U.S. patent number 3,912,842 [Application Number 05/333,537] was granted by the patent office on 1975-10-14 for article of manufacture.
Invention is credited to William M. Swartz.
United States Patent |
3,912,842 |
Swartz |
October 14, 1975 |
Article of manufacture
Abstract
A paper-backed shiny aluminum foil provides a base for forming a
printed design. The printing on the mirror-like surface is by
successive imprints, at least some of which are transparent. In
some places on the sheet all of the successive printed designs are
transparent. There is a transparent over-coating on at least parts
of the printed design which is so related to the subjacent
transparent imprints that incident light will pass through it and
through the subjacent designs to be reflected back by the
mirror-like metallic surface. This printed foil is then laminated
to one side of a fiberboard backing, the opposite side of which is
treated to make it moisture impervious. The assembly is then
embossed in register with the printed design.
Inventors: |
Swartz; William M. (Chicago,
IL) |
Family
ID: |
23303215 |
Appl.
No.: |
05/333,537 |
Filed: |
February 20, 1973 |
Current U.S.
Class: |
428/172; 156/220;
428/207; 427/276; 428/213 |
Current CPC
Class: |
B44C
3/08 (20130101); B32B 15/12 (20130101); B32B
15/20 (20130101); B32B 7/12 (20130101); B44F
1/10 (20130101); B44F 1/04 (20130101); B32B
2590/00 (20130101); B32B 2451/00 (20130101); B32B
2509/00 (20130101); Y10T 428/24901 (20150115); B32B
2309/105 (20130101); Y10T 428/24612 (20150115); Y10T
428/2495 (20150115); Y10T 156/1041 (20150115); B32B
2307/4023 (20130101) |
Current International
Class: |
B44C
3/08 (20060101); B44F 1/04 (20060101); B44C
3/00 (20060101); B44F 1/00 (20060101); B44F
1/10 (20060101); B32B 003/28 () |
Field of
Search: |
;161/4,DIG.3,413,116,220
;117/35R,35S ;156/220 ;428/172,207,213 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Weinblatt; Mayer
Attorney, Agent or Firm: Spector; Morris
Claims
What I consider to be new, and desire to secure by Letters Patent
are:
1. An article of manufacture comprising a foil having a shiny
mirror-like ink receptive surface, a printed design on said
surface, a second foil having a design thereon which includes
portions that are mirror images of and substantially the same size
as the design portions of the first foil, the two foils being
laminated on opposite surfaces of a fiberboard backing with
corresponding above named design portions on the two foils in
register with each other, said laminate being embossed on one side
and debossed on the other side at said registering design portions,
said embossing and debossing being in registration with one another
and one being a counterpart of the other.
2. An article of claim 1 wherein said foils form vapor seals for
said opposite surfaces of the article.
3. An article of manufacture comprising a foil having a mirror-like
reflecting surface, said foil being laminated to a supporting
backing, a base coating of translucent ink over the mirror-like
surface, colored printing on the base coating, the printing pigment
being pervious to light to permit external light to pass
therethrough and through the base coating to the reflecting surface
and be reflected therefrom back through the base coating and the
printing, and a transparent ink coating overlaying the colored
printing and of a thickness many times as great as the thickness of
the printing and the base coating.
Description
PRINCIPLES OF THE INVENTION
For many years there has been an increasing demand for reproducing
by mass production methods handcrafted multi-material,
multi-piece-part articles for use as decorative panels, advertising
displays, and appliance fronts. As the cost of wood and metal, and
especially labor, has increased, the necessity to replace them by
low cost methods and material has become more urgent. Concomitant
with the desire to achieve low cost reproduction has been the
increasing necessity to achieve an ever greater degree of realism
or reproduction far beyond the range available by prosaic methods.
Because the ultimate user is becoming ever more sophisticated, it
is vitally important to provide ultimate realism with respect to
such factors as appetite appeal, skin tones, hair coloring,
woodgrain, cloth, metal, etc.
This invention relates to the use of the various printing arts
combined with the art of embossing ("embossing" are here used
includes debossing) to produce inexpensively and in quantity
surface designs that create, to a high degree, the appearance of
reality and intrinsic value of the article reproduced. There are
many important differences between viewing a three dimensional
object and viewing a flat, color reproduction of the same. To the
extent that these differences can be reduced by embossing and
otherwise treating a flat printed design, the illusion of reality
may be approached. To the extent that the differences remain, their
effects can be counteracted by giving the observer other clues with
respect to the real article by way of the eye or by way of feel.
The clues are impressions that the observer has previously learned
to associate with the object that cause the observer to impart
three dimensional characteristics to the printed design. The needed
clues may be a series, each of which is alone of no great
significiance, but which together produce the desired impact on the
mind of the observer. One of these clues is "changing shadows." A
moving observer of a three dimensional object sees changing shadows
or highlights, changes that are absent when viewing a flat picture
of the object. The effects of the changes in shadows are a
subconscious clue that the object viewed is three dimensional. This
clue can be recreated on a flat print by proper embossing of the
printed surface being viewed. To accentuate the "apparent"
magnitude of the changes in the shadows seen by a moving observer
of the embossed surface it is desirable to reduce or eliminate
"non-changing" shadows that may be present. In other situations
real object surfaces have a texture and finish (i.e.: dull, glossy)
that, associated with the proper color effects, produce an
"appetite appeal" that cannot be reproduced by color effects alone.
In each of these instances the moving eye of an observer sees
changing contrasts when viewing the real objects. When viewing a
picture, the absence of these changing contrasts dispels the
illusion of reality. The combination of a pictorial reproduction of
the object with embossing, with an overcoating that is clear and
preferably colorless, and which has a high surface luster, and with
spot coating of differing lusters, can produce the "changing"
contrasts in the mind of a moving observer to furnish to the mind
the clues of reality. The effect of limited depth of an embossing
or bas-relief can be magnified by color contrasts, properly placed
shadows, shimmering reflections and the like. Further, many real
objects incorporate metallic parts with their distinctive mirror
like and metallic luster. Liquids also exhibit peculiar
metallic-like reflections in addition to their basic high gloss
"wetness." Neither of these metal or liquid effects can be
reproduced in a manner approaching reality by printing on a flat
white substrate. Wood exhibits several characteristics which must
be accurately reproduced to provide the feeling of reality. In
addition to the color, the surface gloss or dullness, the raising
and depressing of the grain lines and the feel of the surface are
necessary to transmit the impression of reality.
Realism, reality, meatallic mirror-like qualities, are
inter-dependent and trigger a certain kind of recall in the mind of
the beholder. The impact of combining clues to create an impression
of reality is synergistic in that combinations of clues lead the
mind to presume the presence of other clues, and thus behold a
total effect that is greater than the effect of the individual
clues.
THE DRAWING
In the accompanying drawing:
FIG. 1 is a broken away front view of a portion of a sheet that is
used with this invention;
FIG. 2 is a section taken along the line 2--2 of FIG. 1;
FIG. 3 is a front view of the sheet of FIG. 1, with a part of a
drawing thereon;
FIG. 4 is an exploded sectional view of a portion of the drawing of
FIG. 3 when embodied in a completed product;
FIG. 5 is a sectional view taken along line 5--5 of FIG. 3 showing
one type of embossing;
FIG. 6 is a sectional view taken along the line 6--6 of FIG. 3
showing another type of embossing;
FIG. 7 is a front view of a modified construction;
FIG. 8 is a rear view of FIG. 7; and
FIG. 9 is an exploded view of the structure of FIG. 7.
DESCRIPTION
FIG. 1 shows a sheet 1 comprising a base sheet of bleached sulfate
paper 2 over which is an aluminum foil sheet 3 laminated, as by a
coating of glue or other adhesive 4. The foil sheet 3 is
exceedingly thin, say of the order of 0.002 inches. The paper 2 is
substantially thicker than the foil, for instance, a thickness of
0.006 inches. The laminate 1 is sufficiently thin and flexible to
pass through the rollers of conventional printing machines. The
paper backing 2 is provided to facilitate handling and prevent
kinking of the very thin aluminum foil 3. The entire exposed
surface of the aluminum foil has a mirror-like surface having a
high metallic luster. It is coated with a protective lacquer or the
like which, upon drying or otherwise, leaves an ink-receptive clear
colorless imperforate film 6. The exposed surface of the foil 3 is
the color of silver. If a different color is desired, that surface
is then overlaid with a transparent coating 8 of lacquer or the
like of the desired color. A yellow coating 8 changes the
appearance of the exposed surface of the sheet 3 to a lustrous gold
color.
The desired art printing is then applied to the surface of the
coated sheet 1 for producing a desired color transparency of a
product, copy and layout. By way of example, four color screened
positive color separations of the transparency are made by
conventional methods for lithography to full size. From these, a
positive for white is made so that white ink may be printed over
those areas of the clear coating 6 that are not to be metallic.
While most of the white positive is solid, certain areas may
provide a white half tone. These areas of white are determined in
accordance with the particular finished designs and effects
desired.
A keyline drawing 10 is made from the positives which provide the
guide for engraving of a female embossing die which is made to
register exactly with the printed image. A male die is also made.
An artistic determination is made with respect to depth of various
embossed areas, with respect to which areas are to be embossed and
debossed, and with respect to the surface finish of the various
areas of the die, i.e., polish, rough, stipple, etc.
The design 10 is printed by lithography on the exposed surface of
the prepared sheet 1. It is printed in successive passes through a
lithograph press with the white color printed first in two
applications, and with the remaining colors printed in a
pre-determined sequence. the white ink is specially formulated with
a very high white pigment content. The color inks are formulated to
be either opaque or transparent as desired in the ultimate design.
Since the lithographic system requires oil based inks as opposed to
solvent based inks, the transparent inks must be made with pigments
as opposed to dye colors, and as a result of the opacity of the
pigment particles the transparent inks are in fact actually
translucent. The successive printed designs differ from one another
with respect to transparency, or opacity, or color, or appearance
of the texture, or kind of ink used, or thickness of application of
the ink. In some of the areas all of the superposed designs are
transparent. In some areas an opaque finish is desired. It is
desirable that the transparent impressions be made first and the
opaque impressions later.
Some of the successive passes through the lithographic press may
leave the design 10 with a patchquilt-like effect as to accentuate
different surface textures portrayed by the picture. For instance
special applications may be necessary by a printing operation 12 to
bring out the texture of human hair as indicated at 22, or for
producing an effect as required by the texture of the fabric at 25,
or to produce a specially desired skin color effect at 23, or the
sparkle of a jewel at 24, or the effects of coldness of the glass
25' in the picture. The patchquilt effect is one of the last
applications of the design on the prepared sheet 1, one of the last
of the printing operations.
The peculiar luster that metal typically exhibits is reduced by the
previous application of the translucent inks. In many instances it
is desired to recover some, and often a maximum, of the lost
characteristic metallic luster. This recovery is obtained by the
subsequent application of a transparent top coating 13 after the
last printing operation. This coating is so related to the
subjacent transparent or semi-transparent imprints that incident
light will pass through the interfaces between it and its subjacent
printed designs, in those areas wherein all of the subjacent
designs are transparent or semi-transparent, and such light will be
reflected back by the mirror-like surface. The completely opaque
areas may be formed before or after the application of the
hereinafter mentioned top coating 12.
After all of the printing operations have been completed the sheet
is subjected to the top coat 13. This top coat is applied by a
roller, or is silk screened in place, to a thickness many, many
times as thick as that of the printing inks used, often as much as
50 times that thickness, or more. The top coat is a transparent
polyethylene, methacrylate or a polyester lacquer. It produces a
shininess that enhances the appearance of the surface of the thus
printed laminated sheet 1. The peculiar luster that metal typically
exhibits is reduced by the application of the translucent
lithographing ink. This luster is recovered to a large degree by
the transparent top coat, so that those areas which are to
reproduce the metallic luster effects of the actual object do so to
an enhanced effect. The top coating also protects the surface from
abrasion. Subsequent coatings of a dulling agent may be applied in
certain specific areas to affect surface finish, gloss or dullness,
and transparency. These spot coatings would normally be applied by
silk screen. The sheet may then be cured in an oven.
The printed sheet 1 is then laminated to a fiberboard sheet 16 as
by a layer of adhesive 17. The board 16 is of the order of 0.07
inches thick. It is composed primarily of kraft fibers with a resin
binder. The fibers may be what are known as "long" fibers,
prepondering fiber lengths being greater than 1 inch. The binder is
a water-proofing resin to inhibit absorption of atmospheric
moisture by the kraft fibers. A sheet of imperforate aluminum foil
18 is laminated on the backside of the fiberboard sheet 16. The
adhesive used in laminating the sheets 1 and 18 on the board 16 is
one that will permit relative sliding that takes place at the
interfaces of the laminate during the subsequent embossing
operations.
The foil sheets on the opposite sides of the board 16 seal the
board against the escape of moisture therefrom and thus eliminate
or inhibit the drying action which might produce warpage. The
aluminum foils on opposite sides of the board 16 may be of the same
thickness so that they will be equally effective in resisting
warpage in one direction or the other to the extent that any
tendency toward warpage may occur.
The laminated, printed, coated board is then die cut into the final
outline of the finished piece or pieces and the individual pieces
are embossed on a mechanical embossing press by male and female
dies in register with the printed design shown. The embossing in
some or in all of the areas may be micro-embossing as shown at 19',
that is embossing to a very slight depth but at a sufficiently
steep angle to be clearly discernable, or it may be deep embossing,
that is embossing to a depth in excess of one-eighth of an inch as
shown at 19.
If the ultimate product is to have designs on both sides of the
fiberboard, the aluminum sheet 18 may be omitted, and a sheet 1'
used in place thereof. The sheet 1' is subjected to the printing
processes above described in connection with the printing of sheet
1. The printed matter on the two foil sheets may be identical but
one being a reverse or mirror image of the other except, of course,
in the case of printed words or the like. The sheets 1 and 1' would
then be laminated to the fiberboard 16 in such a manner that the
designs on the sheets 1 and 1' are in register in those instances
where such registration is desirable.
When an article, such as a display has, on both sides thereof,
registering designs as above set forth, and is embossed so that on
one side of the embossing the design is concave as at 19 in FIG. 5,
and on the other side it is convex, and such a display is mounted
to be seen first from one side and then from the other, as for
instance when the design is mounted to rotate, a distinctly
noticeable illusion is produced. For instance assume that the
picture represents a cylindrical object as a glass of water. On one
side the convex embossing, together with the printed picture,
produces an illusion of the body of a glass projecting forwardly of
the sheet for the full radius of curvature of the glass, even
though the actual forward embossing is only a minor fraction of an
inch. Viewed from the other side where the debossed picture is
actually concave, there is still an illusion of thickness as though
the glass were actually projecting outwardly of the plane of the
sheet. Such illusions, viewed successively attract attention, a
highly desired function in advertising. Likewise, if the
registering pictures on the two sides of the display are direction
oriented, as from left to right when viewed from one side of the
sheet, it will be oriented from right to left when viewed from the
other side of the sheet. This also can be utilized in the
advertising field for attracting attention.
* * * * *