Note: Descriptions are shown in the official language in which they were submitted.
FORMING METHOD OF PATTERNED COATING
BACKGROUND OF THE INVENTION
This invention relates to a method of forming a patterned coating upon
various surfaces, especially a method or illustrating various letters,
characters, or figures upon a coated surEace in a configuration having a
different tone from ad~acent areas.
In order to illustrate various patterns on a coated film, various
methods have been proposed, including: using an addltional coating and a
masking template covering a portion of a pre coated surface; sticking
colored sheets or colored tapes on a pre-coated Eilm: and embossing
patterns on an under layer or substrate before a color coating.
However, these methods have specific drawbacks as follows: the
mas~ing template needs time consuming application and stripping; stepped
irregularities are produced between the first coating film and the second
coating film: the patterns made by sheets or tapes tend to be erased within
a short period; or embossing patterns cannot render an explicit
configuration.
In Japanese Patent Public Disclosure No. 175670/1988, there is
disclosed a method for forming a patterned coating utilizing a magnetic
force. According to this method, at first a liquid coating material
containing powdery magnetic materials, such as nickel, stainless steel or
iron, is applied to a natural surface or pre-coated surface of the object.
Then, while the coating material is fluid, a magnet is brought near. Thus,
the powdery magnetic materials, which are uniformly dispersed within the
liquid coating material, move along magnetic force lines within the coating
film, thereby producing a configuration pattern different from adjacent
areas.
In Japanese Patent Public Disclosure No. 10376/1982, there is
disclosed a method for manufacturing metallic plate having a patterned
coating. According to this method, at first a liquid paint containing an
iron oxide is coated upon a metallic plate. Then, a magnetic pole is
brought near the coated film, so that a pattern corresponding to the
magnetic pole appears upon the film. And then, the coated film is ba~ed to
finish the coated layer.
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However, it has been found that an ordinary magnetic piece having a
dimension of several inches or centimeters cannot produce a desira~ly
explicit configuration pattern. This kind of magnetic piece has speclal
properties such that, in the vicinity of both ends, magnetic forces are
relatively strong but, at the intermediate portion, magnetic forces are
poor. As a result, the configuration made by an ordinary magnetic piece is
liable to become a non-readable, vague pattern.
SU~RY OF THE INVENTION
The present invention overcomes the above drawbacks of conventional
known pattern forming methods and provides an explicit pattern within a
coated object utilizing magnetic force.
The present invention also can provide a method capable of
illustrating miscellaneous patterns without being restricted by the shape
of the magnet itself.
According to the first aspect of the invention, there is provided a
metho~ of forming a patterned coating upon a surface of a substrate,
comprising the steps of: preparing a plurality of separated magnetic
elements to be arranged side by side into an arrayed module of the
elements, bringing said module into close proximity to the reverse side of
a substrate, applying magnetic paint containing powdery magnetic material
upon the surface of said substrate to make a wet film thereon, and
hardening the wet film by baking or drying, thereby providing a continuous
pattern corresponding to the configuration pattern of said module, upon the
surface of the substrate.
In this method, at first an imaginary chain of magnetic force lines
are formed along the module of the elements, and then a substrate is
inserted into the magnetic field and exposed to the magnetic force. When
3~ magnetic paint containing powdery magnetic material is sprayed onto the
surface of the substrate, magnetic fine particles instantly begin to move
within the wet film toward the magnetic force lines. As the wet film loses
its fluidity, the moving magnetic material slows down and stops near the
magnetic force lines. Thus, an explicit continuous pattern corresponding
to the configuration pattern of the module appears in the hardened film.
The appearance of the pattern is not always identical with the
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configuration pattern of the magnetic chain, since magnetic force lines
vary, depending upon the directions of the magnetic elements, especially
upon the positions of North magnetic poles and South magnetic poles
carried on the elements. It should be appreciated that a delicate pattern
can be illustrated in the hardened film by changing the orientatlon of each
magnetic element.
Referring to the magnetic elements, which may be carried on a plastic
sheet or metallic plate, a metallic magnet, ferrite magnet, sintered magnet
or flexible magnet may be used, depending upon the shape or magnetic
properties. Preferably, these magnetic elements are formed through a
moulding process into a relatively small plece having a rectangular,
triangular, polygonal or circular configuration. By a combination of
several conflgurations, any pattern can be illustrated.
According to the second aspect of the invention, there is provided a
method of forming a patterned coating upon a surface of a substrate
comprising the steps of: preparing a plurality of separated magnetic
elements to be arranged side by side into an arrayed module of the
elements, applying magnetic paint containing powdery magnetic material upon
a surface of a substrate to make a wet film thereon, bringing said module
toward the surface or reverse side of said coated substrate in close
vicinity to said wet film while the wet film is fluid, and hardening the
wet film by baking or drying, thereby providing a continuous pattern
corresponding to the configuration pattern of said module, within the
magnetic paint film.
In this method, a module of magnetic elements and a magnetic paint
coated substrate are prepared separately. Then, the magneti~ paint coated
substrate is introduced into the magnetic field produced by the module
while the wet film of magnetic paint is fluid. As the coated substrate is
inserted into the magnetic field and exposed to the magnetic force,
magnetic fine particles instantly begin to move within the wet film in the
direction of the magnetic force lines. As the wet film loses its fluidity,
the moving magnetic material slows down and finally stops near the magnetic
force lines. Thus, an explicit continuous pattern corresponding to the
configuration pattern of the module appears in the magnetic paint film.
These characteristics of the invention are effected by the module of
the magnetic elements, which are closely disposed in order to maintain
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magnetic forces therebetween.
In a preferable embodiment of the invention, each magnetic element
comprises a rectangular or circular metallic plate having a North magnetic
pole and a South magnetic pole situated at the opposite edges thereof, and
adjacent magnetic elements are disposed such that the North magnetic pole
of one alement is positioned in close proximity to the South magnetic pole
of the other element.
In a further preferred embodiment of the invention, the magnetic
elements comprise bar-shaped or U-shaped magnets, each having a North
magnetic pole and a South magnetic pole situated at the opposite edges
thereof, and each magnet is disposed perpendicularly to the substrate.
In a further preferred embodiment of the invention, the magnetic
elements are arranged within a rubber or plastic sheet in a plurality of
striped patterns.
As an example of the magnetic powder to be contained in the magnetic
paint, stainless steel powder, ferrous powder, Fe304 coated mica powder,
alloy powder containing iron, cobalt and nickel, magnetic iron oxide coated
resin particles or the like may be utilized as long as they can move within
the wet film and change direction under the influence of a magnetic force.
Of course, it should be contained and dispersed uniformly in magnetic
paint. The aforementioned ~e304 coated mica powder is well known as a
nacreous pigment of paint. It should be noted that an ordinary pigment can
be utilized in the present invention as long as it has the property of
being influenced by a magnetic force.
As an example of the magnetic paint to be applied to the surface of
the substrate, any kind of ordinary paint can be utilized as long as it can
form a cured film after having gone through a series of processes including
coating under fluid conditions and baking or drying to harden the film.
The magnetic paint includes, other than the magnetic powder, a pigment~
vehicle resin, curing agent, solvent or the like. The ratio of the
magnetic powder present relative to the magnetic paint is to be in a range
such that an explicit pattern appears under the influence of a magnetic
force. According to an experiment, the ratio is preferably more than 0.1
percent of the magnetic paint by weight~
The magnetic paint may be selected from an ordinary type which is
hardened by baking or air drying under ambient temperatures.
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The coating system can be selected from the following:
(1) 1-coat finishing system in which magnetic paint is coated upon a
substrate thereby making a single coating layer.
(2) 2-coat l-bake finishing system in which, first, magnetic paint is
coated upon a substrate, and then clear paint is applied to it by a wet on
wet process, and finally both layers are cured by bakinB.
In an extended practical mode, this invention can apply to
miscellaneous coating processes including more complicated coating steps,
as long as the wet film is magnetically accessible from outside. For
example, after a base color coating is formed upon a surface of a substrate
as a first-coated layer, magnetic paint can be applied to the surface as an
additional ornamental layer. When magnetic elements are brought near the
ornamental layer, ~ome portions of the ornamental layer become thinner
under the influence of magnetic force. As a result, some portions of the
first-coated layer appear and provide delicate color patterns which have
not previously been seen.
It is also possible to apply clear paint over the completed magnetic
powder layer in order to protect the patterned surface from attack.
As an example of the substrate, non-magnetizable material such as
synthetic resin, rubber, ceramic or aluminum plate is preferable, since
these materials do not affect the magnetic force of the magnetic element.
Of course, under the restricted condition that the substrate is relatively
thin, some kinds of magnetizable materials may be used. Especially in the
case where the magnetic elements are brought near to the surface of the
substrate, the influence is small. However, such an operation toward the
surface is not desirable, because a collision may happen between the wet
film and the magnetic elements, resulting in the destruction of the coated
layer.
During the process of the present invention, the module of the
magnetic elements should be supported on a guiding device, which may
comprise a supporting rail, handling arm or similar member. When the
magnetic elements are adhered together by a plastic tape, attention should
be paid to the temperature during the baking process.
The forming method of the invention can be preferably utllized for
illustrating various letters, characters, or figures upon a coated surface.
In addition, the method can be utilized for representing a repetitive
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pattern over a large area of the substrate. In this case, a plurality of
magnetic modules are prepared or a single module is repeatedly used.
Other features and advantages of the invention wlll become apparent
from a reading of the specification, when taken in conjunction with the
drawings, in which like reference numerals refer to like elements in the
several views.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a plan view of a reverse side of a substrate to be coated
utilizing the method of the present invention;
Fig. 2 is a sectional view taken along the line A-A in ~'ig. l;
Fig. 3 is a plan view of the surface of the substrate which is coated
by the method of the present invention;
Fig. 4 is a sectional view of an alternative embodiment similar to
Fig, 2
Fig. 5 is a plan view illustrating an alternative module of multi-pole
type magnetic ele~ents:
Fig. 6 is a perspective view of a modified module utilizing column-
type magnetic elements:
Fig. 7 is a plan view illustrating an arrangement of circular magneticelements:
Fig~ 8 is a plan view illustrating an alternative arrangement of the
magnetic elements in Fig. 7:
Fig. 9 is a perspective view of a modified arrangement utilizing a
combination of several types of magnetic elements;
Fig. 10 is a perspective view of a modified arrangement utilizing a
combination of bar-shaped and U-shaped magnetic elements,
Fig. 11 is a plan view illustrating characters represented by the
method of the present invention.
DESCRIPTION OF T~E PREFERRED EMBODIMENT
Referring to Figs. 1 to 3, there is shown a first embodiment utilizing
the method of the present invention. As shown in Fig. 1, to the reverse
side of the substrate 10 to be coated, is adhered an arrayed module 15
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which comprises a plurality of rectangular magnetic elements 11 supported
on an adhesive tape 30. Each of the magnetic elements 11 carries a North
magnetic pole and a South magnetic pole at the opposlte edges. The
magnetic elements 11 are disposed side by side, and adjacent elements 11
are disposed such that the North pole of one element is positioned in close
vicinity to the South pole of the other element, and that the South pole of
the one element is positioned in close vicinity to the North pole of the
other element. Accordingly, strong magnetic force lines are produced
between the elements, of course in an imaginary form.
Fig. 2 shows the relationship between the coated paint 20, the
substrate 10, the magnetic element 11 and the adhesive tape 30. It should
be noted that the element 11 is firmly adhered to the substrate 10 by the
adhesive tape 30.
Fig. 3 shows a surface which has been coated with magnetic paint. In
this embodiment, after the module 15 of magnetic elements is adhered to the
reverse side of the substrate 10, magnetic paint is sprayed on the surface.
Since an imaginary chain of magnetic force lines is formed along the module
15, as soon as the magnetic paint is thrown into the magnetic field and
applied to the surface of the substrate, magnetic fine particles instantly
begin to move within a wet film of the magnetic paint toward the direction
of the magnetic force lines. As the wet film loses its fluidity, the
movement o the magnetic material slows down and finally terminates near
the magnetic force lines. Thus, a transitional area 24 in which a color
tone is different from that of the adjacent area appears on the surface of
the substrate 10. The configuration of the area 24 corresponds to the
configuration pattern of the module 15. It should be noted that the
configuration of the pattern 24 is not identical with the configuration
pattern of the separated magnetic elements 11.
Subsequently to the pattern making process, the surface of the
substrate 10 is subjected to a baking process or a drying process for
stabillzing the pattern. After stabilization, the transitional area 2~
shows an explicit pattern. This pattern is essentially a transitional tone
area within the coated layer, so that the surface of the substrate 10
remains flat and free from irregularities. This pattern does not vanish as
long as the coated layer remains on the surface. Further, this pattern
does not vary under the influence of sunlight.
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Fig. 4 shows an alternative embodiment of the pattern making process.
At first, an appropriate pre-treatment is applied to the surface of the
substrate 40, and then a primer layer 41 is formed by spraying 11quid paint
on the surface. From this stage, this invention is applied to the pre-
coated surface. In the same way as in the aforementioned process,referring to Figs. 1 to 3, the module of metallic elements 11 is adhered to
the reverse side of the substrate ~0 using an adheslve tape 30. Thus,
subsequently to the primer layer 41, a magnetic paint layer 42 is formed.
When magnetic paint is sprayed upon the primer layer 41 to make a wet film
thereon, the aforementioned pattern is formed within the magnetic paint
layer 42. Further, subsequently to the magnetic paint layer 42, a final
coating layer 43 of clear paint is formed. After the module of the
magnetic elements is removed therefrom, these layers 42 and 43 are
sub~ected to a baking or drying step. In this embodiment, it i3 preferable
to use strong magnetic elements having strong magnetic forces, since the
primer layer 41 is intervening between the substrate and the magnetic paint
layer.
Fig. 5 shows an alternative module 55 consisting of right and left
multi-pole type magnetic elements 51, 52 and so on. Adjacent magnetic
elements 51 and 52 are disposed such that each of the North magnetic poles
of the element 51 is positioned in close vicinity to the South magnetic
pole of the element 52, and that each of the South magnetic poles of the
element 51 is positioned in close vicinlty to the North magnetic pole of
the element 52. According to thls arrangement, the magnetic force lines M
are directed along the longitudinal direction of the module 55, so that a
pattern revealed on the surface of the substrate becomes a continuous I-
shaped pattern having a relatively large width.
Fig. 6 shows a modified module 63 utiliæing column-type magnetic
elements 61, 62 and so on. This module 63 is used to illustrPte a C-shaped
pattern on the surface of the substrate 10. Adjacent magnetic elements 61
and 62 are disposed such that the North magnetic pole of one element is
positioned in close vicinity to the South magne~ic pole of the other
element. According to this arrangement, the magnetic force lines are
directed along the centerline of the module 63, so that a pattern revealed
on the surface of the substrate 10 becomes a continuous C-shaped pattern.
It should be noted that the revealed pattern is not a dotted pattern of the
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column-type magnets.
Fig. 7 shows a modified arrangement of magnetic elements. The module
66 comprises a plurality of circular magnetic elements 64, 65 and so on.
As compared with the arrangement in Fig. 6, each of the magnetic elements
is rotated through 90 , Adjacent magnetic elements 64 and 65 are disposed
such that the North magnetic pole of one element is posltioned in the same
lateral side as the South magnetic pole of the other element, so that two
parallel magnetic force lines M are formed on the upper space of the module
66. According to this arrangement, the magnetic force lines are directed
along the lateral sides of the module 66, so that a pattern revealed on the
surface of the substrate becomes an arcuate pattern, which is not identical
with the dotted pattern of the circular magnets.
Fig. ô shows an alternative arrangement of the magnetic elements in
Fig. 7. In this arrangement, ad~acent magnetic elements 67 and 68 of the
module 69 are disposed such that the North magnetic pole of one element is
positioned in the same lateral side as the North magnetic pole of the other
element, and that the South magnetic pole of one element is positioned in
the same lateral side as the South magnetic pole of the other element.
According to this arrangement, the magnetic force lines M are directed in a
cross~over form due to a repelling force between the same magnetic poles,
resulting in random lines. How~er, due to these random magnetic force
lines, a delicate complicated pattern, similar to an arcuate form, appears
on the surface of the substrate. Of course, this pattern is not identical
with the dotted pattern of the circular magnets.
Fig. 9 shows a modified arrangement utilizing a combination module 75,
including two types of magnetic elements. One type consists of ordinary
two~pole magnetic elements 61 and 62, and the other type consists of multi-
pole magnetic elements 71 and 72. As a result of the combination, the
module 75 can create a continuous H-shaped pattern upon the surface of the
substrate.
Fig. 10 shows a modified arrangement utilizing a combination module
85, including U-shaped magnets 81, 82 and bar-shaped magnets 83, 84. In
these kinds of magnets or magnetic elements, the North magnetic pole and
the South magnetic pole are positioned at their distal ends. As shown in
Fig. 10, each magnet is perpendicularly disposed to the substrate 10. The
upper ends of the magnets are arranged in a grid form, so that the
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combination module 85 reveals a grid form pattern upon the surface of the
substrate 10.
Fig. 11 shows sample characters represented by the method of the
invention. In this Pmbodiment, magnetic elements are filled up within a
rubber or plastic sheet in a plurality oi striped patterns.
In an application of the method of the invention, a North magnetic
pole and a South magnetic pole are easily detected by approaching a compass
to the object. Therefore, the miscellaneous arrangements as shown in the
drawings are easily prepared and utilized. The magnetic elements can be
connected by an adhesive tape or similarly. Since the module of the
magnetic elements can be removed easily, ater usage, no damage occurs to
the substrate.
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