Method for producing a decorative design laminate for application to a substrate utilizing an embossing resin

A carrier having a layer of embossing resin deposited thereon is provided with an image or design applied to the layer of embossing resin. A top film having a layer of adhesive applied thereon is laminated to the carrier. The carrier can be a throw-away or a component type carrier. If a throw-away type carrier is employed, it is peeled from the two laminated sheets, leaving the layer of embossing resin, having the image retained thereon, affixed to the adhesive side of the top film. If a component type carrier is employed, the image retained on the embossing resin is encapsulated between the top film and the carrier. Thereafter, a substrate suitable for aircraft interior panels is provided. The top film having the embossing resin and image affixed thereto is laminated to the suitable substrate. If a texture is desired, a textured material may be applied to the top side of the top film immediately before it is laminated to the suitable substrate. After subsequent lamination, the textured material is removed leaving a textured pattern in the finished component decorative laminate.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
This invention relates to a method for producing a decorative design 
laminate. More particularly, it relates to a novel method for producing a 
decorative design laminate from a computer generated image or design, 
transferring such image from a carrier to a substrate utilizing an 
embossing resin. Even more particularly, the novel method of the present 
invention relates to decorative design laminates for application to 
substrates suitable for aircraft interior panels. 
2. Description of Prior Art 
In the prior art, the most commonly used printing process known for 
aircraft applications, specifically for aircraft interior decorative 
laminates, is silk-screening. Unfortunately, silk-screening has a variety 
of inherent disadvantages. For instance, alterations of a design are 
difficult, costly, and time intensive, since each alteration, even the 
most minute, requires the creation of entirely new sets of screens. Each 
color alteration normally requires employing the costly and lengthy 
process of (1) color mixing and matching, (2) creating complete 
"laboratory" samples, and (3) creating the full-size production design. 
The full-size production design must be consistent with the laboratory 
sample. Multi-colored screens are even more expensive and time-consuming, 
regardless of whether "spot-color" silk-screening is used or four-color 
process silk-screening. Like other forms of prior art, silk screening is 
most economical, absorbing set-up costs, when large quantities are run, 
but such large "runs" often compromise color consistency. Moreover, in the 
aircraft decorative interior market, large quantities of a single design 
are relatively rare. 
Other known processes which are used to decorate laminates for aircraft 
interior products include gravure printing, the use of integrally colored 
materials such as ABS (a type of vinyl), or the use of a solid color film 
laminated to a substrate. The inherent disadvantages of these processes 
are that they (1) limit the design to virtually one or two colors, (2) 
they limit customization of the design which often identifies the airline, 
and (3) they are most effectively produced in large quantities small 
"runs" being expensive and essentially cost prohibitive. 
Various prior art methods exist for inclusion of digitally produced images 
in laminates, but non are suitable for aircraft laminates. One such prior 
art method is known as the "wet-method." An image is digitally created and 
printed electrostatically onto a transfer medium using heat and pressure. 
The image is mirrored, introducing the possibility for error. The image is 
then immersed in water, and using pressure, applied to a second film, from 
which the transfer medium is stripped. 
U.S. Pat. No. 3,350,254 to Morgan et al. discloses a wet method utilizing a 
mixture of oil, resin and an elastomer. An exposed water soluble surface 
of the paper is washed away by wetting. In U.S. Pat. No. 3,350,254, a clay 
is used on the water soluble surface. Thereafter, the printed image 
remains adhered to the layer formed by the mixture. The transferred image 
is washed and dried. A protective laminate, such as transparent vinyl, 
having an adhesive side is often applied over the image to form a 
protective layer. The limitations with this method are: (a) there are 
additional steps (i.e., the wet transfer itself), drying time, and (b) 
this method is not generally amenable with materials used in aircraft 
interior decorative laminates that conform to government regulations of 
aircraft performance standards. This method is also considered messy and 
laborious. 
In an effort to improve image transfer processes, a "dry" method was 
discovered eliminating many of the messy and laborious disadvantages of 
the "wet" method. This dry method uses heat and/or pressure to transfer an 
image printed on transfer paper to a chosen substrate. The transferred 
image is then overlaid with a protective film and secured with an 
adhesive. In this type of "dry" method a mirrored or negative image may 
have to be printed on the transfer paper. Such is shown in U.S. Pat. No. 
3,013,917 to Karlan, et al. Such dry methods also have inherent 
disadvantages. For instance, they are considered slow and unreliable. If 
parts of the image do not transfer, the total image is ruined. High 
rejection rate causes extensive material waste, increased production cost, 
and waste of human resources. The particular overlay materials in typical 
aircraft products such as Tedlar are especially difficult to use with the 
"dry" transfer method since Tedlar will not readily accept the image. 
In an effort to improve the "dry" transfer method, it was discovered that a 
pressure-sensitive adhesive-coated film could be used to lift the image 
from the transfer paper and thereafter secured to a final substrate. Such 
is shown in U.S. Pat. No. 4,983,487 to Gilreath wherein the adhesive 
coated film is shown to be the transfer medium. Unfortunately, the 
Gilreath invention also has many inherent disadvantages. One disadvantage 
is that the adhesive-coated film, used as the transfer medium, must be 
highly transparent so that the image may be viewed when applied to the 
final substrate. Use of a non-transparent film to capture the image would 
frustrate the purpose of the invention in that the image would not be 
viewable once it is applied to the final substrate. A second disadvantage 
is that textures can not be introduced. Since nowhere in Gilreath does the 
invention contemplate the use of an embossing resin, the laminate would 
not have the texture retention capabilities necessary for aircraft 
products. A third disadvantage is that Gilreath may have to be practiced 
utilizing a mirrored image. Use of such mirrored images provides for 
possible transfer error. Fourth, the Gilreath invention would most likely 
not meet many of the strict government regulations or aircraft performance 
standards due to the use of standard adhesives which can be highly 
flammable. Finally, Gilreath does not contemplate the use of an inkjet or 
airbrushed produced image. Therefore, the Gilreath invention is limited in 
its application to electrostatically produced images. 
An improved "dry" method for creating design laminates is needed which can 
overcome the many disadvantages of the prior art. Such method should be 
able to meet the strict government and aircraft performance standards so 
that such design laminate can be used in aircraft interiors. 
SUMMARY OF THE INVENTION 
I have invented an improved transfer method for creating a decorative 
design laminate for the specific use in the aircraft industry. In 
particular, my laminates can be applied to aircraft interior panels. My 
method primarily uses electrostatic, inkjet, and airbrush digitally 
produced and printed images. Further, my method employs the use of an 
embossing resin (which may also serve as a color coat), as the receptacle 
for an image which has either been electrostatically printed and 
transferred to it, or which has been printed directly on it by way of 
inkjet or airbrush technology, a process not known in the prior art. 
Embossing resins in the prior art are known for providing embossing or 
texture retention capabilities for the laminate, and sometimes for 
providing a background color coat on which to silk-screen. Nowhere in the 
prior art is it suggested that embossing resin could be used as the 
carrier for a digitally produced and printed image which can be 
incorporated into an aircraft worthy final laminate for application to 
aircraft interior parts and panels. 
My invention takes advantage of digital printing, heretofore unknown and 
unused in the manufacture of aircraft interior decorative laminates. By 
doing so, complex images can be produced quickly and economically. Changes 
or alterations can be done without expensive and time-consuming creation 
of silk-screens. Design changes can be handled and reviewed remotely, 
without the creation of "laboratory samples." The method is well-suited 
for the typical quantities used in the aircraft interiors and can enhance 
and expand possibilities, heretofore thought of as either impossible or 
too expensive to be practical. My invention, furthermore, allows the 
product to meet the strict government regulations and aircraft performance 
standards. 
My method produces a superior image, capable of more complex designs than 
the prior art. My method allows for alteration of the design more quickly 
and economically than the prior art. My process is better-suited for the 
quantities of prints typically ordered than the in prior art. Large "runs" 
are not necessary with my method. My method yields fewer rejects, thus 
reducing labor and material waste and is therefore more environmentally 
friendly. My process meets or improves the products ability to satisfy 
government regulations or aircraft performance standards. For example, my 
product with a complex image is lighter in weight than a comparable design 
produced by silk-screen.) 
In my preferred method, first, a positive digitally produced electrostatic 
print is provided on a sheet of transfer paper. Secondly, a carrier having 
a layer of embossing resin deposited thereon is laminated to the transfer 
paper using heat and pressure such that the embossing resin contacts the 
image on the transfer paper. The transfer paper is peeled away, thus 
leaving the image retained on the embossing resin on the carrier. In 
alternate methods, the first and second steps are skipped and replaced 
with the single step of printing a digitally produced image by way of 
inkjet or computerized airbrush onto the surface of embossing resin 
deposited on the carrier. Thereafter, in all embodiments, a transparent 
film having an acceptable adhesive is then applied over the top of the 
image to protect the image. Next, the carrier is stripped away, leaving 
the embossing resin and image affixed to the over-laminate which is then 
joined with aircraft worthy substrates in a secondary lamination process. 
Or, the carrier for the embossing resin may be stripped away and the 
embossing resin with the image may be placed between aircraft worthy 
materials and laminated in a secondary laminating operation.

DETAILED DESCRIPTION OF THE INVENTION 
Throughout the following detailed description, the same reference numerals 
refer to the same elements in all figures. 
The method of the present invention is primarily used to create decorative 
design laminates for application to aircraft interior panels and 
structures, although application to other substrates can be affected. The 
preferred method employs is electrostatically printed images, although 
alternate methods employ inkjet and airbrush produced images. The present 
methods uses an embossing resin as means for transferring the printed 
image from a carrier to the target substrate. 
Referring to FIG. 3, a block diagram 10 depicts the steps carried out in 
the novel method of the present invention. In addition, FIG. 3 represents 
the preferred embodiment of the present invention. A computer file 12 
contains a four color process image. The image is electrostatically 
printed on a sheet of transfer paper by a four color electronic printing 
system such as a Xerox.RTM. Plotter 8954. The image or design is printed 
as a positive image for direct transfer. The use of a mirrored image is 
not required in the method of the present invention, although a mirrored, 
or negative, image can be used. The transfer paper used is a normal 
transfer medium such as Wearcoat.RTM. manufactured by Xerox.RTM.. A 
carrier having a layer of embossing resin deposited thereon is laminated 
to the transfer paper such that the layer of embossing resin contacts the 
image printed on the transfer paper. Heat and/or pressure is applied. The 
transfer paper is removed, or peeled off, leaving the image or design 
retained within the layer of embossing resin of the carrier. A film having 
an adhesive side is applied to the carrier paper such that the adhesive 
side of the film contacts the layer of embossing resin encapsulating the 
printed image therein. Pressure and/or heat is again applied. In the 
preferred embodiment, the film is a clear Tedlar.RTM. laminate. Other 
materials can be used for the film, such as,polyethylene, polyester, 
Lexan.RTM. (a polycarbonate), Kynar.RTM., or coated and non-coated vinyls. 
If a throw-away type carrier is employed, as in the preferred embodiment, 
the carrier is peeled from the top film leaving the layer of embossing 
resin, retaining the image therein, adhered to the top film or laminate. 
If a non-throw-away type carrier is employed, as in an alternate method, 
the carrier remains adhered to the laminate as a component of the complete 
laminate, encapsulating the image between the top film and carrier. 
Finally, a substrate suitable for aircraft interior applications is 
provided, whereby the complete laminate is laminated to such substrate. 
Heat and/or pressure can be employed to facilitate such lamination. If 
necessary, a layer of adhesive can be applied to the suitable substrate 
prior to laminating to the substrate. 
Alternate methods employ either an inkjet or airbrush produced image or 
design. In such alternate methods, the use of the transfer paper is 
eliminated. Accordingly, the computer image utilizing an inkjet printer or 
an airbrush delivery system is printed directly to the carrier having the 
layer of embossing resin deposited thereon. The steps of the preferred 
embodiment are thereafter practiced through to the lamination of the 
laminate to the substrate. As in the preferred method employing the 
electrostatically produced image, the alternate method employing either 
the inkjet or airbrush produced image can use a throw-away or component 
type carrier. 
Referring to FIG. 4, a sheet of transfer paper 14 having an image 16 
printed on a top side 18 of transfer paper 14 is applied to a carrier 20 
having a layer of embossing resin 22 on a bottom side 24 of carrier 20. 
Transfer paper 14 with carrier 20 positioned together, as shown in FIG. 4, 
is passed through rollers 26 of a continuous laminator 25 at a speed 
ranging from 1.0-1.3 fpm. In addition, heat in the range of 290.degree. 
Fahrenheit and pressure in the range of 120 psi (or more) is applied as 
transfer paper 14 and carrier 20 pass through continuous laminator 25. In 
an alternate embodiment, a flat bed laminator is used in place of the 
continuous laminator. 
FIG. 5, a cross sectional view of the materials being used in FIG. 4, shows 
transfer paper 14 having image 16 printed on transfer paper top side 18 
being applied to carrier 20 having a layer of embossing resin 22 provided 
on carrier bottom side 24. Referring to FIG. 6, after heat and/or pressure 
has been applied to transfer paper 14 and carrier 20, transfer paper 14 is 
peeled away from carrier 20. Layer of embossing resin 22 of carrier 20 
retains image 16 on carrier bottom side 24. Referring to FIG. 7, carrier 
20 retaining image in layer of embossing resin 22 on carrier bottom side 
24 is laminated to a top film 28 on a bottom side 30 using a continuous 
laminator. Speed in the range of 1.0-1.3 fpm, heat in the range of 
290.degree. Fahrenheit, and pressure in the range of 120 psi (or more) are 
applied in the aforementioned step. Again, an alternate embodiment permits 
a flat bed laminator to be used for the carrier to top film lamination 
step. Referring to FIG. 8, carrier 20, in the preferred embodiment, is 
removed, leaving image 16 and layer of embossing resin 22 adhered to top 
film 28 on bottom side 30. Referring to FIG. 9, top film 28 retaining 
image 16 in layer of embossing resin 22 on bottom side 30 is laminated to 
substrate 32 suitable for aircraft interior applications. 
If introducing a texture to the finished decorative design laminate is 
desired, such can be accomplished by practicing an alternate method of the 
present invention. Referring to FIG. 10, prior to laminating top film 28 
to substrate 32, a layer of textured material 34 is applied to a top side 
36 of top film 28. After lamination, textured material 34 is removed, 
leaving the finished decorative design laminate with a textured pattern, 
as seen in FIG. 11. 
Prior to laminating top film 28 to suitable substrate 32, it may be 
advantageous to insert a layer of adhesive therebetween. If so desired, an 
extra tight bond can be achieved by inserting an intermediate clear layer 
of double sided adhesive tape (not shown) such as Opticlear.RTM.. Double 
sided adhesive tape utilizes a PSA (pressure sensitive adhesive). 
In the preferred embodiment, substrate 32 can be any material desired which 
is used in the display of graphic art and prints but suitable for aircraft 
interior applications. Certain flame and smoke retardant regulations may 
apply. When using the continuous laminator, it is necessary that the 
material be able to move therethrough. Such materials include, polyester, 
polyethylene, Tedlar.RTM., Kynar.RTM., Lexan.RTM., or coated and 
non-coated vinyls. If it is necessary to mount the substrate laminated 
finished image to a second substrate, the laminated substrate used can be 
provided with an adhesive back side for mounting to the second substrate. 
The component and finished decorative design laminate is applied to 
various areas within an aircraft interior. Such areas include, but are not 
limited to, the bulkheads, window panels, overhead bins, flooring, 
galleys, and lavatories. 
Once the finished component decorative design laminate is created, it is 
possible to combine other image creation and transfer methods with the 
novel design laminate of the present invention. For example, the 
decorative design laminate can have a silk-screened image printed on top 
of the laminate. Other desirable results include, but are not limited to, 
metallic, pearlescent, and day-glo effects. 
Equivalent steps and elements can be substituted for the ones set forth 
above to achieve the same results in the same manner.