Patent Publication Number: US-2017360224-A1

Title: Thermoplastic polymer image display device

Description:
FIELD OF THE INVENTION 
     The present disclosure is in the field of image display devices and process of preparation thereof. 
     BACKGROUND OF THE DISCLOSURE 
     Current providers of graphic art media are provided to meet a range of customers needs. Commercially produced graphic art media to be wall hung is generally susceptible to damage from smearing, liquids, scratches and may be damage by merely touching the surface of the graphic art. In another aspect, the post-laminating techniques subsequent to the formation of the subject printed material are time consuming and not economical. Additional problems with the post-lamination process may include wrinkles, curling, delamination, bubbles and other defects. 
     Therefore, there is need for a convenient and economical thermoplastic polymer derived image display device and method of production for the same that overcomes the issues associated with other techniques. 
     SUMMARY OF THE INVENTION 
     Disclosed herein is an image display device for displaying wall art, comprising: a transparent top layer comprising a thermoplastic polymer, wherein the transparent top layer comprises a first side and a second side, and wherein the top layer overlays a viewing side of at least one image. 
     In another aspect, disclosed herein is a method for producing an image display device for displaying wall art, comprising providing a transparent top layer capable of being printed upon with a printing device, wherein the top layer comprises a first side and a second side, and wherein the transparent top layer overlays a viewing side of at least one image. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an exploded illustration of an image display device  100  comprising at least one image  214  with a viewable side  106  as disclosed herein. 
         FIG. 2  is an illustration of an image display device  200  comprising a transparent top layer with a plurality of square and/or rectangular portions  202 ,  204 ,  206 ,  208 ,  210  and  212  capable of being folded and affixed in a cube shape comprising at least one image  214  viewable from one or more sides. 
         FIG. 3  is an illustration of an image display device  300  comprising a cube shape with at least one image  214  with a viewable side  106  as disclosed herein. 
         FIG. 4A  is an illustration of an image display device  400  comprising a cone shape with at least one image  214  with a viewable side  106  as disclosed herein. 
         FIG. 4B  is an illustration of an image display device  500  comprising a pyramid shape with at least one image  214  with a viewable side  106  as disclosed herein. 
         FIG. 4C  is an illustration of an image display device  600  comprising a sphere shape with at least one image  214  with a viewable side  106  as disclosed herein. 
         FIG. 4D  is an illustration of an image display device  700  comprising a cylinder shape with at least one image  214  with a viewable side  106  as disclosed herein. 
         FIG. 5A  is an illustration of a ridge shaped texture  800  of an image display device  100  disclosed herein. 
         FIG. 5B  is an illustration of a wave shaped texture  900  of an image display device  100  disclosed herein. 
         FIG. 5C  is an illustration of a arc shaped texture  1000  of an image display device  100  disclosed herein. 
         FIG. 5D  is an illustration of a saw tooth shaped texture  1100  of an image display device  100  disclosed herein. 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     The following is a detailed description of certain specific embodiments of the image display devices and methods disclosed herein. 
     In one aspect, disclosed herein is an image display device for displaying wall art, comprising: a transparent top layer comprising a polymer selected from the group consisting of a propylene-ethylene copolymer, a high density polyethylene polymer and a low density polyethylene polymer and polypropylene, wherein the transparent top layer comprises a first side and a second side, and wherein the top layer overlays a viewing side of at least one image, wherein the transparent top layer comprises an image enhancing coating. In some embodiments, the top layer is polypropylene. 
     The thermoplastic polymer derived layers of the disclosure are useful for printing images. The images may be applied from an ink jet printing method or a thermal transfer process. The thermoplastic polymer derived layers may be printed upon employing a printing press with a master printing plate or printed via an intermediate substrate. Moreover, images may be printed onto a polymer derived layer employing Retro-gravure printing processes and with a template. In some embodiments, Retro-gravure printing process employs a metal cylinder template. Another method of printing images onto the thermoplastic polymer derived layer is flexographic printing. In some embodiments, the flexographic printing is performed using a Flexopress™. 
     With the red and blue tints and/or an optical brightener added into the film, the printed image on the surface shows an intensified clarity and brightness. In addition, the image resolution is greatly improved. These films are suitable for packaging and label applications where high image quality is desired. 
     The thermoplastic polymer layer of the present disclosure may be of any thickness. In some embodiments, the thermoplastic polymer layer has a total gauge thickness between about 0.3 mil and 5 mil. Polypropylene is because of its excellent physical properties and suitability for thin film manufacturing. The layer thickness ranges disclosed herein are per sheet and the total thickness may increase depending on the number of layers. 
     Turning to the drawings,  FIG. 1  depicts an exploded view of an image display device  100  as disclosed herein. The image display device  100  comprises at least one image  214  with a viewable side  106  and an opposite side  108 . In some embodiments, the image is printed on the second side of the transparent top layer  116 . In this aspect, the image may be printed on a second side  104  of the transparent top layer  116  with the viewable side  106  of the image  214  with the object  232  observable on the right via a view from the first side  102  of the transparent top layer  116 . Therefore, the image may be printed on the second side  104  of the transparent top layer  116 , whereby the opposite side  108  of the image  214  is observed from the second side  104  of the transparent top layer  116  and the viewable side  106  of the image  214  with the object  232  observable on the right side. The image display device  100  may comprise a mount affixed to the wall frame  120 . In some embodiments, the image display device  100  is affixed to a wall frame  120  via fasteners  122 . In some embodiments, the image display device  100  is fastened to the backside of the frame  120  and the frame is a finished wood, metal and/or plastic frame. Alternatively, the image display device  100  may be stretched over the top face of the frame  120  the edges of the image display device  100  fastened to the back of the frame  120  via fasteners  122 . In this manner, the image  214  is protected from damage due because the image has been printed with the viewable side  106  of the image  214  overlaid with the transparent top layer  116 . During the printing process the opposite side  108  of the image  214  as it is being printed on the second side  104  of the transparent top layer  116 . 
     As depicted with the exploded view of  FIG. 1 , the image display device  100  may comprise a bottom layer  118 . The first side  110  of the bottom layer  118  may be laminated to the second side  104  of the transparent top layer  116  following the printing of the image  214 . In some applications, the at least one image  214  is printed on the first side  110  of the bottom layer  118 , whereby the viewable side  106  of the image  214  viewed from the first side  110  of the bottom layer  118  with the object  232  observable on the right side. In some embodiments, the bottom layer  118  and the transparent top layer  116  are subjected to a laminating process. In some embodiments, the bottom layer  118  and the transparent top layer  116  are subjected to a laminating process with a non solvent adhesive. In some embodiments, the image display device further comprises a bottom layer, wherein a first side of the bottom layer is affixed to the second side of the top layer. In some embodiments, the image display device further comprises a bottom layer, wherein the bottom layer is affixed to the second side of the top layer, and wherein the at least one image is printed on a first side of the bottom layer. In some embodiments, the image display device further comprises a bottom layer, wherein the bottom layer is affixed to the second side of the top layer, and wherein the bottom layer is metalized. In some embodiments, the image display device further comprises a bottom layer, wherein the bottom layer is affixed to the second side of the top layer, wherein the bottom layer is metalized, and wherein a metal used for the metalized bottom layer is aluminum. In some embodiments, the image display device further comprises a bottom layer, wherein the bottom layer is affixed to the second side of the transparent top layer, wherein the bottom layer is metalized, wherein a metal used for the metalized bottom layer is aluminum, and wherein the image is printed on a first side of the metalized bottom layer. 
     Turning to  FIGS. 2 and 3 , the image display device  200  of  FIG. 2  comprises a plurality of square and/or rectangular portions  202 ,  204 ,  206 ,  208 ,  210  and  212  are capable of being folded and affixed in a cube shape comprising at least one image  214  viewable from one or more sides. As depicted with folding arrow directions  234 ,  230  and  232 , the image display device  200  is folded into an image display device  300  comprising a cube shape with at least one image  214  with a viewable side  106 . The image display device  200  comprises attachment positions  216  and  222  for affixing the square and/or rectangular portions  202  and  210  to attachment positions  218  and  220  of the square and/or rectangular portions  206  and  204 , respectively via one or more fasteners  302  and  304 . The square and/or rectangular portions  202 ,  204 ,  206 ,  208 ,  210  and  212  may be folded along segments  224 , which may comprise thinner regions of the bottom layer  118  and/or the transparent top layer  116 . Alternatively, the folding along segments  224  is accomplished following a heating step of the thermoplastic layer(s) to allow for formation of a cube and a subsequent cooling stage thereby forming a rigid cube of an image display device  300  as disclosed herein. In some embodiments, the length  228  may be about 5% to 20% longer than length  226 , which allows for attachment positions  216  and  222  to be folded over to be aligned with attachment positions  218  and  220 . In some embodiments one or more of the attachment positions  216  and  222  comprise one or more tabs  236  and  238  to be folded over to be aligned with attachment positions  218  and  220 . In some embodiments, the fasteners  302  and  304  comprise rivets and/or screws. In some embodiments the square and/or rectangular portions  202  and  210  are affixed to square and/or rectangular portions  206  and  204  with adhesive along seams  306  and  308 . In some embodiments the square and/or rectangular portions  202  and  210  are affixed to square and/or rectangular portions  206  and  204  with adhesive and the tabs  236  and  238 . 
     Turning to  FIGS. 4A, 4B, 4C and 4D , and in similar fashion the image display device  200  of  FIG. 2  and the formation of the image display device  300  comprising a cube shape, the image display device  100  may be printed on a appropriately shaped bottom layer  118  and/or the transparent top layer  116  and folded and affixed into a cone shaped image display device  400  comprising at least one image  214  with a viewable side  106 . In this manner,  FIG. 4B  is an illustration of an image display device  300  comprising a pyramid shape with at least one image  214  with a viewable side  106  as disclosed herein.  FIG. 4C  is an illustration of an image display device  300  comprising a sphere shape with at least one image  214  with a viewable side  106  as disclosed herein.  FIG. 4D  is an illustration of an image display device  300  comprising a cylinder shape with at least one image  214  with a viewable side  106  as disclosed herein. 
     Turning to  FIGS. 5A, 5B, 5C and 5D , the image display device as disclosed herein may be treating with heat in the presence of a mold comprised of the shapes  802 ,  902 ,  1002  and/or  1102  as depicted with  FIGS. 5A, 5B, 5C and 5D , respectively. For example, the mold may comprise two opposed rigid wave surfaces  802  which may be used under heat to mold the image display device  100  affording a 3-demensional effect to the image with the contorted bottom layer  118  and/or the transparent top layer  116 . The rigid wave surface  802  may have a plurality of peaks with a height  804  and a width  806 . In some embodiments, the mold may comprise two opposed wave surfaces  902  which may be used under heat to mold the image display device  100  affording a 3-demensional effect to the image with the contorted bottom layer  118  and/or the transparent top layer  116 . The rigid surface  902  may have a plurality of peaks with a height  904  and a width  906 . In some embodiments, the mold may comprise two opposed arc surfaces  1002  which may be used under heat to mold the image display device  100  affording a 3-demensional effect to the image with the contorted bottom layer  118  and/or the transparent top layer  116 . The arc surface  1002  may have a height  1006  and a width  1004 . In some embodiments, the mold may comprise two opposed saw tooth surfaces  1102  which may be used under heat to mold the image display device  100  affording a 3-demensional effect to the image with the contorted bottom layer  118  and/or the transparent top layer  116 . The saw tooth surface  1102  may have a plurality of peaks with a height  1104  and a tooth width  1106  and a width between teeth  1108 . In some embodiments, the image display device  100  may afford a 3-demensional effect to the image with the contorted bottom layer  118  and/or the transparent top layer  116  exhibiting the shapes  802 ,  902 ,  1002  and/or  1102  with the introduction of heat without the use of a mold. The widths and heights of the shapes  802 ,  902 ,  1002  and/or  1102  may be between about 0.1 mm to 300 mm. Depending on the thermoplastic composition used a mold release agent may be used during the heating process to avoid adhesion to the mold. Examples of mold release agents include but are not limited to LMR Lecithin Mole Release, MAC 973 (McLube Division of McGee Industries, Inc.), MAC 444NPB (McLube Division of McGee Industries, Inc.), Loctite® Frekote® PU7000 and/or Loctite® Frekote® PU7001. 
     In some embodiments, the image display device further comprises an image enhancing coating on the first side of the transparent top layer and/or bottom layer. In some embodiments, the image enhancing coating is a varnish or a tint. Colored tints improve the optical properties of images after being printed on the film surface. 
     In another aspect, disclosed herein is a method for producing an image display device as disclosed herein, comprising providing a transparent top layer capable of being printed upon with a printing device, wherein the top layer comprises a first side and a second side, and wherein the transparent top layer overlays a viewing side of at least one image, wherein the transparent top layer comprises a thermoplastic polymer selected from the group consisting of a propylene-ethylene copolymer, a high density polyethylene polymer and a low density polyethylene polymer and polypropylene. 
     Images may be applied to the transparent top layer or a bottom layer using an ink jet printing method or a thermal transfer process. In some embodiments, the image is printed on the second side of the transparent top layer with the viewable side of the image facing the transparent top layer, thereby creating a barrier between the image and any potential damage. In some embodiments, the method for producing an image display device further comprises a bottom layer, wherein a first side of the bottom layer is affixed to the second side of the top layer. In some embodiments, the method for producing an image display device further comprises a bottom layer, wherein the bottom layer is affixed to the second side of the top layer, and wherein the at least one image is printed on a first side of the bottom layer. The bottom layer and/or the transparent top layer may be treated to improve receptivity to printing inks or adherence of affixed images as described herein. The bottom layer and/or the transparent top layer may be treated with an electric charge to improve receptivity to printing inks or adherence of affixed images. In some embodiments, the treatment to the layers used is corona treating. 
     The image display device of the present invention comprises two layers: a transparent top layer and the bottom layer. The layers are formed from polypropylene. The polypropylene derived layers may be printed upon employing a printing press with a master printing plate or printed via an intermediate substrate. Moreover, images may be printed onto a polypropylene derived layer employing Retro-gravure printing processes and with a template that employs a metal cylinder template. Another method of printing images onto the polypropylene derived layer is flexographic printing. In some embodiments, the bottom layer is comprised of polypropylene layers derived from polypropylene extruded with a metal, including but not limited to aluminum or other suitable metalized polypropylene. In some embodiments, the method for producing an image display device further comprises a bottom layer, wherein the bottom layer is affixed to the second side of the top layer, and wherein the bottom layer is metalized. In some embodiments, the method for producing an image display device further comprises a bottom layer, wherein the bottom layer is affixed to the second side of the top layer, wherein the bottom layer is metalized, and wherein a metal used for the metalized bottom layer is aluminum. In some embodiments, the method for producing an image display device further comprises a bottom layer, wherein the bottom layer is affixed to the second side of the transparent top layer, wherein the bottom layer is metalized, wherein a metal used for the metalized bottom layer is aluminum, and wherein the image is printed on a first side of the metalized bottom layer. 
     In some embodiments, the method for producing an image display device further comprises a step of heating the image display device that is capable of changing the shape of the image display device. In one example, the image display device  100  was heated at 400° F. for about 8 minutes. Depending on the type of mold as well as the mold material (i.e., wood, metal and plastic), additives and the film thickness the temperature range may be between about 300° F. to 600° F. and the heat exposure time could be between about 1 minutes to 10 minutes. In another aspect, if a mold is not used, the heating process results in the metalized bottom layer contorting and changing form from a flat surface to form ridges and/or bumps which give the layer a more 3-dimensional appearance. A shaping mold may be used to control the deformation to achieve a desired form. For example, a corrugated form can be used to achieve a “wave” shape. After the heating process and once the thermoplastic is cooled the layer(s) of the image display device become rigid. 
     In some embodiments, the method for producing an image display device further comprises the step of applying an image enhancing coating on the first side of the transparent top layer. 
     Definitions 
     For the purposes of this specification and appended claims, unless otherwise indicated, all numbers expressing quantities, percentages or proportions, and other numerical values used in the specification and claims, are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that can vary depending upon the desired properties sought to be obtained. It is noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the,” include plural references unless expressly and unequivocally limited to one referent. As used herein, the term “include” and its grammatical variants are intended to be non-limiting, such that recitation of items in a list is not to the exclusion of other like items that can be substituted or added to the listed items. As used herein, the term “comprising” means including elements or steps that are identified following that term, but any such elements or steps are not exhaustive, and an embodiment can include other elements or steps. 
     As will be understood by one skilled in the art, for any and all purposes, particularly in terms of providing a written description, all ranges disclosed herein also encompass any and all possible subranges and combinations of subranges thereof. Any listed range can be easily recognized as sufficiently describing and enabling the same range being broken down into at least equal halves, thirds, quarters, fifths, tenths, etc. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third and upper third, etc. As will also be understood by one skilled in the art all language such as “up to,” “at least,” “greater than,” “less than,” and the like, include the number recited and refer to ranges which can be subsequently broken down into subranges as discussed above. Finally, as will be understood by one skilled in the art, a range includes each individual member. 
     The term “thermoplastic layer”, refers to a sheet material that is deformable under the application of heat and after cooling down retains the deformed shape and becomes rigid. The overall thickness of the sheet material is about 0.5 mm, 1.0 mm, 1.5 mm, 1.6 mm, 1.7 mm, 1.8 mm, 1.9 mm, 2.0 mm, 2.2 mm, 2.4 mm, 2.5 mm, 2.6 mm, 2.7 mm, 2.8 mm, 2.9 mm, 3.0 mm, 3.2 mm, 3.4 mm, 3.5 mm, 3.6 mm, 3.7 mm, 3.8 mm, 3.9 mm, or 4.0 mm. Moreover, the width and length of each layer may be between  1  inch and  120  inches. Examples of suitable thermoplastic polymers that can be used to form the layers include polypropylene, a high density polyethylene, a polypropylene copolymer such as an ethylene-propylene copolymer, a styrene polymer, a styrenic copolymer such as alpha-methyl styrene, and polyester such as a polyethylene terephthalate (PET) and a polyethylene terephthalate glycol copolymer (PETG). The layers may comprise a polypropylene monomer or other suitable thermoplastic materials. The metalized layer may be a polypropylene monomer sheet that has been altered to attract metal fibers. The metal fibers employed to produce the metalized layer may include aluminum or other suitable metals. 
     While certain embodiments have been illustrated and described, it should be understood that changes and modifications can be made therein in accordance with ordinary skill in the art without departing from the technology in its broader aspects as defined in the following claims. 
     The present disclosure is not to be limited in terms of the particular embodiments described in this application. Many modifications and variations can be made without departing from its spirit and scope, as will be apparent to those skilled in the art. Functionally equivalent methods and devices within the scope of the disclosure, in addition to those enumerated herein, will be apparent to those skilled in the art from the foregoing descriptions. Such modifications and variations are intended to fall within the scope of the appended claims. The present disclosure is to be limited only by the terms of the appended claims, along with the full scope of equivalents to which such claims are entitled. It is to be understood that this disclosure is not limited to particular methods or devices, which can of course vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting. 
     All publications, patent applications, issued patents, and other documents referred to in this specification are herein incorporated by reference as if each individual publication, patent application, issued patent, or other document was specifically and individually indicated to be incorporated by reference in its entirety. Definitions that are contained in text incorporated by reference are excluded to the extent that they contradict any definitions in this disclosure.