Abstract:
A system and method for automatically applying a gel coat brush stroke pattern over an image surface secured to a support is described. A liquid gel applicator dispenses a predetermined quantity of transparent liquid gel on the image surface. A brush stroking machine is provided with a plurality of brush head modules which are connected to a reciprocating linkage. The linkage causes reciprocal arcuate displacement of bristles secured to the brush head modules. An adjustable support positions the bristles over the image surface for contact with the liquid gel dispensed thereon by the liquid gel applicator. A conveyor displaces the support with the image surface facing up under the liquid gel applicator and the bristles of the brush head modules along a straight axis whereby reciprocating displacement of the bristles imparts brush stroke patterns in the liquid gel over the image surface.

Description:
TECHNICAL FIELD 
       [0001]    A system and method for automatically applying a gel coat brush stroke pattern over an image surface secured to a support is described. 
       BACKGROUND ART 
       [0002]    Various techniques are known whereby to simulate an oil painting by using paper prints of the painting which are usually affixed to a support surface by gluing or lamination and treated to give the resemblance of a real painting. For example in one of my earlier patents I describe a process wherein a print is laminated on a film and then secured to canvass such as by gluing. The canvass is then mounted about a peripheral frame and held taut thereabout. From the rear of the frame a person can observe the canvass giving the impression that the print is either laminated directly on the canvass or is an authentic painting on canvass. To further simulate a real oil painting a gel coat can then be brush stroked on parts of the image surface or on all of the image surface. This technique of brush stroking with a clear varnish or gel coat is expensive if one attempts to simulate the brush strokes which are apparent in the authentic oil painting. However to reduce this labor cost, the technique now used is to apply sporadic varnish brush strokes on the printed image surface. This technique enhances the surface of the print by giving it texture such that a casual observer may see it as a natural oil painting. 
         [0003]    Another known technique of simulating an oil painting is described in U.S. Pat. No. 3,964,946, for example, wherein a photograph is glued onto a textured surface. The photograph is then roiled with a nubby roller to force portions of the photograph into the voids of the textured surface of the roller. After the rolling process is completed, a clear sealing lacquer is applied to the photograph surface and which, after drying, seals the surface for excluding moisture and dirt from the photograph. The clear lacquer liquid can be applied to the surface by a brush to simulate brush strokes or may be sprayed over the surface to provide a seal of the entire surface. The gel medium may also have an antique coloring whereby to simulate aging of the image. The gel medium or lacquer may also be applied over the entire surface and then, by the use of a brush or a cheese cloth or a paper towel, light circular motions are applied onto the gel to create a desired swirl effect to give it more texture. 
         [0004]    These examples of known techniques are all labour intensive and require special drying racks for the lacquer or gel material to set or cure on the image surface of the frame. Because these processes are labour extensive, most of these reproductions are now fabricated in China where labour costs and some material costs are relatively inexpensive. 
       SUMMARY OF INVENTION 
       [0005]    It is a feature of the present invention to provide a system and a method for automatically applying a gel coat brush stroke pattern over an image surface secured to a support and which substantially overcome the above mentioned disadvantage of the prior art. 
         [0006]    Another feature of the present invention is to provide a system and method for automatically applying a liquid gel over a surface of an image surface and to automatically apply brush stroke patterns into the gel coat over the entire surface and further wherein the gel coat is cured quickly in a drying machine in a successive step of the process. 
         [0007]    Another feature of the present invention is to provide a system for automatically applying a gel coat brush stroke pattern over an entire image surface secured to a support and wherein the brush stroke patterns contain different size brush strokes and wherein the texture of the brush strokes within the gel can be controlled to simulate oil paint reliefs over the image surface. 
         [0008]    According to the above features, from a broad aspect, the present: invention provides a system for automatically applying a gel coat brush stroke pattern over an image surface secured to a support. The system comprises a liquid gel applicator having control means to dispense a predetermined quantity of transparent liquid gel on the image surface. A brush stroking machine is also provided and it has a plurality of brush head modules connected to a reciprocating linkage, said brush head modules having bristles at a lower end thereof. Motion generating means is connected to the brush head modules to cause arcuate displacement of the brush bristles. Adjustable support means positions the bristles of the brush head modules over the image surface for contact with the liquid gel dispensed thereon by the liquid gel applicator. Displacement means is provided to cause relative displacement between the brush head modules and the image surface along a straight axis whereby reciprocating displacement of the brush head modules causes the bristles to impart brush stroke patterns in the liquid gel over the image surface. 
         [0009]    According to a further broad aspect of the present invention there is provided a method of automatically applying a gel coat brush stroke pattern on an image surface secured to a support. The method comprises the steps of applying a liquid gel on the image surface in a controlled amount by relative displacement between the image surface and a gel applicator positioned over the image surface and along a straight axis. The method further comprises the steps of providing a brush stroking machine having a first and second series of aligned brush head modules. The brush head modules have bristles at a lower end thereof. The brush head modules are disposed spaced-apart from one another along a first and second straight parallel axis transverse to said straight axis. The brush head modules along the first and second axes are laterally offset from one another in an overlapping relationship aligned with the straight axis. The relative displacement also causes displacement between the image surface with the liquid gel and the brush head modules while causing arcuate reciprocating motion of the bristles to cause the bristles to impart brush stroke patterns in the liquid gel over the entire image surface. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0010]    A preferred embodiment of the present invention will now be described with reference to the accompanying drawings in which: 
           [0011]      FIG. 1  is a schematic diagram illustrating the system and method of the present invention for automatically applying a gel coat brush stroke pattern over an entire image surface which is secured to a support; 
           [0012]      FIG. 2A  is a perspective view showing the gel coat applicator mounted on a support beam with a reciprocating connection; 
           [0013]      FIG. 2B  is a perspective view of a liquid gel dispensing module provided with a spray head or a bead with four bead dispensing nozzles; 
           [0014]      FIG. 3A  is a perspective view of the brush stroking machine having a plurality of brush head modules supported thereby and secured to a motor driven reciprocating linkage; 
           [0015]      FIG. 3B  is a side view of the brush stroking machine of  FIG. 3A ; 
           [0016]      FIG. 4  is a fragmented plan view illustrating the disposition of the brush head modules with respect to the image surface on which is deposited swirls of liquid gel and brush stroke patterns imparted by the bristles of the reciprocating axial displacement of the brush head modules; 
           [0017]      FIG. 5A  is a perspective view of a bristle attachment member provided with groups of bristles; 
           [0018]      FIG. 5B  is a view similar to  FIG. 5A  but wherein the bristles extend all along a circumferential axis of the attachment member; 
           [0019]      FIG. 6  is a perspective view of a frame having an image surface illustrating the shape of the gel pattern deposited thereon and the brush stroke patterns; 
           [0020]      FIG. 7  is a fragmented cross-section view showing a relief pattern formed in the gel by the bristles of the brush stroking heads; and 
           [0021]      FIG. 8  is a schematic illustration showing two series of brush head modules aligned in parallel relationship with the modules offset from one another and wherein the bristle heads are of different diameter sizes along one of the series of brush head modules. 
       
    
    
     DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0022]    Referring now to the drawings and more particularly to  FIG. 1  there is shown generally at  10  the system of the present invention for automatically applying a gel coat brush stroke pattern, as shown at  11  in  FIG. 6  over an entire image surface  12 ′ of a sheet  12  secured to a support  13 , as also shown in  FIG. 6 . The system  10  comprises a liquid gel applicator system  14  which is secured above a conveyor  15  which is driven by a variable drive motor  16 . The conveyor  15  is provided with attachment lugs or bars  17  whereby to convey the support frame  13  and its image surface facing up under the liquid gel applicator assembly  34 . These attachment bars  17  are displaceably secured to the conveyor belt whereby support frames of different sizes can be adapted to the conveyor. Alternatively, they could be fixed and spaced apart sufficiently to convey frames of different sizes. 
         [0023]    With further reference now to  FIGS. 2A and 2B , the liquid gel applicator assembly  14  is comprised of a series of independently controlled liquid gel dispensing modules  18  secured in side-by-side relationship on a support member  19 . The support member  19  is displaceably secured to a guide rail  20  whereby the support member  19  and the liquid gel dispensing modules can be axially reciprocated. The liquid gel dispensing modules are secured in side-by-side relationship along the entire width of the conveyor belt  15  and each module is independently detachable for replacement or servicing. The modules are also provided with valves  21  whereby they can be shut-off to dispense liquid gel  22  for only a certain width across the conveyor belt, the width corresponding to the width of the image surface which is to be conveyed thereunder. The valves  21  are pneumatic control valves whereby the liquid gel dispensing modules are precisely actuated and shut-off when a print with an image surface is conveyed thereunder to assure that gel is released only on the image surface. 
         [0024]    As shown in  FIG. 2B , each of the liquid gel dispensing modules  18  may be provided with a spray nozzle  23  depending on the liquid to be dispensed or with a head  24  having two or more, herein four, gel dispensing nozzles  2 S as used with the present invention. The head  24  is one inch long and the nozzles  25  are adapted to dispense gel along a Y, inch wide area. Each nozzle  25  is also independently controlled to be in an “on” or “off” state. Accordingly, the liquid gel released by the dispensing module  18  is adjustable in width within ¼ inch. As also shown in  FIG. 1  a reciprocating motor  27  is coupled to the support member  19  attached to the guide rail  20  by a suitable linkage. Liquid gel is contained in a reservoir  28  and supplies a manifold  29  to which the dispensing modules are supplied. A pump  30  maintains the pressure in the gel supply system and manifold. Sensors  31  are also suitably mounted in relation to the conveyor whereby to detect the leading edge and trailing edge of the support frames  13  and feed signals to the main controller  32  which controls the operation of the gel coat applicator modules in relation to the position of the image surface  12 ′. 
         [0025]    As hereinshown the applicator modules are reciprocated transversely of the axial direction of travel  39  of the support frames  13  and as soon as the leading edge  13 ′ of the frame  13  reaches a precise position under the liquid gel dispensing modules  18  liquid gel  22  is dispensed. Because the print is traveling at a controlled speed and the liquid gel dispensing modules are reciprocated, the gel will be deposited in swirl patterns  33 , as shown in  FIG. 6 , on the image surface and with the pattern of each nozzle  25  being disposed in side-by-side relationship. Accordingly, there are liquid gel beads deposited over the entire width and length of the image surface  12 ′ but as swirl beads. By controlling the speed of the variable drive motors  16  these patterns will become more compressed or elongated thereby controlling the amount of gel deposited over the entire image surface  12 ′. 
         [0026]    Following the application of the gel onto the image surface  12 ′, the frame with the image surface is then conveyed under a brush stroking machine  40  which is better illustrated with reference to  FIGS. 3A and 3B . The brush stroking machine  40  has a support frame  41  adapted to support an elongated support bar  42  over the conveyor  15 . A plurality of brush head modules  43  are secured to the support bar  42 . The brush head modules  43  are provided with bristles  44  at a lower end thereof. The brush head modules  43  have a cylindrical support body  45  which is axially rotatably retained in spaced-apart cylindrical bores  46  formed in the support bar  42 . As hereinshown, the brush head modules are retained in spaced-apart straight parallel axes  48  and  48 ′. A reciprocating linkage  47 , hereinshown in the form of a T-bar  49 , is supported between the two straight parallel axes  48  and  48 ′. The T-bar has opposed flanges  49 ′ and  49 ″ projecting from both sides thereof with the flanges being connected to respective ones of the cylindrical support bodies  45  of the brush modules whereby to axially rotate them in a reciprocating motion, in a clockwise and counter-clockwise direction. 
         [0027]    As shown in  FIG. 4 , the T-bar  49  is herein illustrated in phantom lines and as the T-bar reciprocates in a first direction indicated by arrow  50 , the cylindrical bodies along the parallel axis  48 ′ will be rotated clockwise as indicated by arrows  51  while at the same time the cylindrical bodies  45  along the other parallel axis  48  will be rotated in a counter-clockwise direction as indicated by arrows  52 . 
         [0028]    As further shown in  FIGS. 3A and 3B , the T-bar  49  is connected to a drive, herein an electric motor  53 , which is mounted on a support  54  and connected to the T-bar  49  by a suitable linkage, not shown but obvious to a person skilled in the art. Of course, when the T-bar is retracted in a direction opposed to the direction  50  as illustrated in  FIG. 4 , the heads will reverse their direction and thus the heads along the parallel axis  48 ′ will now be rotated in a counter-clockwise direction as indicated by arrows  51 ′ and the heads along the axis  48  will be rotated in a clockwise direction as indicated by arrows  52 ′. 
         [0029]    Referring now to  FIGS. 5A and 5B , it can be seen that the lower ends of the brush modules  43  have a removable bristle attachment  55 . These attachments  55  are equipped with bristles  56 . These bristles are secured along a diametrical axis or at least an arcuate portion of the diametrical axis of the bristle attachments  55  which have a circular shape head  55 ′. The bristles  56  can be provided as four individual bristle groups  56 ′ disposed transversely to one another along the diametrical axis  57  of the bristle attachment head  55 ′ or as a continuous bristle of circular shape  56 ″ as illustrated in  FIG. 5B  with bristles extending all along the diametrical axis  57 . These removable bristle attachments  55  are replaceably connected whereby different shapes or sizes of bristle heads may be provided or replaced as they become worn or removed for servicing or to create a different brush stroke effect. 
         [0030]    Referring again to  FIGS. 3A and 3B , there is shown a displacement means which causes vertical displacement of the support frame  42  thereby displacing the brush head modules or bristles relative to the image surface  12 ′ of a frame to be displaced thereunder. This displacement means is constituted by a gear box  60  secured on opposed sides of the support bar  42  and engageable with a toothed rack  61  secured to a respective one of the fixed lateral support walls  62  fixed to the vertical frame posts  41 ′ on opposed sides of the frame  41 . By rotating the handle  62  a connecting rod  63  is axially rotated and the support bar  42  can be vertically positioned. The handles  62  are interconnected together by a link belt  64  whereby the rods  63  can be rotated in unison. Accordingly, there is provided a means for adjusting the horizontal position of the support bar with respect to the conveyor and more importantly to the image surface  12 ′ of the frame  13 . This adjustment means can also be motor driven. 
         [0031]    The bristle heads  56  all lie in a substantially common plane, as shown more clearly in  FIG. 3B , and the displacement means, herein the handle  62  connected to the gear box  60  permits the adjustment and positioning of the brush heads  56  on the image surface or slightly above the image surface whereby to engage into the liquid gel swirl patterns  33 , see  FIG. 6 , thereby controlling the relief (the thickness of the gel) of the brush stroke patterns made in the liquid gel. 
         [0032]      FIG. 7  is an illustration of such relief pattern  65 . As hereinshown the relief pattern is comprised of irregular formations  66  formed in the gel brush stroke patterns  11  by the bristles with some of the gel forming peeks and valleys of irregular shape. This is to simulate brush stroke paint relief formed by a real oil painting. Therefore, one can appreciate that depending on the amount of gel deposited on the image surface  12 ′ and the spacing between the gel and the image surface  12 ′, this relief pattern can be modified wherein the brush strokes may provide a very thick surface, where the brush strokes are very pronounced and easily visible, or a very thin surface if the brushes are positioned very close to the image surface and less gel is deposited on the image surface. Therefore, a multitude of relief patterns can be created automatically by controlling the speed of the conveyor  15  to vary the amount of gel deposited on the image surface and by controlling the position of the bristle heads with respect to the image surface. 
         [0033]    With reference now to  FIG. 8 , it can be seen that in order to provide still different brush stroke effects over the image surface the bristle heads  56  along one or both of the parallel axes  48  and  48 ′ can be of different sizes such as bristle heads  56 ″ along axis  48 . The heads  56 ″ may also be spaced apart along an irregular pattern, that is to say the larger heads  56 ″ can be positioned after two or three of the regular heads  56  or in an alternating sequence or in any other sequence. This would simulate different brush stroke patterns imitating the use of different size brushes used by an artist having created the artwork represented on the image surface. 
         [0034]    It is also pointed of that the conveyor speed can control the shape of the brush stroke patterns whereby a slow speed would make the patterns more compressed and a higher conveyor speed will make the brush stroke patterns  11  more elongated. The speed of the reciprocating motor  53  can also modify the bristle stroke pattern. Also, the speed of the conveyor can be made variable along the length of the image surface whereby to impart into the gel brush stroke patterns of different lengths thereby further enhancing the brush stroke pattern effect to imitate a real painted image surface. Of course this can be programmed in the memory  32 ′ of the controller  32 . With such an arrangement there would need to be a different conveyor positioned under the brush stroking machine  40  and it would have to be synchronized with the conveyor  15 . 
         [0035]    With further reference now to  FIG. 1 , it can be seen that after the frame with the image surface has been entirely coated with brush stroke patterns  11 , the frame is conveyed by a transfer conveyor  70  or the same conveyor  15  into a UV dryer or curing machine  71  which has its own conveyor  72  operating at a controllable speed. Because the liquid gel has an ultraviolet curable agent therein, the ultraviolet UV curing machine  71  provided with ultraviolet lighting generating UV rays will quickly solidify the liquid gel as the frame  13  is conveyed through the curing machine  71 . The frame  13  is then automatically discharged from the curing machine onto a discharge conveyor  73  for packaging at another station. 
         [0036]    The system  10  of the present invention therefore provides a method of automatically applying a gel coat brush stroke pattern  11  on an image surface  12 ′ formed on a sheet  12  and secured to a support, such as the frame  13  shown in  FIG. 6 . Of course, the frame  13  can be a solid board and the sheet  12  can be laminated on canvass  68 , such as shown in  FIG. 7 , which is held taut over a peripheral frame  13  as is well known in the art. The method can therefore be summarized as comprising the steps of applying a liquid gel on an image surface in a controlled amount by relative displacement between the image surface and the gel applicator machine  20  positioned above the image surface and along the straight axis of conveyance of the frame by the conveyor  15 . The frame is then conveyed under a brush stroking machine whereby bristles are reciprocated to form brush stroke patterns into the gel coat entirely over the image surface. By adjusting the spacing between the bristles and the image surface one can create different relief patterns in the gel coat as is desirable and this may depend on the various images imprinted on the sheet  12  secured to the frame  13 , or other criteria. 
         [0037]    It is within the ambit of the present invention to cover any obvious modifications of the preferred embodiment described herein provided such modifications fall within the scope of the appended claims.