Abstract:
An eye-catching bold sign and method of making same wherein the sign has a digital, near-photographic image applied, using a digital file, to a transparent polymeric substrate. The sign further incorporates solid block or defined shapes that may be transparent, translucent, semi-translucent, or opaque. The shapes are defined by the same digital file and may be formed by layers of metallic or non-metallic paint, adhesive vinyl sheet, or discreet portions of either paint or vinyl sheet. The shapes are defined by selective removal of areas of an opaque backing.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     None 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not Applicable. 
     BACKGROUND OF THE INVENTION 
     This invention relates to a sign or signage, and in particular to signage incorporating a transparent substrate with a graphic on its rear face, the graphic being viewed through the substrate. 
     It is well-known in the art to make a sign with a polymeric substrate such as, for example, a sheet of polycarbonate. This substrate is sufficiently transparent to enable a graphic placed on its rear face to be viewed through the substrate. Such signs are widely used indoors and outdoors. They may be backlighted, but they need not be. 
     One type of such signs is made by applying a near-photographic quality image to the substrate. Near-photographic quality signs are typically produced from a digital data file by applying the image as a series of dots or pixels in accordance with the data file. As used herein, near-photographic quality means that the viewer is presented with an image which, at a particular viewing distance, appears very similar to a photograph. In common usage for signs viewed at stores, displays, and tradeshows or the like, near-photographic quality images have at least one hundred thousand individual dots or pixels, more preferably at least one million or more pixels. 
     One method for applying such an image uses a transfer process, such as with a machine made by the Xerox Corporation, the 950 Series II. A second method uses an RGB laser such as a Lambda machine made by the Durst Company of Germany. A third method uses an electrostatic process. A fourth method uses an ink jet printer to apply an image. In applying a near-photographic image, a computer-based digital file is typically utilized which directs whatever process applies the pixels to create the image. Each of these is known in the art. Further known in the art is the method of applying ink films to a material, as disclosed in U.S. Patent Blake, et al., U.S. Pat. No. 5,144,328; Helinski, U.S. Pat. No. 4,666,757; and Abe, et al., U.S. Pat. No. 5,072,304; these being incorporated by reference herein. 
     The image is typically applied on a reverse side of a generally optically clear substrate, so as to be viewed through the substrate from the front side. In order for the image to adhere properly to the substrate, typically a coating is applied to the side of the substrate on which the image is placed. Once an image is applied to the substrate, the image is typically permanently affixed by a protective polymeric layer in the form of a sheet applied over the image, laminating the image between two layers of polymeric material. If the desired resulting sign is opaque, a solid white layer is first applied to the rear surface of the protective layer to balance the colors, and then an opaquing layer is applied, typically solid gray in color. 
     Such signs may capture minute detail, but the pigments used in applying the image typically lack eye-catching intensity and boldness. 
     An entirely different type of laminated polymeric sign is also known in the art, on which bold, eye-catching shapes, such as block letters or designs, of a contrasting material are affixed to the substrate. Signs and methods of making them using variations of this process are disclosed in U.S. Patent, Collins, et al., U.S. Pat. No. 4,440,590; Logan, U.S. Pat. No. 5,277,736; Logan, U.S. Pat. No. 5,288,358; and Coplan, U.S. Pat. No. 5,352,314, and are incorporated by reference herein. 
     In an example of making such signs, shapes are cut into a vinyl sheet with one side having a pressure-sensitive adhesive and a backing. This may be done by hand, by a computer-controlled X-Y plotter-cutter such as the Roland Digital Group CAMM-1, PNC-1850, or by any other method. In this method, cutting is done through the vinyl sheet without cutting through the backing. The sheet is then “weeded,” that is, the portions of undesired vinyl are removed from the backing. Next, an adhesive tape, commonly referred to as transfer or application tape, is applied to the non-tack side of the remaining vinyl portions. The backing of the vinyl sheet is then removed, exposing the pressure-sensitive adhesive of both the desired vinyl portion and the transfer tape. Each vinyl shape remains properly aligned on the transfer tape. 
     In order to apply the desired vinyl portions to the sign substrate, typically water with a mild soap is sprayed onto the rear surface of the sign substrate. Both the transfer tape and desired portions are applied on top of the soapy water. The adhesive of both is able to partially adhere to the substrate despite the soap, though not very well. This allows the alignment of the vinyl pieces as a group to be adjusted. Once proper positioning of the group of pieces is achieved, the transfer tape and desired vinyl portions are held in place, typically both adhesively and manually, while the soapy water is squeegeed or pressed from between the substrate and the adhesives. After the water has been removed, the transfer tape is peeled from the substrate while the vinyl portions remain affixed to the substrate. 
     This second method may be modified to produce signs with different colored elements. For instance, the process may be repeated with a second, different colored sheet of vinyl. In addition, the sign may sprayed with a paint of a particular color, as well as a metallic color. 
     Signs made by this method are typically bold and eye-catching, but they lack fine details and nuanced design. 
     BRIEF SUMMARY OF THE INVENTION 
     One of the objects of the present invention is to provide a sign that is both detailed and eye-catching. 
     Another object is to provide methods of producing such a sign. 
     In accordance with one aspect of the present invention, generally stated, a sign is provided comprising a first transparent sheet, an image media layer applied to one side of the sheet, and an opaquing layer behind the image media layer, the opaquing layer comprising at least one blank portion defining at least one discrete non-opaque element. The term sheet is used broadly herein to include sheets of various thicknesses, from films to rigid sheets. Preferably, the transparent sheet is polymeric, but it may be glass or other material. 
     Preferably, the sign further comprises a white layer between the image media layer and the opaquing layer, the white layer including at least one opening corresponding to the discrete non-opaque element. 
     The preferred sign further comprises a translucent third polymeric sheet applied to the opaquing layer to protect that layer from abrasion or other damage and to give a bold, eye-catching appearance to the discrete non-opaque element or elements. Preferably, the third polymeric sheet applied is a continuous sheet of adhesive vinyl. 
     Preferably, the image media layer is a near-photographic quality image applied using a digital file. In the preferred embodiment, the near-photographic quality image is applied by a wide-carriage color ink-jet printer. Other well-known methods that could be utilized include digital photographic methods, direct electrostatic methods, and electrostatic transfer methods. The particular method of applying the image is not critical to the broader aspects of the invention, although it is preferred that the image be generated from a digital file. The image is preferably full color. 
     In the preferred embodiment and in accordance with another aspect of the invention, the at least one non-opaque element is shaped by a digital plotter and preferably corresponds to at least one pre-determined portion of the image media layer. It is preferred that the same, single digital file is used to apply the image media layer and to shape the at least one non-opaque element, although different portions of the file may be extracted and manipulated differently. Preferably, the sign further includes a plurality of non-opaque elements corresponding one-to-one to a plurality of pre-determined portions of the image media layer. 
     In one embodiment, at least one of the non-opaque elements is covered with metallic paint. It will be seen that in some instances the metallic paint will be opaque and will render opaque the non-opaque element of the completed sign. It will also be seen that in other instances the metallic paint may be non-opaque. In another embodiment, at least one of the non-opaque elements is covered with a translucent layer and preferably the translucent layer is an adhesive vinyl sheet. In another embodiment, a plurality of the non-opaque elements are covered with a translucent layer, at least one of which is further covered with a second translucent layer. The second translucent layer is white. The non-opaque elements generally correspond to portions of the image media layer which are intended to be emphasized. Illustrative of such elements are letters, numbers, logos, lighted elements, such as windows or streetlights, or product images. The discrete elements may also be image elements such as colors or textures that cannot be applied by the image media layer applicator, e.g., an ink jet printer. 
     In accordance with a second aspect of the present invention, generally stated, a method of making a sign is provided, the steps comprising applying an image media layer to a first transparent sheet; and applying an opaquing layer behind the image media layer, the opaquing layer comprising at least one blank portion defining at least one discrete non-opaque element. Preferably, the method includes applying a second polymeric sheet to the image media layer. Preferably, the method includes applying a white layer behind the image media layer before applying the opaquing layer. In one embodiment, the method further includes applying a translucent layer to at least one non-opaque element. In a further embodiment, the method includes applying a layer of metallic paint to at least one non-opaque element. 
     In accordance with another aspect of the invention, the method includes applying a near photographic quality image media layer, using a digital file, to the first transparent polymeric sheet and applying a first adhesive sheet material shaped by a digital plotter and the digital file as to correspond to predetermined portions of the image media layer. Preferably, the method further comprises applying an opaquing layer to the image media layer and semi-translucent material, and removing at least a portion of the semi-translucent material to define non-opaque elements. In a further embodiment, this method further includes applying a semi-translucent layer generally white in color to the adhesive semi-translucent material and to the image media layer and includes applying the opaquing layer to the semi-translucent layer generally white in color. In one embodiment, the method further comprises applying a second semi-translucent material to the opaquing layer and the non-opaque elements. In another embodiment, the method includes applying metallic paint to the non-opaque elements. In another embodiment, the method includes applying a second transparent polymeric sheet to the image media layer; and applying a first adhesive semi-translucent material to the second transparent polymeric sheet, the material shaped by a digital plotter and the digital file to correspond to predetermined portions of the image media layer. 
     In accordance with another aspect of the present invention, a method of making a sign is disclosed, the steps including applying a near photographic quality image media layer using a digital file to a first transparent polymeric sheet, applying a second transparent polymeric sheet to the image media layer, spraying the second transparent polymeric sheet with an adhesive retarding fluid, applying a first adhesive semi-translucent material to the sprayed second transparent polymeric sheet so as to correspond to predetermined portions of the image media layer, the material being shaped by a digital plotter and the digital file, squeegeeing the fluid from between the semi-translucent material and the polymeric sheet, applying an opaquing layer to the first adhesive semi-translucent material and the second transparent polymeric sheet, and removing at least a portion of the first adhesive semi-translucent material so as to define non-opaque elements. In one embodiment, the method includes applying a layer of metallic paint to at least one non-opaque element. In another embodiment, the method includes applying a second adhesive semi-translucent material to at least one non-opaque element. This method preferably includes applying a semi-translucent layer generally white in color to the first adhesive semi-translucent material and the second transparent polymeric sheet. 
     Other aspects of the invention will become apparent in view of the following description and claims. 
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
     In the drawings, FIG. 1 is a front plan view of a sign made in accordance with the present invention; 
     FIG. 1A is an enlarged view of the section of the sign of FIG. 1 labeled as A; 
     FIG. 2 is a rear perspective view of a polymeric substrate and an applied image illustrating a first step in making the sign of FIG. 1; 
     FIG. 3 is a front plan view of the polymeric substrate and applied image of FIG. 2; 
     FIG. 4 is a rear perspective view of the polymeric substrate and applied image of FIGS. 2 and 3, with a laminate being applied; 
     FIG. 5 is a front perspective view of a sheet of adhesive polymeric sheet with selected shapes cut into the sheet for use in forming the sign of FIG. 1; 
     FIG. 6 is a front perspective view of a weeded sheet of the adhesive polymeric sheet of FIG. 5 showing the backing of the sheet; 
     FIG. 7 is a front perspective view of the sheet of FIG. 6 with transfer tape applied; 
     FIG. 8 is a is a plan view of the transfer tape of FIG.  7  and selected cut shapes of FIG. 5; 
     FIG. 9 is a is a rear perspective view of the polymeric substrate of FIG. 1 with an applied image being sprayed with a tack-retardant fluid; 
     FIG. 10 is a rear perspective view of the polymeric substrate of FIG. 9 with the transfer tape of FIG. 8 being applied; 
     FIG. 11 is a rear perspective view of the polymeric substrate of FIG. 10 with transfer tape being removed; 
     FIG. 12 is a rear perspective view of the polymeric substrate of FIG. 11 with two layers of paint; 
     FIG. 13 is a rear perspective view of the polymeric substrate of FIG. 12 with a selected portion of the selected shapes removed; 
     FIG. 14 is a rear perspective view of the polymeric substrate of FIG. 13 with an additional layer of paint; 
     FIG. 15 is a rear perspective view of the polymeric substrate of FIG. 14 with additional selected portions of the selected shapes removed; and 
     FIG. 16 is a rear perspective view of the polymeric substrate of FIG. 15 with an additional polymeric sheet being applied. 
    
    
     Corresponding reference numerals will be used throughout the several figures of the drawings. 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The following detailed description illustrates the invention by way of example and not by way of limitation. This description will clearly enable one skilled in the art to make and use the invention, and describes several embodiments, adaptations, variations, alternatives and uses of the invention, including what I presently believe is the best mode of carrying out the invention. 
     Referring initially to FIG. 1, a sign  10  of the present invention is depicted. The sign  10  is permanent and formed of a generally transparent polymeric substrate  12 , preferably polycarbonate with a thickness of 8-10 mils. The sign  10  presents to an observer an image  14 , generally extending to the boundaries of the substrate  12 , which may incorporate one or more of some or all of the following: an opaque media image  16  (represented by the area depicting several items and representing a digital image extending to the boundaries of the substrate  12  in this FIG. 1 only); opaque design area  18 ; a generally transparent design area  20 ; a generally translucent design area  22 ; and a painted design area  24 . 
     Referring now to FIG. 2, the substrate  12  is depicted. The substrate  12  has a front side  30  presented to the viewer and a back side. 32 . Applied to the back side  32  of the substrate  12  is an image media layer  36 , specific details of which are depicted with a dashed line. The image media layer  36  is near-photographic quality, preferably applied by an ink jet printer so as to be ink dots resulting in a generally transparent or translucent image. The image media layer  36  is a digitized image contained in a digital file applied by a computer-controlled apparatus. In order to maximize the adherence of the image media layer  36 , a coating  38  is applied to the substrate  12  during its manufacturing process. One example of the preferred substrate  12  and coating  38  is available under the tradename Lexjet. 
     As depicted in FIG. 2, the image media layer  36  is typically applied to the substrate  12  in the reverse of the desired image presented to a viewer as to be viewed through the substrate  12 . Referring now to FIG. 3, the substrate  12  is shown from the viewer&#39;s perspective with the image media layer  36  visible through the substrate  12 . The image media layer  36  contains image details or designs  40 . These image designs  40  may be places where no image media layer  36  was applied to the substrate  12 , or may be portions of the image media layer  36  which are of particular interest. 
     The image media layer  36  is preferably protected from contact or abrasion. Accordingly, as depicted in FIG. 4, a generally transparent laminate  46  is applied onto the image media layer  36 . The laminate  46  may be applied through a number of processes, such as using pressure-sensitive adhesive or using a heat process. 
     FIG. 5 shows a polymeric sheet  50  of a particular color C, one side of which has a high-tack adhesive  52  covered with a backing  54 . The polymeric sheet  50  is preferably made of vinyl. As the image media layer  36  was applied to the substrate  12  from a digital file, the same digital file is used to cut sheet designs  56  into the polymeric sheet  50 , the polymeric sheet preferably being cut by an X-Y plotter-cutter as discussed above as to cut the vinyl but not the backing  54 . Thus, the backing  54  remains adhered to both the desired sheet designs  56  and the undesired portion of the polymeric sheet  50 . The sheet designs  56  are cut in the reverse so as to correspond to the laminate back side  58  (FIG.  4 ). 
     The polymeric sheet  50  is then weeded. By weeding, the undesired portion of the polymeric sheet  50  is removed while the desired sheet designs  56  remain adhered to the backing and remain properly aligned with respect to each other. As can be seen in FIG. 6, the desired sheet designs  56  are depicted adhered to the backing  54 . 
     As shown in FIG. 7, a masking-type tape, commonly referred to as transfer or application tape  60  with a low-tack adhesive  62 , is applied as to cover the sheet designs  56 . The backing  54  is then peeled away from the transfer tape  60 , exposing the adhesive side  52  of the sheet designs  56  and the tape adhesive  62 , as is shown in FIG.  8 . 
     The adhesive side  52  of the sheet designs  56  is of a higher-tack than the tape adhesive  62 . The placing of the sheet designs  56  on the laminate  46  is typically done manually and needs to allow slight manual shifting of the sheet designs  56  before adherence is permanent. To facilitate this manual shifting, the laminate back side  58  is prepared first by spraying a thin layer of tack-retarding liquid, preferably water with a dissolved mild soap, to the back side  58  of the laminate  46 , as depicted in FIG.  9 . If the laminate  46  is not present, the tack-retarding liquid may be sprayed directly onto the image media layer  36 . As is obvious, if the laminate  46  is not present and the image media layer  36  is water soluble ink, the tack retarding liquid should not be sprayed on the image media layer  36 . 
     Referring to FIG. 10, the adhesive side  52  of the sheet designs  56  and the tape adhesive  62  are placed against the back side  58  of the laminate  46 , and the sheet designs  56  are properly aligned with the image designs  40 . Once the alignments is completed, adherence is strengthened between the sheet designs  56  and the laminate  46  by pressing them together. The soapy water mixture is then squeegeed out from underneath the transfer tape  60 . During this squeegeeing, one may desire to manually hold the transfer tape  60  firmly in place. Once the soapy water has been removed, the transfer tape  60  is peeled off, as is shown in FIG.  11 . 
     As noted above, the tape adhesive  62  of the transfer tape  60  has a lower tack than the adhesive side  52  of the sheet designs  56 . The soapy water acts as a tack-retarding fluid, hindering the adhesion of both the adhesive side  52  and the tape adhesive  62  allowing these to be properly positioned without adhering strongly until after the soapy water is squeegeed. Once the water has been squeegeed, the transfer tape  60  may be peeled away. Because of the tack of the transfer tape  60  is lower than the adhesive side  52 , the sheet designs remain affixed to the laminate  46 . 
     As the image media layer  36  is generally transparent or translucent, the colors are not balanced, instead varying depending on the backdrop or lighting. Accordingly, as is shown in FIG. 12, a solid white layer  72  is applied to the back side  58  of the laminate  46 . This white layer  72  allows the colors of the image media layer  36  to be properly perceived by a viewer. Next, an opaquing layer  74  is applied to the white layer  72 . Typically and preferably, the opaquing layer  74  is a solid gray color. 
     Both the white layer  72  and the opaquing layer  74  are made of a paint or the like which is easily torn as to produce a sharp and predictable edge. The sheet designs  56 , by virtue of their thickness, are raised portions and are readily located. The above-mentioned opaque media image  16  (FIG. 1) is the portion of the image media layer  36  which received the white layer  72  and opaquing layer  74  directly without being separated by the sheet designs  56 . 
     Referring now to FIG. 13, the next step is peeling one or more of the sheet designs  56  to leave a blank portion or opening  80  where the laminate  46  is visible from the back side of the opaquing layer. As mentioned above, the sign  10  may have opaque design areas  18 , transparent design areas  20 , translucent design areas  22 , and painted design areas  24 . By adding the opaquing layer  74 , any sheet design  56  that is not peeled will result in an opaque design area  18 . The transparent design areas  20 , translucent design areas  22 , and painted design areas  24  are formed from the blank portions or openings  80  in the opaquing layer  74  as described below. It may be noted that the blank portion or opening is sometimes referred to herein as a “discrete non-opaque element” although when painted it may become opaque. 
     If painted design areas  24  are desired, for instance metallic painted areas, these are preferably applied next by spraying a paint layer  86  (FIG.  14 ). Only the sheet designs  56  corresponding to where the paint layer  86  is to be applied should be peeled prior to spraying the paint layer  86 . For each color or type of paint desired, this process is preferably repeated by peeling only specific sheet designs  56  that are to be covered by a particular color immediately prior to spraying the particular color. 
     To create both transparent design areas  20  and translucent design areas  22 , the sheet designs  56  corresponding to these areas are peeled forming blank portions  80 , as depicted in FIG.  15 . As further depicted in FIG. 16, a translucent design area  22  is created by applying a second polymeric sheet  90 , preferably vinyl with an adhesive side  92 , over a blank portion  80  (FIG.  15 ). A transparent area  20 , as shown in FIG. 16, is created simply by peeling the corresponding sheet design  56 , leaving a blank portion  80 . 
     In an alternative embodiment, opaque design areas  18  of various colors may be created. This can be achieved by repeating the steps necessary to apply the sheet design in one color with a different colored polymeric sheet  50 . As there are several steps involved in this, there are further a number of permutations and combinations that could be created. Multiple paint colors could be applied, sheet designs  56  being peeled up for each specific color. Multiple colors for translucent design areas  22  may be achieved by sequentially applying multiple pieces of colored polymeric sheet. These variations are merely illustrative. 
     In another alternative embodiment, a semi-translucent final layer (not shown) may be added. This final layer may be affixed as to cover the entire back side of the sign  10  as a finishing step. Preferably, the final layer is white, and, preferably, it is a adhesive vinyl sheet. The purpose of the final layer is to protect the sign and to insure proper color balance. Furthermore, as one may desire for any portions of the sign  10  which would otherwise be transparent design areas  20  to allow light to pass through, the final layer being semi-translucent serves to diffuse the light creating an even passage of light through the otherwise transparent design area  20 . 
     In view of the above, it will be seen that the several objects and advantages of the present invention have been achieved and other advantageous results have been obtained. 
     As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.