WO2011133013A1

WO2011133013A1 - A method for producing a decorative substrate with printed images

Info

Publication number: WO2011133013A1
Application number: PCT/MY2010/000072
Authority: WO
Inventors: Ashley Joseph John
Original assignee: Individual
Current assignee: Individual
Priority date: 2010-04-23
Filing date: 2010-05-07
Publication date: 2011-10-27
Anticipated expiration: 2012-10-23
Also published as: MY147782A

Abstract

A method for producing a decorative substrate (20)comprises the steps of first, etching a surface of a non-porous and rigid substrate (30) to produce a roughened surface (33) of the substrate (30); subsequently, depositing a base coating (41) onto the roughened surface (33) of the substrate (30); drying said substrate until the base coating (41) is completely adhered on the substrate (30); jetting liquid material onto the base coating (41) of the substrate to form an image printed surface (51) and applying a protective coating (61) onto the image printed surface (51) of the substrate (30) and drying it completely at ambient temperature. Such decorative substrate (20) provided with printed images on its surface are resistant to water, microorganisms growth and common non-acidic household detergents.

Description

A METHOD FOR PRODUCING A DECORATIVE SUBSTRATE WITH

PRINTED IMAGES

Background of the Invention

Field of the Invention

The present invention relates to a decorative substrate that can be utilized for interior and exterior building construction. More particularly, a non-porous and rigid substrate that includes glass, mirror and the like, having images printed upon its surface and the method of producing thereof.

Description of Related Arts

Unique interior designs of a building construction with the application of various types of decorative materials have achieved an extraordinary demand due to advancing changes in human lifestyle. People enjoy the living and working environment with the wonders of interior design. One of the decorative materials which is broadly acknowledged in this industry is materials with printed colour images on its surface such as glass, mirror, ceramic, metal and plastic materials. It is important to produce a high resolution colour image on such materials especially glass and mirror as they can be utilized in flooring, roofing, walls, windows and door decoration because colours are a powerful visual perceptual human property which will affect human behaviours, emotions and lifestyle.

Many approaches of manufacturing glass and mirror with printed colour images have been disclosed in prior arts. An example of one such approach has been disclosed in U.S. Pat. 4133919. The method includes applying a rubber masking material in accordance with a predetermined pattern, curing it to form a rubber masking layer and then sandblasting the surface containing the rubber masking layer thereon and subsequently removing the rubber masking layer; may be repeated in order to form a dual density visual image on the surface of the glass or the plastic sheet.

Another approach to make a decorative glass panel has been presented in U.S. Pat. 6982137. A xerographically produced image is applied onto a surface of a substrate wherein the surface comprises an electrostatic powder deposition coating which requires oven-baking at a temperature of about 350 °F to 400 °F to achieve an eighty to ninety- five percent cure. After the substrate with the electrostatic powder coating is cooled to room temperature, a transfer sheet with xerographic colour image is transferred onto it and the image is heat pressed for three to five minutes at same temperature with the oven- baking process. Subsequently, a second layer of powder coating is applied electrostatically and said substrate is heated for a sufficient time to completely cure and bond all coatings together. This approach has a drawback that during the oven baking process; the high temperature may cause bubbling up of the coating layer and the transfer sheet, hence affecting the quality of the images.

As disclosed in U.S. Pat. 4748054, a method of providing different coloured layers of paint on glass involves the steps of roughening a surface of glass by sandblasting, applying a first lot of soluble resist to predetermined areas of the roughed glass and then applying a first colour paint onto the glass. The soluble resist is preferably that known as sugar lift which is a saturated solution of sugar; or water soluble resist in the form of gum Arabic both of which can be used. After that, a first colour paint is applied to the glass; the first lot of soluble resist to expose unpainted roughed glass is washed off and dried before the application of a second lot of soluble resist on top of some of the first coloured paint and on top of some of the exposed unpainted roughened glass. Then, applying a second coloured paint to the glass and washing off the second lot of soluble resist to leave the glass with at least one area where the first and second colours are overlaid.

However, the disclosed prior art techniques are time consuming and have limitations. The products have shorter durability due to the de- lamination of the coating that is applied, on the glass or mirror or the like. Besides that, the colour of the images adhered on the surface of the materials are easily distorted.

Accordingly, there exists a need in the relevant art to provide an alternative technique to produce a non-porous and rigid substrate with printed high resolution images on its surface which is able to overcome the foregoing and other difficulties long since associated with the prior art.

Summary of Invention

The present invention presents a method for making a non-porous and rigid substrate which will preferably be a glass or a mirror with full colour images permanently adhered on its surface (hereinafter referred as decorative substrate), in such a manner that the printed images are high resolution images (preferably from 300 to 720dpi resolution) and the decorative substrate is resistant from water, microorganisms growth and common non-acidic household detergents. This is accomplished by etching a surface of the substrate before depositing a base coating onto it. Subsequently, a predetermined image is adhered onto the base coated substrate by jetting liquid materials onto it whereby the liquid materials are cured by electromagnetic radiation such as ultraviolet radiation in a short period of time. Then, the substrate is dried for a sufficient period of time after application of a protective coating onto the image printed surface. The resulting product could be utilized in interior and exterior decoration in building construction.

One of the objectives of the present invention is to provide a decorative substrate including glass, mirror and the like which allow single colour to multi colour images to be printed upon its surface.

Another objective of the present invention is to provide a decorative substrate including glass, mirror and the like which could withstand from water, microorganisms growth and common non-acidic household detergents.

Another objective of the present invention is to provide a decorative substrate including glass, mirror and the like having enhanced strength and durability.

A further objective of the present invention is to provide a decorative substrate including glass, mirror and the like that prevents de- lamination, peeling and/or bubbling of the image.

Another further objective of the present invention is to provide a decorative substrate including glass, mirror and the like which when produced using the method described in the present invention is cost effective, commercially viable, can be produced in volume and readily installed within an architectural industry accepted period of turn-around time. Brief Description of the Drawings

The features of the invention will be more readily understood and appreciated from the following detailed description when read in conjunction with the accompanying drawings of the preferred embodiment of the present invention, in which:

Figure 1 is a flow diagram of the method for producing the decorative substrate;

Figure 2 is a schematic structure of a non-porous and rigid substrate; and

Figure 3 is a schematic structure of a decorative substrate that is produced according to the present invention.

Detailed Description of the Invention

Referring now to the several figures in which identical elements are numbered identically, a description of the preferred embodiment of the present invention will now be provided.

Figure 1 illustrates a flow diagram of the method for producing a decorative substrate (20). The method used to form the decorative substrate (20) according to the present invention generally includes the steps of: first, etching a surface of a non-porous and rigid substrate to produce a roughened surface (21); after that, depositing a base coating onto the roughened surface of the substrate (22) and subsequently drying the substrate until the base coating completely adheres on the surface (23). Then, jetting liquid materials onto the base coating to form a desired image printed surface (24). Lastly, applying a protective coating onto the image printed surface and drying the formed product completely at ambient temperature in a sufficient time (25).

Referring to Figure 2 and Figure 3, the non-porous and rigid substrate (30) mentioned thereof may be made from any non-porous, rigid materials include aluminium sheet, acrylics, ceramics, stones, woods materials but preferably glass and mirror. Such substrate (30) may have different geometric configurations, but according to one embodiment of the present invention the substrate (30) has a flat and planar structure. Glass is a non-crystalline solid material which is typically brittle, transparent and comprises smooth surfaces. However, the smooth surfaces are unable to provide strong adhesion with any substances applied upon it. In order to form single colour or full colour patterns on the surface of the substrate (30) comprising similar properties with glass, an etching process needs to be accomplished.

With reference to Figure 2 and Figure 3, the substrate (30) comprises two surfaces including an upper surface (31) and a lower surface (32). Both of the upper surface (31) and the lower surface (32) may carry similar characteristics such as clear, transparent and non-porous surfaces. In another instance, the lower surface (32) of the substrate (30) may further comprise a silver layer. The method for producing the decorative substrate (20) is preferably applied to the upper surface (31) but could alternatively be applied to the lower surface (32) if the lower surface (32) comprises similar characteristics as those previously mentioned.

As described above, there exists a difficulty for any substances to firmly stick on the transparent and non-porous surface (preferably upper surface (31)) of the substrate (30). Consequently, the etching process is carried out by spraying a high velocity of stream of particulate materials onto the transparent and non-porous surface of the substrate (30) to roughen the surface. Preferably, the particulate materials used in roughening the transparent and non-porous surface (31) according to the present invention are crystalline materials, for example, aluminium oxide (Al₂0₃) or silica sand, which is being chosen to utilize in the etching process due to their ordinary character, the crystal structure and the hardness. When the aluminium oxide (Al₂0₃) or silica sand bombards the transparent and non-porous surface of the substrate (30), a plurality of pores or grooves is created on the upper surface forming roughened surface (33) with strong adhesion and gloss retention properties; wherein the plurality of pores or grooves may have uneven shape and might not be visually distinguishable.

After etching the transparent and non-porous surface (31) of the substrate (30), the subsequent step of producing the decorative substrate (20) is depositing a base coating (41) onto the roughened surface (33) of the substrate (30). Suitable material for forming base coating (41) to be employed in the present invention may include various mixtures, such as chemical compositions containing groups of polyurethane, polyisocynate and solvents.

The base coating (41) may be manually deposited on the roughened surface (33) of the substrate (30) layer by layer (preferably a minimum two passes) with sufficient time for drying of each layer before application of subsequent layer by using any spraying device known in the art. Such deposition may cause the resulting base coating (41) to have a thickness of about 100 microns. The pores or grooves of the roughened surface (33) of the substrate (30) provide the grip for the base coating (41). Next, the coated surface is permitted to dry for a period of time to form an adequate adhesion between the base coating (41) and the roughened surface (31). The optimum time for drying the base coated substrate is about two to three hours at ambient temperature, preferably between approximately 25°C to 38°C. In some circumstances such as at lower temperature, the required drying time is extended to between five to six hours. Upon drying, the base coating (41) is firmly adhered to the roughened surface (33) of the substrate (30) due to the coefficient friction exhibited between them.

Following the deposition of the base coating (41) on the roughened surface (33) of the substrate (30), the desirable step to produce high resolution images on the surface of the substrate (30) involves jetting liquid materials onto the base coated surface (41) of the substrate (30). The liquid materials that are jetted thereon may include any types of ink, preferably but not limited to, ultraviolet (UV) curable ink.

A predetermined pattern or image (51) is established and well dispersed when liquid materials are jetted from a print head nozzle of a known inkjet printing device onto the base coating (41) of the substrate (30) and simultaneously exposed to the electromagnetic radiation such as ultraviolet (UV) radiation which is able to penetrate to the depth of the liquid materials and fully cure them at the same time. The liquid materials or the predetermined images could be either single colour images or full colour images bonded tightly to the base coating (41) and forming the image printed surface (51).

The next step is applying a protective coating (61) on the image printed surface (51) of the substrate (30).Whereby, this step can be carried out immediately or within one hour of forming the image printed surface (51). Preferably the material utilized in this step may be made from similar chemical composition with the base coating (41). For example, it may be derived from the chemical groups containing polyurethane, polyisocynate and solvents. The protective coating (51) may be applied on the image printed surface (51) using similar technique as that used for applying the base coating (41). It is applied onto the image printed surface (51) by spraying the chemical particles onto the image printed surface (51) layer by layer to a standard of about 150 microns thick (minimum three passes). After application of each layer of the protective coating (61) on the image printed surface (51) of the substrate (30), it is dried completely over an adequate time, preferably of about twenty four hours at ambient temperature (preferably between 25°C to 38°C). An extended drying duration of more than twenty four hours to thirty six hours may be needed to produce the decorative substrate (20) at temperature lower than room temperature. The application of the protective coating (61) could prevent the printed image from de-laminating, scuffing, scratching and peeling off.

The decorative substrate (20) produced according to the method described in the present invention may be a translucent decorative substrate (20) or an opaque decorative substrate (20) depending on the type of protective coating (61) utilized. These appearances are determined by the visibility of the protective coating (61) as it may be a transparent or an opaque coating depending on the requisition and application of the decorative substrate (20) in a building construction.

It has been found that the resulting decorative substrate (20) that comprising of a roughened surface (33); a base coating (41) on top of the roughened surface (33); a coloured image jetted on the base coating (41) and a protective coating (61) applied on the coloured image printed surface (51), has significantly increased strength and enhanced durability. The production method described herein enables the decorative substrate (20) to withstand from normal wear and tear, water, microorganism growth and detergents such as common non- acidic household detergents. Such decorative substrate (20) works well in wet conditions like bathrooms, as the colour images will not distort while retaining its high resolution. The decorative substrate (20) may be installed in wet areas by adhering the surface with protective coating (61) to a wall or other intended interior bonding surface. As a result, the decorative substrate (20) could be installed in the interior as well as exterior of a building to provide a visually pleasing environment for a human.

Although the present invention has been described with reference to specific embodiments, also shown in the appended figures, it will be apparent for those skilled in the art that many variations and modifications can be done within the scope of the invention as described in the specification and defined in the following claims.

Claims

Claims I/We claim:

1. A method for producing a decorative substrate (20) comprising the steps of:

first, etching a surface of a non-porous and rigid substrate (30) to produce a roughened surface (33);

subsequently, depositing a base coating (41) onto the roughened surface (33) of the substrate (30);

subsequently, drying said substrate until the base coating (41) completely adhered on said surface of the substrate (30); subsequently, jetting liquid materials onto the base coating (41) of the substrate (30) to form an image printed surface (51); and

applying a protective coating (61) onto the image printed surface (51) of the substrate (30) and completely drying it.

2. A method for producing a decorative substrate (20) according to claim 1, wherein the non-porous and rigid substrate (30) referred to any rigid materials including aluminium sheet, acrylics, ceramics, stones, woods but preferably glass and mirror.

3. A method for producing a decorative substrate (20) according to claim 1, wherein the surface of the substrate (30) may be a non- porous surface.

4. A method for producing a decorative substrate (20) according to claim 1 , wherein the base coating (41) and protective coating (61) may be made from similar chemical mixtures.

5. A method for producing a decorative substrate (20) according to claim 1, wherein the base coating (41) and protective coating (61) may be derived from the groups containing polyurethane, polyisocynate and solvents.

6. A method for producing a decorative substrate (20) according to claim 1, wherein the decorative substrate (20) is resistant to water, microorganisms growth and common non-acidic household detergent.

7. A method for producing a decorative substrate (20) according to claim 1 , wherein the image printed surface (51) of the substrate (30) may include single colour images and full colour images.

8. A method for producing a decorative substrate (20) according to claim 1, wherein the protective coating (61) may be transparent coating and/or opaque coating.

9. A method for producing a decorative substrate (20) according to claim 1, wherein the base coating (41) may be deposited layer by layer, with sufficient time for drying of each layer before application of a subsequent layer.

10. A method for producing a decorative substrate (20) according to claim 1, wherein the protective coating (61) may be applied layer by layer, with sufficient time for drying of each layer before application of a subsequent layer.

11. A method for producing a decorative substrate (20) according to claim 1, wherein the liquid material includes ultraviolet (UV) curable ink.