a first thin layer of glue and a second layer constituted by a decoration or a pattern to be imparted.

According to another embodiment of the invention, the above-mentioned strip-like elastic support layer is constituted by a continuous strip made of paper, fabric, plastic or the like, which carries, on its side intended to come into contact with the element to be decorated, a first thin layer of glue, a second layer constituted by a decoration or a pattern to be imparted and a third layer constituted by a transparent decorative protective film.

By way of example, a band-shaped elastic support layer produced by Miroglio Texille, Italy (address: Strada Tagliata18, Alba (CN)) has proved particularly advantageous.

When the element to be decorated is transported on a horizontal surface (on a chain or a roller), the decoration is automatically attached to the element by the combined action of heat and pressure. Decorations carried on a web made of paper, fabric, plastic or the like are continuously pressed and transferred to the surface of the component by a rotating press roller made of silicon material. The press rolls are suitably heated, for example by means of an electrical resistance. The temperature thereof is also controlled by electronic means and finely kept constant. If a glue layer and/or a protective paint layer is attached to the decoration, these layers are also transferred to the component by the same press roller.

Elements made of deformable material (plastic, glass fibre reinforced synthetic material, etc.) or elements made of metal having vulnerable or damageable regions (small thickness, protruding flanges, etc.) can also be decorated in specific areas of their pre-reinforcement, which can be reinforced by suitable spacers (made of wood, plastic, metal, etc.).

If the element to be decorated is complex, several press rollers may work simultaneously. Each pressure roller is adapted to operate in a specific area of the cross-section of the component, the shape of which corresponds to the shape of the local decorative area.

After the transfer step is completed, the strip made of paper, fabric, plastic or the like and containing the decoration can be recovered by means of a unwinding and rewinding system. After the possible sublimation and fixing steps, the decorated component will remain in an air circulation, infrared or ultraviolet oven until the whole cycle is finished. In this step, the ink on the surface of the member can be completely sublimated and completely fixed. The component is left in the oven and held at a temperature of between 100 and 300 ℃ for 1 to 30 minutes.

The method according to the invention is particularly suitable for producing wood-or marble-imitated aluminum alloy components comprising a first primer layer forming the base colour and a second layer consisting of a decorative element. In addition, the component may also include a third layer of a transparent decorative protective paint film, depending on the end use of the component.

The invention will be explained below by reference to the attached drawings, which are non-limiting and comprise:

figure 1 schematically shows a strip-like elastic carrier layer according to the invention,

figure 2 schematically shows another strip-like elastic carrier layer,

in fig. 3, which schematically shows an embodiment of the decorating steps according to the invention, it is possible to use either only one rotary press roller (fig. a) or several press rollers (fig. b, c and d) in the decorating step.

Referring to the figures, the belt-like elastic support layer 1 is constituted by a disposable continuous strip 5 of paper, fabric, plastic or similar material, which strip 5 carries the decoration 2 to be transferred. According to one embodiment of the invention, the band-like elastic support layer 1a is also constituted by a disposable strip 5 carrying the decoration 2 to be transferred, on the surface of the decoration 2 facing the element to be decorated a layer of glue 3 to facilitate the attachment of the decoration constituted by a special sublimable organic ink, and on the other surface of the decoration a transparent paint film 4 for protecting the decoration 2 underneath.

The elastic carrier layer 1 or 1a is continuously pulled from a roll or the like (not shown) and pressed by means of profiled rotating press rollers 7-17 against the element 6 to be decorated, the side of the carrier layer carrying the decoration or glue facing the element, as is schematically shown in the cross-sectional view of the figure. These rolls have been suitably heated and maintained at a constant temperature, as previously described. The double action of heat and pressure generated by the rollers contributes to the action of glue 3, so that the decorative layer or the composite layer of decorative and protective paint will adhere to the surface of the element 6 to be decorated, which is transported lengthwise in a horizontal plane, pressed by the appropriately shaped rollers. The strip of paper, fabric, plastic, with the glue, the decoration and possibly the protective paint layer, is wound onto a second rewinding reel, while the decorated component is submitted to the next step, i.e. sublimation and fixing in an air circulation, infrared or ultraviolet oven.

In summary, the apparatus for carrying out the decorating step according to the invention comprises:

a member to be decorated, which can be conveyed along a longitudinal axis,

at least one first reel on which an elastic carrier layer in the form of a strip is wound and unwound, the carrier layer comprising a strip of paper, fabric or plastic, a layer of decoration to be transferred and optionally a layer of glue and/or a transparent protective paint layer or film,

at least one rotating pressure roller, which can be elastically driven and has a shape conforming to the external shape of the element to be decorated, which is heated and maintained at a constant temperature, for transferring the layer of decoration and possibly the protective paint layer onto the surface of the element by the action of heat and/or pressure,

at least one second reel on which the strip made of paper, fabric, plastic is wound again after the decor and protective layers have been removed.

Claims (14)

1. A method for the multi-modal decoration of elements made of metal, plastic, composite or similar material, characterized in that it comprises the following steps:

pre-treatment, i.e. subjecting the component to at least one surface treatment, such as degreasing, cleaning, anodizing, neutralization, chromium plating, chromium phosphate treatment, phosphating, cobalt nitrate treatment, treatment with chromium-free articles or the like, mechanical polishing or the like,

decoration, i.e. the application of a decoration, conveyed from a strip-like elastic support layer, produced from at least one first reel, to the surface of the above-mentioned pretreated piece by the action of temperature and/or pressure generated on at least one rotating pressure roller made of elastically driven, suitably shaped, heated and thermostated material.

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

-pre-painting, i.e. applying at least one layer of paint, liquid or powder paint, onto the surface of said pre-treated structure, so as to form a primer layer,

-preheating, i.e. heating the above-mentioned pre-painted components to 50-200 ℃,

-sublimation and fixation, i.e. heating and holding between 100 and 300 ℃ for 1 to 30 minutes said component comprising said decoration.

3. Method according to claim 1, characterized in that said decoration is attached to the surface of said pretreated structure by means of a thin layer of glue which, in cooperation with said action of temperature and/or pressure, can fix the decoration.

4. The method according to claim 1, characterized in that a transparent decorative protective layer is also added to the decoration attached to the surface of said pretreated structure by the combined action of temperature and/or pressure.

5. Method according to claim 1 or 2, characterized in that said structure, after said decoration step and said possible sublimation and fixing step, is subjected to a further protective treatment, namely the application of a transparent paint and subsequent drying in an air, hot air, infrared or ultraviolet oven.

6. The method of claim 5, wherein said clear paint is a liquid paint.

7. A method according to claim 1, characterised in that the above-mentioned band-like elastic carrier layer (1), according to the invention, is formed by a continuous strip (5) of paper, fabric, plastic or the like, which carries the decoration or the pattern (2) to be transferred on the side thereof intended to contact the element to be decorated.

8. Method according to claims 1 to 6, characterized in that said strip-like elastic support layer (1a) is constituted by a continuous strip (5) made of paper, fabric, plastic or the like, which carries, on its side intended to come into contact with the element to be decorated, a first thin layer of glue (3) and a second layer constituted by a decoration or pattern (2) to be imparted.

9. Method according to claims 1 to 6, characterized in that said strip-like elastic support layer (1a) is constituted by a continuous strip (5) made of paper, fabric, plastic or the like, which carries, on its side intended to come into contact with the element to be decorated, a first thin layer of glue (3), a second layer constituted by a decoration or pattern to be imparted (2) and a third layer constituted by a transparent decorative protective film (4).

10. Method according to claims 1 and 2, characterized in that said strip-like elastic support layer is a support layer produced by the firm Miroglio Tessile, alba (cn), italy.

11. Method according to claims 1 and 2, characterized in that the element made of deformable plastic, synthetic material or the like or the element with flexible zones is decorated in the specific area where it is pre-reinforced, reinforced by means of shims of wood, plastic, metal and similar materials.

12. An aluminum alloy structural member bearing a wood-like pattern or a marble-like pattern, characterized in that it comprises a first primer layer constituting a ground color and a second layer constituted by a garnish.

13. An aluminium alloy member according to claim 12, characterized in that it comprises a third layer consisting of a transparent decorative protective paint film.

14. An apparatus for implementing the decoration method according to claim 1, characterized in that it comprises:

-a member (6) to be decorated, which can be conveyed along a longitudinal axis,

-at least a first reel, on which and from which there is wound and unwound an elastic bearing layer (1) in the form of a strip comprising a strip (5) of paper, fabric or plastic, a decoration (2) to be delivered and possibly a layer of glue (3) and/or a transparent protective paint layer or film (4),

at least one rotating pressure roller (7-17) which can be elastically driven and which has a shape conforming to the external shape of the element (6) to be decorated, is heated and maintained at a constant temperature for transferring, by the action of heat and/or pressure, the layer of decoration and possibly of protective paint onto the surface of the element,

at least one second reel on which the strip made of paper, fabric, plastic is wound again after the decor and protective layers have been removed.