REFLECTIVE DISPLAY AND METHOD OF MANUFACTURE

Abstract: Displays are commonly used in the area of marketing. The problem with traditional displays is their two-dimentsional, flat appearance. A need exists for a more aesthetically pleasing display with a three-dimensional appearance. This need is fulfilled with a display having a transparent plastic substrate (12) and a colored image (18) formed on the substrate (12). The colored image (18) is formed on the substrate (12) by process printing a large number of small dots (26), colored red, yellow, and blue, in a predetermined pattern onto the substrate (12). The red, yellow and blue ink dots (26) are translucent to visible light. A reflective layer (30) is deposited against the ink layer (24) to reflect light which passes through the ink layer (24) and thereby give the image (18) formed by the ink layer (24) a shiny, metallic appearance. A stratum (32) of opaque white ink is deposited between the reflective layer (30) and predetermined portions of the image (18) to block the passage of visible light from the predetermined portions to the reflective layer (30).

Description: RELECTIVE DISPLAY AND METHOD OF MANUFACTURE FIELD OF THE INVENTION The present invention pertains generally to signs and displays. More particularly, the present invention pertains to colored displays which can be used on clothing tags, decals, packaging material, and the like. The present invention particularly, though not exclusively, pertains to process printed image displays that have portions formed on the displayed image to enhance the effectiveness of the display. BACKGROUND OF THE INVENTION In the area of marketing, displays and designs have been widely used on many products to increase the appeal of the products and thereby make the products more attractive to potential purchasers. For example, fanciful displays and designs have been used on greeting cards, packaging, decals, and the like to enhance the appeal of these products. Just one of the many types of displays which are commonly used are displays which have a trnasparent plastic substrate on which a design is formed. As can be readily appreciated, a large number of techniques exist for forming the desired design on a plastic substrate. Of particular importance to the present invention is the technique known as process printing, of which lithographic process printing and silk screen printing are well-known species. In its most basic sense, process printing involves forming an image on a substrate by depositing a large number of very small, closely-spaced colored dots onto the substrate. Each of the dots has one of the four primary colors, i.e. red, blue, yellow, or black. The desired image is formed on the substrate by particularly depositing the variously colored dots onto the substrate in a predetermined pattern, i.e. a predetermined color combination. The pattern or combination in which the dots are deposited forms the desired image and also establishes the colors of the image. Typically, when an image is to be formed on a plastic substrate for use as a clothing label, packaging, and the like, the dots are translucent ink and are process printed onto the substrate. The image thus formed has a two-dimensional, flat appearance. The present invention recognizes that the effect of process printed displays can be enhanced by making portions of the display appear to be metallic and shiny, thereby giving the display a three-dimensional appearance. Accordingly, it is an object of the present invention to provide a display which has a plastic substrate and an image process printed thereon. It is a further object of the present invention to provide a display which has a process painted image with portions of the image having a metallic, shiny appearance. Another object of the present invention to provide a display which has diverse applications and which is cost effective to manufacture. SUMMARY OF THE INVENTION A display which can be used as a greeting card, clothing label, decal, packaging material, or the like has a transparent plastic substrate, on which is formed a colored image. The image is formed by process printing a large number of relatively small translucent colored ink dots onto the substrate. In accordance with well-known process printingtechniques, e.g. lithographic process printing and silk screen printing, the ink dots are colored yellow, blue, and red, and are deposited onto the substrate in a predetermined pattern to form the desired colored image. Additionally, a stratum of opaque white ink may be deposited over the ink dots which form preselected portions of the image. Accordingly, those portions of the image which have white ink deposited thereon are substantially opaque to visible light. On the other hand, those portions of the image which do not have white ink deposited thereon are substantially translucent to visible light. A reflective layer is deposited over the translucent ink dots and white ink stratum which form the printed image. This reflective layer is preferably a metalized mylar sheet which is laminated to the substrate against the ink dots and white ink layer. Alternatively, the reflective layer can be a layer of metallic paint which is deposited over the ink image onto the substrate by spraying or by dipping the substrate in a container of the paint. In any case, the effect of the reflective layer is to reflect light which passes through the translucent portions of the image, thereby giving the translucent portions of the image a shiny, metallic appearance. The novel features of this invention, as well as the invention itself, both as to its structure and its operation, will be best understood from the accompanying drawings, taken in conjunction with the accompanying description, in which similar reference characters refer to similar parts, and in which: BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a front view of a display; Figure 2 is a blown-up view of a portion of the display shown in Figure 1, showing the colored ink dots which form the image on the display; Figure 3 is a cross-sectional view of the display as seen along the line 3-3 in Figure 1; Figure 4 is a cross-sectional view of the display as seen along the line 4-4 in Figure l; and Figure 5 is a block diagram of the method of manufacturing the display. ■ DESCRIPTION OF THE PREFERRED EMBODIMENT Referring initially to Figure 1, a display is shown and generally designated 10. Display 10 includes a transparent substrate 12. Substrate 12 can be a plastic sheet or a glass pane, and furthermore can be tinted or clear. In any event, substrate 12 must permit the passage of selected wavelengths of light in the visible spectrum through substrate 12. Finally, substrate 12 also has a first surface 14 and a second surface 16, best shown in Figures 3 and 4. Figure 1 also shows that substrate 12 can have any desirable image 18 printed thereon, such as the fish 20 jumping over the waves 22. As seen in cross-reference to Figures 1, 3, and 4, image 18 is formed on substrate 12 by depositing a layer 24 of ink onto side 16 of substrate 12. In accordance with the present invention, the ink which is used for layer 24 is relatively viscous and is curable within a relatively short period of time (e.g. six seconds) . More specifically, it is preferred that the ink be curable with ultraviolet (UV) light. Further, the ink should be relatively viscous, such as any of the enamel, epoxy and acrylic inks which are well known in the art. Also, it is to be appreciated that the ink which forms predetermined portions of ink layer 24 may be translucent, while the ink that forms other predetermined portions of ink layer 24 may be opaque. Preferably the entire ink layer 24 is translucent, for purposes to be shortly disclosed. As shown in cross-reference to Figures 1 and 2, the ink which forms layer 24 is deposited onto substrate 12 as a plurality of relatively small, closely spaced colored ink dots 26. Ink dots 26 are deposited onto substrate 12 by any suitable method of process printing, for example lithographic process printing or silk screen printing. As is well known in the art, the dots 26 which are printed onto substrate 12 are yellow, black, blue, and red, although other colors may potentially be used. Dots 26 are deposited onto substrate 12 in a predetermined color combination which establishes both the shape and color of image 18. It is to be appreciated that the diameter 28 of the dots 26 is preferably small f in order to establish a relatively high degree of resolution of image 18. For example, when using the well known silk screen process printing, a four hundred (400} line per inch mesh will form dots 26 which have a diameter 28 of approximately twenty five ten thousandths (.00025) of an inch. On the other hand, when using lithographic process printing, the diameter 28 of dots 26 can be established to be as small as industrially useful. Referring to Figures 3 and 4, a reflective layer 30 is shown deposited against ink layer 24. Furthermore, Figure 4 shows that reflective layer 30 can be deposited against portions of side 16 of substrate 12 which are not covered by ink layer 24. It is to be understood, however, that reflective layer 30 need only be deposited against selected portions of ink layer 24 that form portions of image 18 which are to appear metallic, e.g. waves 22. In the preferred embodiment, reflective layer 30 is a sheet of metalized mylar which is laminated onto ink layer 24 and side 16 of substrate 12. Alternatively, reflective layer 30 can be a layer of metallic paint or ink which is deposited onto ink layer 24 and substrate 12 by spraying the metallic paint or ink onto ink layer 24 and substrate 12. Reflective layer 30 can even be a layer of metallic ink or paint which is deposited onto ink layer 24 and substrate 12 by dipping side 16 of substrate 12 (and, hence, ink layer 24) into a container of the metallic paint or ink which is to form re lective layer 30. It will be recalled that the ink which forms ink layer 24 is preferably translucent. Accordingly, light can pass through ink layer 24 and be reflected back through ink layer 24 by reflective layer 30 to give ink layer 24 a metallic, shiny appearance. If desired, however, light which passes through preselected portions of ink layer 24 which are not to appear metallic may be blocked from reflective layer 30 by forming the preselected portions from opaque ink. Preferably, however, the entire ink layer 24 is translucent, and a non-shiny opaque stratum 32, shown in Figure 4, is deposited between the preselected portions of ink layer 24 which are not to appear metallic and reflective layer 30. In the preferred embodiment, opaque stratum 32 is a layer of white ink which is process printed onto the preselected portions of ink layer 24. Opaque stratum 32 of light to reflective layer 30 blocks the passage from those portions of ink layer 24 on which stratum 32 has been deposited. Consequently, those preselected poritons of ink layer 24 which have opaque stratum 32 deposited thereon will not appear to be metallic. On the other hand, those portions of ink layer 24 which do not have opaque stratum 32 deposited thereon will have a metallic shiny appearance. To illustrate, as shown in cross-reference to Figures 1 and 3, no opaque stratum 32 is deposited on the portion 36 of ink layer 24, which forms fish 20 of image 18. Consequently, light can pass through portion 36 and be reflected back through portion 36 by reflective layer 30, which gives portion 36 (and, hence, fish 20) a metallic, shiny appearance. On the other hand, as seen in cross-reference to Figures 1 and 4, opaque stratum 32 is deposited between preselected portion 34 (which forms waves 22) of ink layer 24 and reflective layer 30. Consequently, light which passes through portion 34 will be blocked from reflective layer 30 by opaque stratum 32. Thus, portion 34 (and, hence, waves 22) will not appear to be shiny or metallic. METHOD OF MANUFACUTURE In the method of manufacturing display 10, reference is initially made to Figures 2 and 5. In accordance with well known methods of process printing, including silk screening and lithographic process printing, a large number of relatively small, closely spaced colored dots 26 are deposited onto side 16 of substrate 12, shown in Figure 2, to form ink layer 24. This depositing step is indicated at block 38 in Figure 5. Typically, each dot 26 will be a red, yellow, or blue translucent ink dot. The variously colored dots 26 are deposited onto substrate 12 in a predetermined combination, in accordance with well known methods of process printing, to form the image 18 shown in Figure 1. Next, at block 40, a suitable opaque stratum 32, for example opaque white ink, is deposited over preselected portions of ink layer 24 (e.g. , portion 34) which form those portions of image 18 (e.g., waves 22) that are not intended to appear metallic. No opaque stratum 32, however, is deposited against those portions of ink layer 24 (e.g., portion 36) which forms portions of image 18 (e.g., fish 20) that are to appear metallic. Stratum 32 may be sprayed, painted, or printed over portion 34 in accordance with well known ink deposition techniques. Next, reflective layer 30 is deposited against portions of ink layer 24 which form portions of image 18 that are intended to appear metallic. As seen in Figure 4 , however, reflective layer 30 may additionally be deposited against both ink layer 24 and portions of side 16 of substrate 12 which are not covered by ink layer 24. In any case, reflective layer 30 is preferably a metalized mylar sheet. The mylar sheet which constitutes reflective layer 30 can be laminated or glued onto ink layer 24 and substrate 12. This step is represented at block 42a. On the other hand, reflective layer 30 may be a layer of metallic paint which can be sprayed or printed onto ink layer 24 and substrate 12, as indicated at block 42b in Figure 5. Layer 30 in the form of metallic paint can even be deposited against ink layer 24 and side 16 of substrate 12 by gently dipping side 16 of substrate 12 into a container (not shown) of the metallic paint. This step is indicated in Figure 5 at block 42c. In any case, display 10 is subsequently cured, for example by exposing display 10 to ultraviolet light, at block 44. While a particular process printed image with reflective coating as herein shown and disclosed in detail is fully capable of obtaining the objects and providing the advantages herein before stated, it is to be understood that it is merely illustrative of the presently preferred embodiments of the invention and that no limitations are intended to the details of construction or design herein shown other than as described in the appended claims.

Claims: We Claim: 1. A display (10) having a transparent plastic substrate (12), an ink layer (24) process printed onto the substrate (12) to form a predetermined image (18), the ink layer (24) having predetermined portions that are being substantially translucent to light, and a reflective layer (30) deposited against the predetermined portions of ink layer (24) to reflect light which passes through the predetermined portions of the ink layer (24) to give predetermined portions of the image (18) formed by the predetermined portions of the ink layer (24) a shiny appearance. 2. A display (10) as recited in claim 1 further characterized by an opaque stratum (32) deposited on preselected portions of the ink layer (24) between the preselected portions and the reflective layer (30) to substantially block the passage of light from the preselected portions to the reflective layer (30) . 3. A display (10) as recited in claim 2 characterized in that the opaque stratum (32) is a layer of opaque white ink. 4. A display (10) as recited in claim 1 characterized in that the image (18) is process printed onto the first side of the substrate (12) by silk screening. 5. A display (10) as recited in claim l characterized in that the image (18) is process printed onto the first side of the substrate (12) by lithographic process printing. 6. A display (10) as recited in claim 1 characterized in that the reflective layer (30) is a layer of metalized mylar, and the metalized mylar layer is laminated against the ink layer (24) and the substrate (12). 7. A display (10) as recited in claim 1 characterized in that the reflective layer (30) is a layer of metallic paint, and the metallic paint layer is painted over the ink layer (24) . 8. A display (10) having a transparent plastic substrate (12) having a plurality of colored ink dots (26) deposited thereon to form an image (18) , the ink dots (26) being translucent, and a reflective layer (30) formed"against the ink dots (26) to reflect light passing through the ink dots (26) to give the image (18) a metallic appearance. 9. A display (10) as recited in claim 8 further characterized by an opaque stratum (32) deposited on preselected portions of the ink dots (26) between the preselected portions and the reflective layer (30) to substantially block the passage of light from the preselected portions to the reflective layer (30) . 10. A display (10) as recited in claim 9 characterized in that the opaque stratum (32) is a layer of opaque white ink. 11. A display (10) as recited in claim 8 characterized in that the ink dots (26) are deposited onto the substrate by silk screening. 12. A display (10) as recited in claim 8 characterized in that the ink dots (26) are deposited onto the substrate (12) by lithographic process printing. 13. A display (10) as recited in claim 8 characterized in that the reflective layer (30) is a metalized mylar sheet laminated against the ink dots (26). 14. A display (10) as recited in claim 8 characterized in that the reflective layer (30) is a layer of metallic paint, and the layer of metallic paint is painted over the ink layer (24) . 15. A process for manufacturing a display (10), characterized by the steps of process printing a plurality of colored ink dots (26) onto a transparent plastic substrate (12) to form an image (18) thereon, the ink dots (26) having translucent portions, and depositing a reflective layer (30) against the colored ink dots (26) to reflect light passing through the ink dots (26) to give the translucent portions a metallic appearance. 16. A process for manufacturing a display (10) as recited in claim 15 characterized in that the reflective layer (30) is a sheet of metalized mylar and the depositing step is accomplished by laminating the sheet to the substrate (12) . 17. A process for manufacturing a display (10) as recited in claim 15 characterized in that the reflective layer (30) is a metallic paint and the depositing step is accomplished by dipping the substrate into a container of the paint. 18. A process for manufacturing a display (10) as recited in claim 15 characterized in that the reflective layer (30) is a metallic paint and the depositing step is accomplished by spraying the paint onto the substrate (12) . 19. A process for. manufacturing a display (10) as recited in claim 15 characterized in that the process printing step is accomplished by silk screening the dots (26) onto the substrate (12) . 20. A process for manufacturing a display (10) as recited in claim 15 characterized in that the process printing step is accomplished by lithographically printing the dots (26) onto the substrate (12) . 21. A process for manufacturing a display (10) as recited in claim 15 further characterized by the step of depositing an opaque stratum (32) between the reflective layer (30) and predetermined portions of the ink dots (26) , to substantially block the passage of light through the predetermined portions. 22. A process for manufacturing a display (10) as recited in claim 21 wherein the opaque stratum (32) is white ink.

Inventors: LONGOBARDI LAUWRENCE J, LOVISON DOUGLAS I, LONGOBARDI, LAUWRENCE, J., LOVISON, DOUGLAS, I.
Applicants: SIGNS & GLASSWORKS INC, SIGNS & GLASSWORKS, INC.
Application year: 1991
Main classification: B05D1
IPC codes: B41M1, B42D15, B44F1, G09F13