U.S. patent application number 17/466878 was filed with the patent office on 2022-03-03 for repositionable display panel.
This patent application is currently assigned to Shutterfly, LLC. The applicant listed for this patent is Shutterfly, LLC. Invention is credited to Gregory Lee Franklin, Michael Lane Polk.
Application Number | 20220068164 17/466878 |
Document ID | / |
Family ID | |
Filed Date | 2022-03-03 |
United States Patent
Application |
20220068164 |
Kind Code |
A1 |
Polk; Michael Lane ; et
al. |
March 3, 2022 |
Repositionable Display Panel
Abstract
A repositionable display panel includes a rigid image plate that
includes a front surface configured to receive a colorant to form
an image thereon and a back surface opposite to the first surface.
The rigid image plate is defined by an image plate thickness and
image plate widths. A spacer block is defined by a spacer block
thickness and spacer block widths smaller than the image plate
widths. A pressure-sensitive adhesive layer between the back
surface of the rigid image plate and the spacer block bonds the
rigid image plate and the spacer block together.
Inventors: |
Polk; Michael Lane; (Mint
Hill, NC) ; Franklin; Gregory Lee; (Indian Trail,
NC) |
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Applicant: |
Name |
City |
State |
Country |
Type |
Shutterfly, LLC |
Redwood City |
CA |
US |
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|
Assignee: |
Shutterfly, LLC
Redwood City
CA
|
Appl. No.: |
17/466878 |
Filed: |
September 3, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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17095167 |
Nov 11, 2020 |
11138910 |
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17466878 |
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29746210 |
Aug 12, 2020 |
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17095167 |
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International
Class: |
G09F 7/18 20060101
G09F007/18; C09J 7/38 20060101 C09J007/38 |
Claims
1-19. (canceled)
20. A repositionable display panel, comprising: a rigid image plate
comprising a surface configured to receive a colorant to form an
image thereon; a spacer block; and a pressure-sensitive adhesive
layer positioned between the rigid image plate and the spacer
block, wherein the pressure-sensitive adhesive layer is configured
to bond the rigid image plate and the spacer block, and wherein the
spacer block is smaller than the rigid image plate.
21. The repositionable display panel of claim 20, wherein when
bonded together, an edge of the rigid image plate to an edge of the
spacer block is in the range of 1.5 to 5 times a thickness of the
spacer block.
22. The repositionable display panel of claim 20, wherein the rigid
image plate is made of a metal, wood, plastics, a composite
material, a glass, or ceramics.
23. The repositionable display panel of claim 20, wherein the rigid
image plate includes a colorant absorption layer on the surface of
the rigid image plate configured to receive the colorant, wherein
the image is formed by the colorant in the colorant absorption
layer.
24. The repositionable display panel of claim 20, wherein the
colorant is directly printed onto the surface of the rigid image
plate configured to receive the colorant.
25. The repositionable display panel of claim 20, wherein the
colorant is transferred to the surface of the rigid image plate
configured to receive the colorant using thermal dye transfer or
thermal sublimation to form the image.
26. The repositionable display panel of claim 20, wherein the
spacer block is made of a foam material.
27. The repositionable display panel of claim 20, wherein the
pressure-sensitive adhesive layer comprises an acrylic material or
a rubber-based material.
28. The repositionable display panel of claim 20, further
comprising: a double-sided adhesive tape comprising a first surface
configured to be attached to a surface of the spacer block on an
opposite side to the rigid image plate, wherein the double-sided
adhesive tape includes a second surface configured to be attached
to a wall surface.
29. The repositionable display panel of claim 28, wherein the
pressure-sensitive adhesive layer has a stronger bonding power than
the double-sided adhesive tape.
30. The repositionable display panel of claim 28, wherein a surface
area of the double-sided adhesive tape is relative to a weight of
the repositionable display panel, and a surface area of the
pressure-sensitive adhesive layer is proportional to the surface
area of the double-sided adhesive tape.
31. The repositionable display panel of claim 20, wherein the
pressure-sensitive adhesive layer is positioned between the rigid
image plate and the spacer block such that the image formed on the
surface of the rigid image plate is not obscured when the rigid
image plate and the spacer block are bonded by the
pressure-sensitive adhesive layer.
32. The repositionable display panel of claim 20, wherein a width
and a height of the spacer block are smaller than a width and a
height of the rigid image plate.
33. A repositionable display panel, comprising: a rigid image
plate, comprising: a front surface configured to receive a colorant
to form an image thereon; and a back surface opposite to the front
surface; a spacer block; and a pressure-sensitive adhesive layer
between the back surface of the rigid image plate and the spacer
block, wherein the pressure-sensitive adhesive layer is configured
to bond the rigid image plate and the spacer block, and wherein the
spacer block is smaller than the rigid image plate.
34. The repositionable display panel of claim 33, wherein when
bonded together, an edge of the rigid image plate to an edge of the
spacer block is in the range of 1.5 to 5 times a thickness of the
spacer block.
35. The repositionable display panel of claim 33, further
comprising: a double-sided adhesive tape comprising a first surface
configured to be attached to a surface of the spacer block on an
opposite side to the rigid image plate, wherein the double-sided
adhesive tape includes a second surface configured to be attached
to a wall surface.
36. The repositionable display panel of claim 35, wherein the
pressure-sensitive adhesive layer has a stronger bonding power than
the double-sided adhesive tape.
37. The repositionable display panel of claim 35, wherein a surface
area of the double-sided adhesive tape is relative to a weight of
the repositionable display panel, and a surface area of the
pressure-sensitive adhesive layer is proportional to the surface
area of the double-sided adhesive tape.
38. The repositionable display panel of claim 33, wherein the rigid
image plate is made of a metal, wood, plastics, a composite
material, a glass, or ceramics.
39. The repositionable display panel of claim 33, wherein the
spacer block is made of a foam material.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of U.S.
application Ser. No. 17/095,167, filed Nov. 11, 2020, which is a
continuation-in-part of U.S. application Ser. No. 29/746,210, filed
Aug. 12, 2020, the disclosures of which are hereby incorporated by
reference in their entireties.
BACKGROUND OF THE INVENTION
[0002] The present application relates generally to technologies
for producing customized image product, and in particular, to a
personalized display panel that can be flexibly attached to a
surface without altering the surface.
[0003] In recent years, the popularization of digital media and
digital printing technologies has created great demands for
consumer products decorated with customized images. An important
category of such products are photo decor products that are used
for decorating homes, offices, and public surroundings. Recently,
there has been a surge in the demand for personalized photo decor
products in response to temporary and short-term housing as well as
the increased interest in more frequent changes in decorations at
home.
[0004] A drawback for most conventional photo display products is
that they require nails and fasteners to secure them on wall
surfaces. There is a need for personalized photo display products
that can be decorate a wall without damaging it. There is also a
need for photo decor products that are portable and easily placed
on walls.
SUMMARY OF THE INVENTION
[0005] In a general aspect, the present invention relates to a
repositionable display panel that includes a rigid image plate
having a front surface that can receive a colorant to form an image
thereon; and a back surface opposite to the first surface, wherein
the rigid image plate is defined by an image plate thickness and
image plate widths; a spacer block defined by a spacer block
thickness and spacer block widths; and a pressure-sensitive
adhesive layer between the back surface of the rigid image plate
and the spacer block, wherein the pressure sensitive layer can bond
the rigid image plate and the spacer block, wherein the spacer
block widths are smaller than the image plate widths.
[0006] Implementations of the system may include one or more of the
following. When bonded together, an edge of the rigid image plate
to an edge of spacer block can be in the range of 1.5 to 5 times a
thickness of the spacer block. The rigid image plate can be made of
a metal, wood, plastics, a composite material, a glass, or
ceramics. The rigid image plate can include a colorant absorption
layer on the front surface, wherein the image is formed by a
colorant in the colorant absorption layer. The spacer block can be
made of a foam material. The pressure-sensitive adhesive layer can
include an acrylic material or a rubber-based material. The
repositionable display panel can further include a double-sided
adhesive tape comprising a first surface configured to be attached
to a surface of the spacer block on an opposite side to the rigid
image plate, wherein the double-sided adhesive tape includes a
second surface configured to be attached to a wall surface. The
pressure-sensitive adhesive layer can have a stronger bonding power
than the double-sided adhesive tape. The colorant can be
transferred to the front surface of the rigid image plate using
thermal dye transfer or thermal sublimation to form the image on
the front surface of the rigid image plate.
[0007] In another general aspect, the present invention relates to
a method of manufacturing a repositionable display panel that
includes forming an image on a front surface of a rigid image
plate; placing the rigid image plate with a back surface upward in
an alignment fixture; receiving a spacer block having a surface
attached with a pressure-sensitive adhesive layer; removing a
release liner from the pressure-sensitive adhesive layer attached
to the spacer block; placing the spacer block in the alignment
fixture with the pressure-sensitive adhesive layer facing down;
attaching the pressure-sensitive adhesive layer on the spacer block
to the back surface of the rigid image plate in in the alignment
fixture; loading an assembly of the rigid image plate and the
spacer block into an arbor press; and applying pressure on the
spacer block against the rigid image plate to activate a
pressure-sensitive adhesive in the pressure-sensitive adhesive
layer to bond the spacer block to the rigid image plate to form a
repositionable display panel.
[0008] Implementations of the system may include one or more of the
following. The method can further include printing one or more
alignment markers on an alignment sheet associated with the rigid
image plate printed with the image; attaching the alignment sheet
on the back surface of the rigid image plate; and aligning the
spacer block relative to the rigid image plate in the alignment
fixture using the one or more alignment markers before step of
attaching. The step of aligning the spacer block relative to the
rigid image plate can include aligning of the spacer block relative
to the rigid image plate in the alignment fixture using the one or
more alignment markers. The method can further include printing
product tracking information on the alignment sheet. The method can
further include attaching a double-sided adhesive tape on the
spacer block of the repositionable display panel, wherein the
repositionable display panel is attached to a wall surface by the
double-sided adhesive tape. The pressure-sensitive adhesive layer
has a stronger bonding power than the double-sided adhesive tape,
wherein the method can further include removing the repositionable
display panel from the wall surface by detaching the double-sided
adhesive tape from the wall surface without breaking the
pressure-sensitive adhesive layer.
[0009] The disclosed system and method can include one or more of
the following advantages. The disclosed photo display product and
the associated manufacturing method can provide personalized wall
decorations without drilling nails and damaging wall surfaces. The
disclosed photo display product is portable and can be conveniently
positioned on and removed off walls, which make them convenient for
temporary or short-term living. The disclosed photo display product
also allows more frequent changes of display content on a wall and
allows for different combination of personalized photos on a wall
surface. The disclosed photo display product also does not require
inserting prints into a frame as in some conventional display
products.
[0010] These and other aspects, their implementations and other
features are described in detail in the drawings, the description
and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a cross-sectional view of a repositionable display
panel in accordance with some embodiments of the present
invention;
[0012] FIG. 2 is a front perspective view of the repositionable
display panel spaced away from a surface;
[0013] FIG. 3 is a side view of the repositionable display panel
spaced away from a surface;
[0014] FIG. 4 is a rear perspective view of the repositionable
display panel;
[0015] FIG. 5 is a side perspective view of the repositionable
display panel; and
[0016] FIG. 6 illustrates a process for manufacturing the
repositionable display panel in accordance with some embodiments of
the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0017] Reference will now be made in detail to specific embodiments
or features, examples of which are illustrated in the accompanying
drawings. Generally, corresponding reference numbers will be used
throughout the drawings to refer to the same or corresponding
parts. Also, wherever possible, the same reference numbers will be
used throughout the drawings to refer to the same or the like
parts.
[0018] Referring to FIG. 1, a repositionable display panel 100
includes a rigid image plate 110 that includes a front surface 111
and a back surface 112 opposite to the first surface 111. The rigid
image plate 110 is defined by an image plate thickness and image
plate widths. The front surface 111 is adapted to receive a
colorant to form an image thereon. The rigid image plate 110
includes a colorant absorption layer on the front surface 111. The
image is formed by a colorant such as a dye or an ink in the
colorant absorption layer. In some embodiments, the image is formed
on the rigid image plate 110 using thermal dye transfer or thermal
dye sublimation. In some embodiments, a colorant can be directly
printed onto the front surface 111 of the rigid image plate
110.
[0019] The rigid image plate 110 can be made of a metal, wood,
plastics, a composite material, a glass, or ceramics. The rigid
image plate 110 can have width dimensions of 5'.times.7',
8'.times.8', 8'.times.10', 10'.times.14', etc., and is kept thin
such as in a range of 0.030'' to 0.045'' and light weight so that
it can be securely attached to a wall surface with a removeable
double-sided adhesive tape.
[0020] The repositionable display panel 100 also includes a spacer
block 120 adjacent to the back surface 112. The spacer block 120 is
defined by a spacer block thickness and spacer block widths. The
repositionable display panel 100 further includes a
pressure-sensitive adhesive layer 130 between the back surface 112
of the rigid image plate 110 and the spacer block 120. The
pressure-sensitive adhesive layer 130 bonds the rigid image plate
110 and the spacer block 120 together. The spacer block 120 is made
of light and solid material such as a foam material. The
pressure-sensitive adhesive layer 130 can be formed by an acrylic
or a rubber-based material. In some embodiments, the spacer block
120 can also be glued to the rigid image plate 110.
[0021] When the repositionable display panel 100 is attached to a
wall for display and decoration, as shown in FIGS. 2-3, the spacer
block 120 can give the appealing visual effect of "lifting" the
rigid image plate 110 off from the surface of the wall. The spacer
block widths of the spacer block 120 are substantially smaller than
the image plate widths such that the spacer block 120 is hidden
behind the rigid image plate 110 in most viewing angles to the
repositionable display panel 100 attached to a wall 200. The
overall product specification and performance can depend on the
dimensions of the rigid image plate 110 and the spacer block 120.
Specifically, the difference between the widths of the rigid image
plate 110 and the widths of the spacer block 120 relative to the
thickness of the spacer block are configured to provide the visual
lifting effect as described above. The above dimensions are such
that the edge of the rigid image plate to edge of spacer block is
within a range of 1.5 to 5 times or 2 to 4 times of the thickness
of the spacer block. For example, for a rigid image plate 110 of
8''.times.8'' in widths, the spacer block 120 have widths of
5''.times.5'' and 1/2'' in thickness. The outer edge of the spacer
block is thus inset from the back edge of the rigid image panel
(110) approximately 11/2'', which provides a `hidden` lift
appearance of the spacer block when viewed from most angles.
[0022] The pressure sensitive adhesive must cover a specific
surface area to provide enough strength so that a double-side
adhesive tape 140 (described below) removes from the wall when the
product is repositioned, the spacer block 120 does not detach from
the rigid image plate 110. The spacer block size provides the rigid
image plate support and a mechanical interface for the proper
amount of double-sided tape surface area (proportional to the
adhesive strength) relative to overall product weight, to properly
adhere to a wall and provide long-lasting adhesion without falling
off. The ratios of these components result in the balance and
functionality of the product performance.
[0023] The back side of the repositionable display panel 100 is
shown in FIGS. 4-5. Other details of the repositionable display
panel are disclosed in the commonly assigned pending U.S. patent
application Ser. No. 29/746,210, titled "Repositionable Display
Panel", filed on Aug. 12, 2020, the disclosure of which is
incorporated herein.
[0024] When a user receives the repositionable display panel 100,
he or she can remove a release liner from one side of a
double-sided adhesive tape 140 to attach a first surface to the
spacer block on an opposite side to the rigid image plate, and then
remove a release liner from an opposite surface to attach the
repositionable display panel 100 to a wall surface. The
pressure-sensitive adhesive layer has a stronger bonding power than
the double-sided adhesive tape 140 which allows the repositionable
display panel 100 to be detached from the wall surface by detaching
the double-sided adhesive tape 140 from the wall surface without
breaking the pressure-sensitive adhesive layer. The double-sided
adhesive tape 140 can have exemplified dimensions of 1''.times.4''
and a peel strength of approximately 1/2 lb. per square inch, which
can hold an exemplified weight of 0.26 lb. for the repositionable
display panel.
[0025] Referring to FIG. 6, a process of manufacturing a
repositionable display panel is now described. An image is formed
on a front surface of a rigid image plate (step 602). The rigid
image plate can include a colorant absorption layer on the front
surface. The image can be formed on the rigid image plate using
thermal dye transfer or thermal dye sublimation. The image can also
be direct printed to the rigid image panel. The rigid image plate
is placed in an alignment fixture with a back surface upward (step
604). The printed image is facing downward. A spacer block having a
surface attached with a pressure-sensitive adhesive layer is
received. A release liner is removed from the pressure-sensitive
adhesive layer attached to the spacer block (step 606) to expose
the pressure-sensitive adhesive to the air. The spacer block is
placed in the alignment fixture with the pressure-sensitive
adhesive layer facing down (step 608). The pressure-sensitive
adhesive layer on the spacer block is attached to the back surface
of the rigid image plate in in the alignment fixture (step 610).
Next, the assembly of the rigid image plate and the spacer block is
loaded into an arbor press (step 612). Pressure is then applied on
the spacer block against the rigid image plate to activate a
pressure-sensitive adhesive in the pressure-sensitive adhesive
layer, which bonds the spacer block to the rigid image plate to
form a repositionable display panel (step 614).
[0026] In some embodiments, an interim alignment sheet can be
attached to back surface of the rigid image plate, and moved
together with the rigid image plate printed with the image. The
alignment sheet is printed with product, which includes product
tracking information for tracking the rigid image plate, the
intermediate product assemblies, repositionable display panel and
the repositionable display panel. The product information can
include consolidation order, sub-batch ID, orientation, date,
printer identification that printed or transferred the image, and a
barcode or a 2D matrix code that embeds with such information. The
alignment sheet can also be printed one or more alignment markers
for aligning the spacer block to the rigid image plate. In the
alignment fixture, before step of attaching, the spacer block is
aligned relative to the rigid image plate using the one or more
alignment markers on the back surface of the rigid image plate. The
one or more alignment markers can also include orientation
indicators for aligning of the spacer block relative to the rigid
image plate in the alignment fixture.
[0027] In some embodiments, using the alignment markers to guide
the orientation, an operator removes one release liner of a
double-sided adhesive tape 140 (FIG. 1) and applies it to the upper
portion of the spacer block on the back of a repositionable display
panel. After a customer receives the repositionable display panel,
the customer removes another release liner of the double-sided
adhesive tape 140 on the back of the repositionable display panel,
and attach it on to a wall 200 (FIGS. 2 and 3). The
pressure-sensitive adhesive layer has a stronger bonding power than
the double-sided adhesive tape 140, which allows the repositionable
display panel to be removed from the wall surface by detaching the
double-sided adhesive tape 140 from the wall surface without
breaking the pressure-sensitive adhesive layer 140 between the
spacer block and the rigid image plate.
* * * * *