METHOD OF DECORATION

Abstract: A method of decorating an article, especially an article made of plastic material (for example, an acrylic bath panel). The method may involve the application of a decal (10), which contains sublimation inks, to the article. Alternatively, the method may involve the direct application of decorative material to the article. After the application of the decorative material to the article, the latter may be formed using conventional vacuum forming techniques or using injection moulding techniques. In all cases, the decorative material is caused to sublime so that it (at least in part) diffuses into the surface of the article to be decorated. A protective film may be applied to the article before the decorative material is applied; in such cases the decorative material sublimes through the protective film into the surface of the article.

Description: METHOD OF DECORATION This invention concerns a method of decoration, particularly but not exclusively a method of decorating items made of certain plastics materials, and/or a method of decoration using decals. Difficulties can be encountered when decorating many different items and materials. For example, with items such as plastics material baths, bath panels or the like, it would often be desirable to apply a decoration to the item. Such items being conventionally made of plastics materials such as acrylic. However, using conventional techniques it is difficult to provide a decoration on such material which is durable and would not be worn away during use and/or cleaning of the item. Furthermore, such items are generally provided with a protective layer of a plastics material film such as polyethylene. This layer is applied during manufacture of the plastics material, usually into sheets of material and is desirably only removed at the latest possible opportunity for example after a bath has been installed in a building. To provide a decoration on the item by conventional methods would require removal of the protective layer at an earlier date, thereby increasing the possibility of the item becoming damaged prior to use. For example, damage can readily occur during installation of an item. Al ernatively, some other form of protection such as a further layer would be required to be applied following decoration. According to the present invention there is provided a method of decoration, the method comprising applying a decorative material onto a surface of a member, and heating the member such that at least part of the decorative ma erial diffuses into the member whilst still being visible through said surface. Preferably the member is heated subsequently to application of the decorative material thereon. The decorative material is preferably applied onto a remo able protective layer on the member, and during said heating at least part of the decorative material passes through the layer to diffuse into the member. The protective layer preferably comprises a plastics material film such as polyethylene. Alternatively the protective layer may comprise paper, which may be coated with for example polypropylene or si licone . The member is preferably made of a plastics material such as an acrylic, polypropylene or ABS ( aery loni t ri 1 e butadiene styrene). The subsequent heating of the member may take place during forming of an article from the member. The article may be formed by vacuum forming. Alternati ely, the decorative material may be applied to a member during injection moulding thereof, such that the heating is provided by the moulding process . The member may alternativel comprise other materials, for example wood or steel, and said materials may be provided with a coating which may comprise a plastics material, such as for example powder coated steel . The decorative material may be applied in the form of a decal. The decal is preferably flexible. Any backing paper for the decal is preferably removed prior to heating of the member. The decal preferably includes a water soluble, pressure sensitive and/or heat sensitive adhesive engageable with the member. The decal may be of the water slide type, comprising a removable backing paper or support layer releasably held on the decal by a water actuable adhesive . Alternatively the decal may be of the heat release type, with a first heat sensitive adhesive on the design layer for adhering the decal to an article to be decorated, and a further heat sensitive adhesive releasably holding a backing paper or support layer on the decal . As a further alternative, the decal may comprise a pressure sensitive adhesive on the design layer, and a further adhesive releasably holding the backing paper or support layer on the decal. Said further adhesive may be water soluble. As a still further alternative, no adhesive may be provided on the design layer of the decal but adhesive may be applied on to the member, preferably by spraying, prior to the decal being applied thereto. The backing paper may be held on said decal by any of a heat sensitive adhesive, a water actuable adhesive, or a pressure release adhesive which permits the backing paper to be peeled off. The invention also provides a decal usable in a decorative material according to any of the preceding si paragraphs. In an alternative arrangement the decorative material may be applied directly onto the member, by for example screen or ink jet printing. The surface of the member may be prepared prior to printing, by for example application of a primer. The decorative material preferably comprises one or more inks which sublime. The decorative material preferably comprises inks in the form of organic dyes which are stable at the temperature the member is heated to. Plasticisers may be provided in the inks, and/or where the decorative material is in the form of a decal, in the carrier layer . A heat absorbing material may be provided at selective areas on the decorative material where high colour intensity is required. The heat absorbing material is preferably particulate and insoluble, and may comprise carbon black. Where the decorative material is in the form of a decal, the heat absorbing material is preferably provided in the carrier layer. The invention further provides a member or article decorated by a method according to any of the preceding eighteen paragraphs. Embodiments of the present invention will now be described by way of example only, with reference to Figs. 1 to 3 of the accompanying drawings, which respectively show diagrammatic sectional views of first, second and third decals according to, and usable in methods according to, the invention. A decorated bath panel is made by the following method. A sheet of acrylic with a polyethylene protective film on at least one side is mounted on a frame. A decorative pattern of decals is applied onto the plastics film so as to adhere thereto, and the backing paper for the decals is removed. The decals comprise a required pattern of inks and may be in the form of any of the first, second or third decals as will be hereinafter described. The framed sheet is placed on a vacuum plate with the decorated side upwards. Heating units are located over the top of the sheet and switched on to apply a temperature of between 130 and 220°C. The particular temperature chosen depends on the grade of acrylic material used and/or the colour intensity required. Once a required plasticity of the acrylic is obtained suction is applied to the appropriate parts of the vacuum plate to suck the now plastic sheet into a required shape. Once this shape is achieved cold air is blown onto the shaped sheet to regain rigidity, and the sheet is subsequently removed from the plate and frame. During heating of the sheet to provide and maintain the required plasticity, the inks in the decal volatilise and part thereof passes through the polyethylene film and diffuses into the surface of the sheet. The bath panel thus formed still has a protective film and this protective film would usually only be removed following installation of the panel in a bathroom. Removal of the protective film with any decorative material left thereon will reveal a decoration on the bath panel which whilst visible, is not formed directly on the surface of the panel and therefore cannot be readily worn away. Following removal of the film, excess decorative materials on the bath panel can be cleaned off with a suitable solvent or detergen . There is thus described a method of decorating an article, in this instance a bath panel, which provides a durable decoration which is not formed directly on the surface of the panel. This method of decoration can be combined with the vacuum forming method used to shape the article. This decorative method permits the protective film on the acrylic material to be retained until after installation. The drawings show three decals usable in this method. The first decal 10 is of the water slide type. The decal 10 comprises a conventional water slide decal paper 11. Provided on the paper 11 is a layer of water soluble gum 12. Provided on the layer 12 is a carrier layer 13 in the form of a water insoluble acrylic such as Synocryl 9123S (TM) available from Cray Valley Products. A plasticiser may be provided in the carrier layer. The plasticiser may comprise phthalate, adipate or other esters . Provided on the layer 13 is an appropriate design layer 14. The layer 14 comprises organic dyes dispersed in a carrier such as an acrylic solution or emulsion. The organic dyes may be in the form of inks such as Sericol Subliscreen (TM). Inks which sublime have been found to be particularly appropriate for use with this method. A plasticiser may also be provided in the layer 14. Plasticisers have been found to increase colour intensity in the decorated product and assist movement/diffusion of the inks into the plastics materials and particularly through the protective layer. In use, the paper 11 would be removed from the decal 10 by sliding, using water to release the paper 11 from the layer 12. The decal 10 can then be positioned on an article with the layer 12 providing adhesion onto the article . Fig. 2 shows a heat release decal 20. The decal comprises a conventional decal paper 21. On the paper 21 a layer 22 of a first heat sensitive adhesive is provided. The layer 22 comprises: a wax such as paraffin or microcrystalline wax; a tackifier such as a rosin ester e.g. Staybelite (TM); an adhesive such as vinyl acetate e.g. Elvax (TM); and non-blocking additives such as micronised waxes. A carrier layer 23 is provided above the layer 22, of a similar type to the layer 13. A design layer 24 again of a similar type to the layer 14 is provided on the layer 23. A heat adhesive layer 25 is provided on the layer 24. The layer 25 comprises a polyethylene glycol wax with a melting point of around 60-70°C. In use, the decal 20 is heated to melt the adhesive of the layer 25. The decal 20 is then placed on an article to be decorated, with the layer 25 against the article, and providing adhesion thereto. The decal 20 can then be "ironed" onto the article with the further heat melting the adhesive in the layer 22 and 416 - 1 0 - permitting removal of the paper 21. Fig. 3 shows a third decal 30. The decal 30 comprises a decal paper 31 similar to the paper 11. A release layer 32 similar to the layer 12 is provided on the paper 31. A carrier layer 33 is provided on the layer 32. The layer 33 may comprise modified cellulose such as cellulose acetate butyrate, or a similar layer to the layer 13 could be used. A design layer 34 similar to the layer 14 is provided on the layer 33. A pressure sensitive adhesive layer 35 is provided on the layer 34. The pressure sensitive adhesive may comprise an adhesive such as Sericol Drystick Extra (TM). In use, the decal 30 is placed on an article to be decorated and "ironed" without heat thereonto to activate the layer 35. The paper 31 can subsequently be removed using water to activate the layer 32. With the decal 30 it is possible to use a very thin carrier layer 33 which is advantageous as the decal 30 is required to stretch and distort during the forming process. The decals 30 can be stored interleaved with silicone paper. As a further alternative, a decal (not shown) could be used without any adhesive on the design layer. With such a decal adhesive would be applied onto the article, probably by spraying a "spray mount" type adhesive, and the decal placed onto the adhesive. The backing paper may be held on by any of a heat sensitive, water actuable or pressure release adhesive, and removed accordingly. In the latter case the backing paper can simply be peeled off. The i n vention can be used other than with vacuum forming. For example, with injection moulding it may be possible to provide a decal in a mould such that the decoration on the decal is taken up by plastics material placed into the mould, with the heat of moulding providing the required diffusion of the inks into the plastics material. Heat could be applied other than during forming of an article. The heat could be applied as a separate stage. Where the decal is to be applied prior to forming of an article, a flexible decal is required. Methods according to the invention can be used to decorate other materials such as for example, polypropylene or A8S. The latter may be used as tubing for use for example in plumbing. Here the decorative method may be used for providing a marking rather than an aesthetic decoration. The method is usable with materials other than plastics material. For example coated metals such as powder coated steel could be decorated. Wood could also be decorated using this method with for example a plastics coating, or when uncoated for example if varnished. The decorative material may be applied other than as a decal. For example, the decorative material could be applied directly by screen or ink jet printing. A primer may be applied prior to printing. Whilst in the above described example a decorative material is applied to a protective film, the material can in many instances be applied directly onto an article to be decorated. Further the material can be applied onto a wide range of protective films, which may comprise papers. However, the invention provides the advantage of enabling a protective layer to be maintained if required. Various other modifications may also be made without departing from the scope of the invention. For instance, a heat absorbing material may be provided at selective locations on the decorative material to provide enhanced colour intensity. The heat absorbing material is preferably particulate and insoluble such that it does not pass through the protective layer nor into an article being decorated. A suitable heat absorbing material is carbon black which in a decal could be provided in the carrier layer. Whilst endeavouring in the foregoing specification to draw attention to those features of the invention believed to be of particular importance it should be understood that the Applicant claims protection in respect of any patentable feature or combination of features hereinbefore referred to and/or shown in the drawings whether or not particular emphasis has been placed thereon.

Claims: CLAIMS 1. A method of decoration, the method comprising applying a decorative material onto a surface of a member, and heating the member such that at least part of the decorative material diffused into the member whilst still being visible through said surface. 2. A method according to claim 1, in which the member is heated subsequently to application of the decorative material thereon. 3. A method according to claims 1 or 2 , in which the decorative material is applied onto a removable protective layer on the member, and during said heating at least part of the decorative material passes through the layer to diffuse into the member. 4. A method according to claim 3, in which the protective layer comprises a plastics material film. 5. A method according to claim 4, in which the protective layer comprises polyethylene. 6. A method according to claim 3, in which the protective layer comprises paper. 7. A method according to claim 6, in which the protective layer is coated. 8. A method according to claim 7, in which the protective layer is coated polypropylene or silicone. 9. A method according to any of the preceding claims, in which the member is made of a plastics material. 10. A method according to claim 9, in which the member is made of an acrylic. 11. A method according to claim 2 or any of claims 3 to 10 when dependent on claim 2, in which the subsequent heating of the member takes place during forming of an article from the member . 12. A method according to claim 11, in which the article is formed by vacuum forming. 13. A method according to claim 2 or any of claims 3 to 10 when not dependent on claim 2, in which the decorative material is applied to a member during injection moulding thereof, such that the heating is provided by the moulding process . 14. A method according to any of claims 1 to 8, in which the member comprises materials other than plastics material . 15. A method according to claim 14, in which the member comprises wood or steel. 16. A method according to claims 14 or 15, in which said materials are provided with a coating. 17. A method according to claim 16, in which the coating comprises a plastics material. 18. A method according to claim 17, in which the materials comprise powder coated steel. 19. A method according to any of the preceding claims, in which the decorative material is applied in the form of a decal. 20. A method according to claim 19, in which the decal is flexible. 21. A method according to claims 19 or 20, in which any backing paper for the decal is removed prior to heating of the member. 22. A method according to any of claims 19 to 21, in which the decal includes a water soluble, pressure sensitive and/or heat sensitive adhesive engageable with the member. 23. A method according to any of claims 19 to 22, in which the decal is of the water slide type, comprising a removable backing paper or support layer releasably held on the decal by a water actuable adhesive. 24. A method according to any of claims 19 to 22, in which the decal is of the heat release type, with a first heat sensitive adhesive on the design layer for adhering the decal to an article to be decorated, and a further heat sensitive adhesive releasably holding a backing paper or support layer on the decal. 25. A method according to any of claims 19 to 22, in which the decal comprises a pressure sensitive adhesive on the design layer, and a further adhesive releasably holding the backing paper or support kayer on the decal. 26. A method according to claim 25, in which said further adhesive is water soluble. 27. A method according to any of claims 19 to 26, in which no adhesive is provided on the design layer of the decal but adhesive is applied on to the member prior to the decal being applied thereto. 28. A method according to claim 27, in which adhesive is applied on to the member by spraying. 29. A method according to claims 27 or 28, in which the backing paper is held on said decal by any of a heat sensitive adhesive, a water actuable adhesive, or a pressure release adhesive which permits the backing paper to be peeled off. 30. A decal usable in a method of decoration according to any of claims 19 to 29. 31. A method according to any of claims 1 to 18, in which the decorative material is applied directly onto the member . 32. A method according to claim 31, in which the decorative material is applied by screen or ink jet printing. 33. A method according to claims 31 or 32, in which the surface of the member is prepared prior to printing. 34. A method according to claim 33, in which the surface of the member is prepared by application of a primer. 35. A method according to any of the preceding claims, in which the decorative material comprises one or more inks which sublime. 36. A method according to claim 35, in which the decorative material comprises inks in the form of organic dyes which are stable at the temperature the member is heated to. 37. A method according to claims 35 or 36, in which plasticisers are provided in the inks, and/or where the decorative material is in the form of a decal, in the carrier layer. 38. A method according to any of the preceding claims, in which a heat absorbing material is provided at selective areas on the decorative material where high colour intensity is required. 39. A method according to claim 38, in which the heat absorbing material is particulate and insoluble. 40. A method according to claims 38 or 39, in which the heat absorbing material comprises carbon black. 41. A method according to any of claims 38 to 40 when dependent on at least claim 19, in which the heat absorbing material is provided in the carrier layer. 42. A member or article decorated by a method according to any of the preceding claims. 43. A method of decoration substantially as hereinbefore described with reference to Fig. 1 of the accompanying drawings . 44. A method of decoration substantially as hereinbefore described with reference to Fig. 2 or the accompanying drawings . 45. A method of decoration substantially as hereinbefore described with reference to Fig. 3 or the accompanying drawings . 46. A decal substantially as hereinbefore described with reference to Fig. 1 or the accompanying drawings. 47. A decal substantially as hereinbefore described with reference to Fig. 2 or the accompanying drawings. 48. A decal substantially as hereinbefore described with reference to Fig. 3 of the accompanying drawings. 49. Any novel subject matter or combination including novel subject matter disclosed, whether or not within the scope of or relating to the same invention as any of the preceding claims. AMENDED CLAIMS [received by the International Bureau on 8 February 1998 (08.02.98); original claims 1-49 replaced by new claims 1-11 (2 pages)] 1. A method of decoration of a member made of a plastics material, the method comprising applying a removable protective layer bearing decorative material onto a surface of the member, subsequently heating said member in conjunction with the applied protective layer so that at least part of the decorative material borne by the protective layer is thereby diffused from the protective layer into into the member, and when the protective layer is no longer required removing it from the member leaving the diffused decorative material still visible through its surface. 2. A method as claimed in claim 1 , in which the protective layer comprises a plastics-material film. 3. A method as claimed in claim 1 or claim 2, in which the protective layer comprises paper, preferably coated with polypropylene or silicone. 4. A method as claimed in any of the preceding claims, in which the member is made of an acrylic plastics material. 5. A method as claimed in any of the preceding claims, in which the heating of the member subsequent to application of the decoration-bearing protective layer takes place during vacuum-forming of an article from the member. 6. A method as claimed in any of the preceding claims, in which the member also comprises materials other than plastics materials. 7. A method according to any of the preceding claims, in which the decorative material is applied to the protective layer in the form of a flexible decal, and in which any backing paper for the decal is removed prior to heating of the member in conjunction with the protective layer. 8. A method as claimed in any of the preceding claims, in which the decorative material comprises one or more inks in the form of organic dyes which are stable but sublime at the temperature to which the member is heated. 9. A method as claimed in claim 8, in which plasticisers are provided in the inks and/or in the carrier layer of a decal. 10. A method as claimed in any of the preceding claims, in which a particulate and insoluble heat-absorbing material, which preferably is or includes carbon black, is provided where high colour-intensity is required. 11. A method as claimed in claim 10, in which the heat-absorbing material is provided in the carrier layer of a decal.

Inventors: EVANS TIMOTHY BARRETT, EVANS, TIMOTHY, BARRETT
Applicants: EVANS TIMOTHY BARRETT, WAVENEY PLASTICS LTD, EVANS, TIMOTHY, BARRETT, WAVENEY PLASTICS LTD.
Application year: 1996
Main classification: B44C1
IPC codes: B41M5, B44C1