Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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224.250
PLASTIC ARTICLE HAVING A PRINTED
INAGE OR COLOR SU~LIMATED INTO A SURFACE THEREOF
USING LIGHT-FAST DYES OR VOLATIZABLE INKS AND
METHOD OF MAKING SUCH ~ ARTICLE
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BACKGROUND OF THE INVENTION
Field of the Invention
The preseint invention relates to a plastic article of
cured resin and, more particularly, to a reinforced
plastic panel having a dye or volatizable ink
sublimated into a:surface thereof, and to a method of
making suoh an~ article.
.Description~of~the~ Prlor Art
einfor ~ ~plastic~panel-, such as a panel made.by
cur1ng a~film~of~Iiquid ther setting resin with:glass
f ~ rs~.in it~for~reinforc-ment:, have found wide
acc ~ ance.~ Such~panels have~excellent s~rength and
resistance to abuse~from~weather, chemicals and
i~it ~ abrasion. Typical uses of these panels have been in
.the~cons~tructi~n~ and~transportation industries~as hard, ~.
:durable walls and:wal1 1:iners.
However, such~panels~would::enjoy even wider de~and if
it w-re possible~to provide graphics on them, but i:t is
exactly the property of the panels that gives them such
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great utility that also makes it difficult to decorate
them: their resistance to reaction with other
substances. A coating printed or painted on such a
panel using conventional techniques has very little
durability.
Various approaches have been t~ried to solve that
problem. For example, the panel surface can be
specially prepared prior to printing or painting, using
a substance that will make ink or paint adhere better
to the panel, or the panel can be specially treated
after printing or painting, by curing or applying
protective coatings. Neither approach is particularly
satisfactory because both involve substantial
additional material and labor costs. And the printed
or painted coatings are still not particularly durable.
Moreover, it i5 clearly impracticable to mass produce
panels having graphic designs by individually painting
each panel. -~
Of course, it is also possible to make uniformly
colored panels by dyeing the liquid resin before it is
cured to form the panel, but that does not solve the
problem of providing a durable graphic design on the
;Anothér~proposed solution involves embedding a
témp~ate;~of plastic or~other suitable material in the
liqu~id resin before it is cured. This, however, has ~ ~-
not proved feasible from a cost standpoint, since
making a template is very expensive, and a template can
at best~provide a limited number of different visual
effects.~ Other techniques for decorating panels are `~ ;
also known,~such as applying contact paper or
wallpaper, but none are capable of providing a wide
variety of graphic effects suitable for economic mass -~
production.
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Thus, a versatile manner of printing on plastic
articles such as reinforced panels of a cured resin,
suitable for mass production and capable of providing a
wide variety of graphic effects, heretofore has not
been available.
SUMMARY OF THE INVENTION
It is an object of the invention to solve these
problems by providing a plastic article of a cured
resin having a durable pattern thereon.
In accordance with one aspect of the invention, the
plastic article is a reinforced panel that comprises a
cured resin having a dye or ink subliminated under heat
and intense pressure into a surface thereof.
In accordance with another aspect of the invention, a
method comprises providing a reinforced panel of a
cured resin and transferring a dye or ink from a sheet
into a surface of the panel by sublimation of the dye
or ink under heat and intense pressure.
~ BRIEF DESCRIPT~ION OF THE DRAWINGS
~
The~present invention can be best understood by
re~erence to the detailed dèscription of preferred
embodiments set forth below taken with the drawings, in
ii I which
Fig. lA is an isometric ~iew of a panel and how a
pattern is provided thereon in accordance with the
present invention;
Fig. lB shows a section of a panel in accordance with
one embodlmont the present invention;
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Fig. 2 is schematic representation of a method of
making the panel shown in Fig. lB;
Fig. 3 is an isometric view of an apparatus for
carrying out the method depicted in Fig. 2;
Fig. 4 is a cross-section of the apparatus shown in
Fig. 3 with a panel in place therein; and
Fig. 5 is an isometric view of a section of a panel in
accordance with another embodiment of the present
invention.
DETAILED DESCRIPTION OF PREFERRED EN~ODIMENTS -~
Fig. lA shows a panel l of a cured thermosetting resin
having embedded glass fibers distributed throughout the
panel for increased strength. A suitable material for
such a panel is a thermosetting polyester resin such as
the~unsaturated~polyoster r-sin sold~by Aristech --
Chemicals Inc. of Linden,~New Jersey, under~the
des ~ nation~MR17112~ This resln comes dlssolved in a
;monomer such~a~styrene, and~suitable additional
rs,~fillers~and;~dyes can be added~as desired, to
lend;~color,~di~f-ring degrees of opacity or other
properties~to~the f1nished product. ;-
In a process that is well known to those skilled in
this~;~art, ~an~uncured l1qu~id resin is deposited ln a ~
film~onto a moving~belt.~ Chopped glass fibers are ~ ~-
~dropped onto the~-film in an appropriate concentration
and th- moving~liquld-resin/glass-fiber fiim is~passed ---
through~an oven to cure and harden the resin. The
continuous structure thus formed is cut into desired~
lengths to form individual panels. Such panels and
this method of maklnq them are well known. A more
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detailed descriPtiOn of this process is set forth in
the 1989 Modern Plastics Encvclopedia at page 290. -
It is possible to practice the present invention using
plastic articles of a wide variety of materials, such
as panels of acrylics, nylon 66, polycarbonates or
hybrid materials such as polyester/urethane or
polyester/acrylic. For example, a resin comprising a
combination of 85% polyester and 15% acrylic provides a
panel particularly suited for use in conditions in
which the panel is exposed to ultraviolet radiation.
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In addition reinforcing materials other than chopped
glass fibers, including a wide variety of natural and
synthetic materials, may be used. And, other
processes, such as casting or extruding, can be
employed to make panels or other plastic articles
suitable for practicing the present invention.
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The present invention resides in the unique manner in
which a pattern can be provided on articles such as the
panel 1, and in a panel 10 having such a pattern on it,
as shown ln Fig. ~lB, by using a heat transfer paper 2
(shown in phantom lines in Fig. lA) having on it a
graphic des~ign 3 or any other indicia to be transferred
;to~the~pan~
Transfer paper sultable for practicing the present
invention is well known to those familiar with textile
printing. Typically, to print on cloth, the transfer
paper and~th- cloth~ar-~fed from rolls through the nip
of heated rollers, and the heat of the rollers causes
the dyes or~inks on the paper to volatize or vaporize
and transfer to the cloth. This type of transfer
printing is described, for example, in U.S. Pat-nt
,632,291, U.~S. Patent 3,829,286, U.S. Patent
3,940,246, U.S. Patent 3,969,071 and Canadian Patent
860,888. It is expected that transfer paper like that
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discussed in these patents will, generally speaking, be
suitable for use in practicing the present invention.
Types of transfer sheets other ~t3ha~Atransfer paper may
be used, such as aluminum foil~ However, paper is
preferred for the present invention since it is the
most effective for achieving the purposes of the
invention. It is also possible to use wide variety
o~P n~ C CaOL~5,
of dyes or volatizable inks,~although to date light- ~ /J
fast, fiber-reactive disperse dyes have been found to
be particularly advantageous. In addition, the graphic
design may be placed on the transfer sheet in many ~
different ways, such as offset printing, gravure ~-
printing, flexography or screen printing. Those
skilled in the art will be able to determine the most
suitable material for the transfer sheet, and the most
advantageous technique for providing the graphic
pattern thereon. For the most part, commercially ;-;~
available transfer paper conventionally used for -
textile printing, such as those provided by
Technographics, Inc., by Panel Prints Inc. or by Storey
Transprints, are suitable for practicing the present
invention.
The transfer paper can be coated with wax or silicone
before the pattern is printed thereon, whi¢h inhibits
thè~dye or ink ~f the pattern from being absorbed by
the paper. Transfer paper typically used in textile
printing is rated between 28 and 60 grams. Light
weight paper within ~his range can be used for bolder ~-~
designs, while heavier paper is needed for more
intricate designs. Water-base colors generally
penetrate deeper when transferred to the plastic
article, although they are more expensive and require
that the paper be pressed against the article for a
longer period. Dyes or inks used in the present
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invention can be specially formulated to enhance
certain properties, such as color fastness.
Fig. lB shows the panel 1 after the graphic pattern 3
on the transfer paper 2 has been sublimated into its
surface. This panel 10 is characterized by the
provision in its surface of a pattern 12, which
corresponds to the pattern 3, that results from the
sublimation, under heat and intense pressure, of the
dye or ink of the pattern 3 into the surface of the
panel 1. The resulting pattern 12 on the panel 10 will
not rub off and cannot be scraped off. A tenacious
bond is created between the dye or ink of the pattern 3
and the cured resin of the panel 1. It has the
appearance of a chemical bond, in that the dye or ink
becomes an integral part of the panel material. The
heat and intense pressure under which the process is
carried out causes the cured resin to be particularly
receptive to the dye or ink that has been vaporized
from the surface of the transfer paper 2.
;Fig. 2 illustrates schematically a preferred embodiment
of~the~method of tbe present invention. The panel 1
and~t~he~printed trans~fer paper 2 are placed between a
rigid~;upper platen 20 and a rigid lower platen 22. A
sheet 2~4 of~absorbent tissue paper is placed between
the~lower~platen 22 and the panel 1. The tissue paper
acts as a blotter and enables the panel to be printed
uniformly across the entire surface, without blank
ar-as. After the panel has~been printed, the tissue
paper will remain loosely adhered to the panel, and
will prevent~the printed pattern from migrating from
one panel to another if the panels are stacked on top
of each other before the printed pattern has completely
cured ~which tàkes about 2 to 10 minutes). Suitable
tissue paper for this purpose is an 11 pound thermal
transfer tissue paper, also known as blotting tissue,
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distributed by Beaver Paper & Mfg. Co., Piedmont Court,
Doraville, GA 30340. -
The platens 20 and 22 may be of any suitable material,
although steel coated with Teflon~ is particularly -
useful. In addition, more uniform pressure may be
obtained if a pad of silicone rubber is placed between
the bottom platen 22 and the sheet of absorbent tissue -~
paper 24.
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Generally, a pattern can be transferred to a plastic
article in accordance with the present invention by ~ `
pressing the article and a transfer sheet together at a ;-~
pressure of about 5 to 20 pounds per square inch at an
elevated temperature of about 300-F to 450-F for about
30 to 90 seconds.
In one preferred embodiment, the platen 20 is heated so ~ ~
`~ that the panel 1 and transfer sheet 2 are subjected to ; ;
a temperature of about 380-F to 420-F and are pressed
together by a force F that generates about 5 to 10 ~ -~
pounds~per square inch (psi) on the panel 1 for a dwe}l
time of about 45 to 60 seconds. This will result in a -~
we~ defined pattern on a panel that has a smooth
surrace.
~3.` ~ In~anoth-r~pr ferred embodiment, the panel and transfer
sheet 2 are subjected to a temperature of about 380-F
to 420-F while being pressed together at a pressure of
10 to 15 psi for~about ~60 to 75 seconds. This will
result in~a~well-defined pattern being printed on a
panel that~has~a~téxtured surface. Such panels are
also well;known and~are fabricated by embossing the
- ~ resin wh~ile it is~still;liquid and then curing~it with
the~embossed texture.~ For example, a panel may be made
with a surface that simulates cloth or wood-grain, or
any other desired texture.
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Figs. 3 and 4 depict a preferred embodiment of
apparatus suitable for carrying out the method
illustrated in Figure 2.
Fig. 3 is a schematic, isometric view of an apparatus
with a frame 50 having a staging table 52 and a cooling
table 54 mounted at opposite sides of the frame 50. A
continuous sheet of transfer paper 2 is provided in a
feed roll 56 mounted at the top of the frame on the
same side as the staging table 52. Used transfer paper
2 is wound on a take-up roll 58 mounted at the top of
the frame on the same side as the cooling table 54.
Between the feed roll 56 and the take-up roll 58, the
transfer paper 2 passes through an enclosure 60 inside
the frame 50 (see Fig. 4). A continuous sheet 24 of
absorbent tissue paper is provided in a feed roll 62
mounted to the end of the staging table 52. Used
tissue paper is wound on a take-up roll 64 mounted to
the end of the cooling table S2. Between the feed roll
62 and the take-up roll 58, the sheet 24 also passes
through the enclosure 60.
Fig. 4 is a -ch-matic view of the enclosure 60 with a
panel l therein. The panel 1 passes between the upper
platen;20 and the lower platen 22, with the transfer
paper 2 and~tissue paper 24 in the relative positions
shown in Fig. 2. Thè platens 20 and 22 are typically
made of ste~l having their faces coated with ~eflon~.
The upper platen 20 is heated and is mounted to a
floating head 66 that enables the upper platen 20 to
conform to~the~angu}ar orientation of the lower platen
20, so that~pressure is uniformly applied to the panel
1. The floating head 66 is attached to a hydraulic ram
(not shown) for exerting sufficient pressure to provide
the tenacious bond between the panel and the sublimated
dyestuff or ink from the transfer paper 2 that
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characterizes the present invention. An exhaust vent
68 allows venting of any vapors generated by the
sublimation of the dyestuffs or inks on the transfer
paper 2.
In operation, a panel 1 is placed on the staging table
52 on top of a clean portion of the tissue paper 24
that has been drawn off the roll 62. The panel 1 and ' '-~
tissue paper 24 move together toward the enclosure 60,
with a length of clean transfer paper 2. The transfer
paper 2, panel 1 and tissue paper 24 thus enter the
enclosure 60 together and are stopped when the panel
reaches the lower platen 22. The upper platen 20 is - ''
pressed against the panel 1 having the transfer paper 2
on top and the tissue paper 24 on the bottom with a ''-
preæsure and for a time in accordance with the above .~-~
guidelines. It is desirable to be able to generate a '~
force as high as 160,000 pounds to create the tenacious ~-~
bond between~the dyestuffs or inks and the panel for a
rectangulsr panel 5 ft. x 10 ft. Accordingly, the
apparatus and the hydraulic ram must be constructed to
be capable of exerting such a force.
Af~t-r the r quired~dwell time, as discussed above, the
panel,~ and~the transfer paper and tissue paper, are
moved~out of the~enclosure~60 toward the cooling table
54~ The~ transfer~paper is stripped from the panel --~
~; ~ surface as the pan-l' leaves the enclosure and is wound -~
onto~the take-up roll' 58. The printed panel lo is then
removed from the cooling table 54.
The apparatus depicted in Figs. 3 and 4 is well suited
to mass-production,~since a panel can be positioned on
the staging~tabl- while anoth-r panel is being printed
and a third panel is'cooling on the cooling table.
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Fig. 5 illustrates another embodiment of a panel in
accordance with the present invention. This panel 10'
is similar to panel 10, except that it has been further
treated after transfer thereto of a pattern.
In this embodiment, a panel such as panel 10 is
provided with an acrylic coating. This coating is put
on the panel by spraying or using coated rollers to
deposit a film of liquid acrylic plastic, such as that
sold by Borden, Inc. under the name Krylon No. 1301 or
by Johnson Wax under the name Future0 floor covering.
This film is cured by baking at temperatures up to
400-F, or air drying, to provide a hard, glossy finish
that resembles kiln-fired ceramic tile. A suitable
tool is then used to provide scored channels 100 in the
panel. These channels are sufficiently deep to extend
into the underlying panel. If the cured resin used to
make the panel is suitably colored, and the pattern is
chosen properly, the resulting product resembles a
plurality of ceramic tiIes, with the channels 100
resembling grout between the tiles.
The present invention thus provides a versatile
technique for printing on~fiberglass reinforced panels
of~cur-d~thermosetting resin.
As desoribed~above, a panel can be printed on one side.
Or, in an alternate embodiment, another sheet of
transfer`paper can be placed between the bottom platen
22~and the~panel 1 (see Fig. 2~ to print simultaneously ~ i
on both sides of~the~panel. In this alternate
embodiment the bottom platen 22 will also be heated.
In addition;,~ the~panel is translucent, unique visual
effects can be~created by printing on both sides of the
panel. In still another variation within the scope of
the invention, the panel can be pigmented and then
printed. This latter embodiment is particularly useful
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for providing a wood-grain finish, since a suitably ~;
textured panel can be pigmented tan or light brown and
a wood-grain pattern can be printed onto the panel in
deeper shades of brown, thus giving a rich wood-grain
effect. In addition, scratches are not highly
noticeable since the underlying panel is pigmented.
EXAMPL~S
To illustrate the tenacity of a pattern provided on a
panel in accordance with the present invention, as
compared to the prior art, panels were made using
sheets of transfer paper provided by Technographics,
Inc., 1359 Broadway, Room 1202, New York, NY 10018, and
having thereon a conventional dyestuff typically used
for printing on textiles. This tranæfer paper was
placed in an apparatus such as that depicted in Figs. 3
and 4 with panels of cured thermosetting resin sold by
Dyrotech Industries, Inc., under the trademark
GLASBORD.
An embodiment of the inventive process was used in
these example~s in which dyestuff was transferred at
400-P~;for 60 seconds at 10 psi. The high heat (400~F)
and~pressure ~10 pSl) of thls embodiment of the
inventive process forced the sublimation inks into the
top 3 to 4 mils ~1 mil = 0.001`inch) of the panel
surface~ The decorative finish produced by the present
invention has better resistance to chemicals, stains,
and mechanical abuse than the other common decorating
methods (i.e.! scr en printing, hot stamping, painting,
applying contact paper and wallpapering) used in these
examples, as shown by the following test results.
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Test panels were decorated using the methods listed
below:
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A. Inventive process; a solid black pattern.
B~ Inventive process; a white, gray and black
speckled pattern.
C. Inventive process; a yellow tile pattern.
D. Screen printing process; two coats of black ink.
E. Hot stamping process; using wood qrain and gold
foil decals.
F. ,~pray painting; using exterior, black, acrylic-
urethane paint.
G. Spray painting; using black, all-purpose enamel.
H. Brush painting; using one coat primer and two
coats white interior latex.
I. Brush painting; using no primer and two coats
white interior latex.
J. Applying vinyl contact paper with a wood grain
pattern.
K. Applying vinyl wallpaper with one coat of sealer.
L. Applying vinyl wallpaper with no sealer.
All of the above were applied to two different types of
; Glaobord5 panel surfaces: smooth and deeply embossed.
Two other substrates Yere decorated using the inventive
process and were included in the testing.
M.~ Smooth, white~Pormica~ panels.
N. Smooth, white tile board.
The~following tests were~run on the test panels:
Scratch esistance: Four different items (a quiarter, a
key, a fork, and a razor knife) were dragged across the
~r,;~; surface (one time each) at a 45 angle. Panels were
~; then visually evaluated~from a 3 ft. distance and given
an "A" rating for visually acceptable or a "U" rating
for visualIy unacceptable. Then the panels were ~iven
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a close visual inspection and given one of the
following ratings: l = no damage, no change; 2 = mild
damage, surface changed but would probably not require
replacement or repair; and 3 = severe damage, would
require replacement or repair.
Abrasion Resistance: Four different abrasive materials
(fine steel wool, grade 000; coarse steel wool, grade
1; fine sandpaper, 150 grit; and coarse sandpaper, 60
grit) were dragged across the surface 3 times each with
a 1 kg. weiqht. Panels were evaluated as described
under Scratch Resistance.
Staining/Cleanability: Seven staining agents were used
(1 = black Sharpie marker, 2 - green crayon, 3 = yellow
~; mustard, 4 = ketchup, 5 = French dressing, 6 = grape
juice, 7 = coffee with cream and sugar). Each of the
staining agents was applied to the panel surfaces and
allowed to sit for approximately 24 hrs. Then six
different cleaning methods were used to try to remove
each stain. These methods are listed below from the
least harsh to the most harsh.
Warm water with a Handiwi~e~: light pressure.
2. Warm water with Palmolive~ soap and a Handiwipe~;
firm scrubbing and pressure.
3. Fantastik spray cleaner sprayed on and allowed to
sit for one minute, then wiped with a Handiwipe~
' and then rinsed with warm water.
4. Softscrub~ mi}d-abrasive cleaner containinq
bleach; firmly scrubbed with a Handiwipe~ for one
~-~ minute and then rinsed with warm water.
S~ 5. Comet~ cleanser: firmly scrubbed with a Handiwipe~
for one minute then rinsed with warm water.
6. S.O.S.~ steel wool soap pad; scrubbed with warm
water for 15 seconds and then rinsed with warm i~i
water. ~ - ~
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Cleaning of each stain started with the least harsh
cleaning method and progressed until the stain was
removed; the method that removed the stain was
recorded. A rating of "7" is used below to denote that
none of the clea~ing methods worked.
Chemical Resistance: Eight different chemicals were
used (1 = methylene chloride, 2 ~ methyl ethyl ketone,
3 z toluene, 4 = 40% sodium hydroxide solution, 5 = 40%
acetic acid solution, 6 = household ammonia, 7 = white
distilled vinegar, 8 - tap water). Pieces of cotton or
gauze were saturated with each chemical, then placed on
the panel surfaces, and covered with a watch glass to
minimize evaporation. Evaluations were made after 30
min., 1 hr., 2 hr. and 6 hr. Panels were rated using
the same system used for Scratch Resistance and
Abrasion Resistance.
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Test Results
The test results are shown below in tabulated form.
SCRATCH RESISTANCE TESTING -- SMOOTH SURFACE PANELS
Sample Ouarter Kev Fork Knife Ratin~
A. Inventive panel, black A2 A2 A2 U3 2.5
B. Inventive panel, speckled A1 A2 A2 ~2 1.7
C. Inventive panel, yellow U3 U3 U3 U3 4.0
D. Screen print, black U3 U3 U3 U3 4.0
E. Hot atamp U3 U3 U3 U3 4.0
F. Sprayed acrylic/urethane A2 U3 A2 A2 2.5 ~ -
G. Sprayed enamel A2 U3 U3 U3 3.5
H. Brushed latex (primer) U3 U3 U3 U3 4.0
I. ~rushed latex (no primer) U3 U3 U3 U3 4.0
J. Vinyl contact paper A2 U3 U3 A2 3.0
~. Vinyl wallpaper (sealer) Al U3 A2 A3 2.5
L. Vinyl wallpaper (no sealer) Al A2 Al A3 1 7 ~
M. Formica~ Al A2 A2 A3 2 0
N. Tile board A2 A2 A2 U3 2.5
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SCRATCH RESISTANCE TESTING -- DEEPLY EM~OSSED SURFACE ~ -
BamDle Quarter Kev Fork Knife B3~1ng ~-
A. Al A2 A2 A3 2.0
B. ~ Al A1 A2 A2 1.5
C. A2 A2 Al A2 1.7
D. A3~A3 A3 U3 3.0 ;~
E. U3U3 U3 U3 4.0
F. A3A3 A2 A2 2.5
i G. A2A3 A3 A3 2.7
H. A3U3 U3 U3 3.7 -
I. U3U3 U3 U3 4.0
J. U3U3 U3 A3 3.7
. A2U3 A2 A3 2.7
L. Al A2 A2 A3 2.0 ; ~;~
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A - Vi-ually acceptable at 3 ft.
U - Vi~ually unacceptable at 3 ft.
No damage or~change on the surface (close exam).
2 - Surface changed but repair not needed (close exam).
3 - Surface~damaged and~need repair ~close exam).
` Overall rating is a calculated average using the following values~
Al ~ 1, A2 - 2, A3 = 3, U2 - 3, U3 = 4 ~U3 is the worst rating).
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ABRASION ~ESTING -- SMOOTH SURFACE
Fine Coarc- Fine Coar~e Over-
Steel Steel Sand- Sand- all
Sam~le _Wool Wool oaoer pa~er Ratina
A. Inventive panel, black A1 A2 U3 U32.7
B. Inventive panel, cpeckled Al Al A2 A21.5
C. Inventive panel, yellow A1 Al A2 A21.5
D. Screen print, black A2 A2 A3 U32.7
E. Hot ~tamp Al Al U3 U32.5
F. Sprayed acrylic/urethane U3 U3 U3 U34.0
G. Sprayed enamel U3 U3 U3 U34.0
H. Brushed latex ~primer) A2 A2 Al A21.7
I. Brushed latex (no primer~ A2 A2 Al U32.2
J. Vinyl contact paper Al A2 U2 U32.5
K. Vinyl wallpaper ~sealer) Al Al Al A11.0
L. Vinyl wallpaper (no sealer) A1 Al Al A11.0
M. Formica~ Al Al Al A21.2
N. Tile board Al Al A2 A21.5
i
~ A3RASION TESTING -- DEEPLY EM30SSED SURFACE
-
Flne Coarce Fine Coar~e Over-
Steel Steel Sand- Sand- all
_ Sam~le Wool Woo~, paoer paper ~atina
A. Al A1 A2 A21.5
8. Al Al Al A11.0
C. Al A2 A2 A21.7 ` -~
~; D. A2 A2 A3 A32.5
E. A2 A2 U3 U33.0
;~ F. A2 U3 U3 U33.5
G. U3 U3 U3 U34.0
H. A2 A2 A3 A32.5
I. Al A2 A3 A322
~J~ J. A2 A2 U3 U330
K. Al Al A1 A11.0
L. A1 A1 A1 A11.0
~ ~ A - Visually acceptable at 3 ft.
; , U - Vi~ually unacceptable at 3 ft.
; 1 - No damage or change on the surface (close exam).
2 - Surface changed but no repair needed ~close exam).
3 - Surface;damaged and needs repair ~clo~e exam).
~^~ overall rating is a calculated average using the following values:
A1 - 1, A2 - 2, A3 ~ 3, U2 - 3, U3 - 4 ~worst rating).
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STAINING/CLEANABILITY TESTING -- S~OOTH SURFACE
Black Green Yellow French Grape Overall
Sam~le Marker Crayon Mustard ~etchu~ Dressinc Juice Coffee Ratlna
A. 4 2 1 1 1 1 1 1.6
B. 4 2 1 1 1 1 1 1.6
C. 4 2 1 1 1 1 1 1.6
D. 7d 2 7c 1 7c 1 7c 4.6
E. NA NA NA NA NA NA NA NA
F. Se 2e 1 1 1 1 1 1.7
G. 6 4 4e 1 2ce 1 2c 2.9
H. 7 4 7 4 1 7 7 5.3
I. 7 3 7 4 1 7 4 4.7
J. 7b 2 7b 1 1 1 1 2.9
K. 7 3 7 1 1 3 1 3.3
L. 7 3 7 1 1 3 1 3.3
M. 6 3 6 1 1 1 1 2.7
N. 5 1 5 1 1 1 1 2.1
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STAINING/CLEANABILITY TESTING -- DEEPLY EMBOSSED S~JRFACE
Black Green Yellow French Grape Overall
Sam~le Marker Cravon Mustard Xetchuo DressLna ~y~ Coffee RatLn
A. 5a 2a 1 1 1 1 1 1.7
B. 4a 2a 1 1 1 1 1 1.6
C. 5a 2a 1 1 1 1 1 1.7
D. 7d 2 7c 1 7c 1 7c 4.6
E. NA NA NA NA NA NA NA NA
F. 4e 1 1 1 1 1 1 I.4
G. 4e 4- 3e 2ce 1 2c 1 2.4
H. 7 4 7 4 1 7 7 5.3
I. 7 5 7 4 1 7 4e 5.0
J. 7b 2 7b 1 1 1 1 2.9
K. 7 3 7 1 1 3 1 3.3
L. 7 3 ~ 7 1 1 3 1 3.3
, .
Lower case lettering code: a - soft brush used to remove residue from
the valleys in the deep emboss
pattern.
b - de~ign i9 wearin~ off.
c - lo~ of gloss.
d - lo~ of glos~ after 3, and then unable
to tell if stain was removed.
e - 3urface looks scratched or
de~LgnlpaLnt was removed from embossed
peaks.
Numbers refer to the various cleaning methods used (1 i9 the least
harsh, 6 is the most harsh, and 7 means the stain could not be
removed). See above for detaLls.
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:
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:
2 ~; 7 2 ~
-- 19 --
CHEMICAL RSSISTANCE TESTING -- SMOOTH SURFACE
(1) (2) (3) ~4) ~4) (5) (5) ~6) ~7) ~8) Overall
Sam~le5h Sh lh ~h ~h 2h 6h 6h 6h gh Ratin~
A.U3 U3 A2 Al Al Al A2 Al Al A12.2
B.U3 A2 Al Al Al Al Al Al Al A11.7
C.U3 A2 Al Al Al Al Al Al Al A11.7
D.U3 U3 U3 Al U3 Al A2 U3 A2 A13.4
E.NA NA NA NA NA NA NA NA NA NA NA
F. U3 Al A2 Al Al Al A2 A2 Al A12.0
G. U3 U3 U3 Al A2 A2 A2 A2 Al A13.0
H. U3 A3 U3 Al U3 U3 U3 Al U3 A13.7
I. U3 U3 U3 Al U3 U3 U3 A2 A2 A23.9
J. U3 U3 A2 A2 U2 A2 U2 U2 U2 U23.6
K.U3 U3 Al Al Al Al Al Al Al A12.0
L.U3 U3 Al Al Al Al Al Al Al A12.0
N.U2 A2 A2 Al Al Al Al Al Al A11.7
CHEMICA~ RSSISTANCE TSSTING -- DEEPLY E~BOSSSD SURFACE
Overall
SamDle :~h Sh iLh ~h ~h 2h 6h 6h 6h 6h Ratin~
A.U3 U2 Al Al Al Al Al Al Al Al l.9
B.U3 A2 Al Al Al al Al Al Al A11.7
C.U3 U3 A2 Al Al Al Al Al Al A12.1
D.U3 U3 U3 Al U3 Al Al U3 Al A13.1
E.NA NA NA NA NA N~ NA NA NA NA NA
F. U3 U3 U3 Al Al Al Al A2 Al A12.5
G. U3 U3 U3 Al Al A2 A2 U3 Al A13.0
H. U3 A3 U3 Al U3 U3 U3 A2 U3 A13.9
I. U3 U3 U3 Al U3 U3 U3 Al A2 A13.6
J. U3 U3 A2 A2 U2 A2 U2 U2 U2 U23.6
K.U3 U3 Al Al Al Al Al Al Al A12.0
L.U3 U3 Al Al Al Al Al Al Al A12.0
Column headings: number~ in ~ ) de~ignate solvent type ~see below) or
exDo~ure time in hrs. (h).
Solvent tyDes: (1) Methylene chlorido ~5) 40% Acetic Acid
(2) Methyl ethyl ketone (6) Household ammonia
~3) Toluene (7) Vinegar
4) 40~i Sodium hydroxide ~8) Water
~ .
,
~f~
: ~2~728
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Final Overall RatLngs ~8e~t to Wor~t)
This rating i- the average of the overall ratings for each of the four
test~ (ScratCh Re~istance, Abra~ion Re-i~tance, Staining/Cleanability,
and Chemical Reiai~tance)
Ra~inqL_ sam~le
1 4 B Inventive proce-- on embonsed Glanbord~ panel
1 6 B Inventive proce~ on ~mooth Gla~bord- panel
1 8 A Inventive procea- on embosi3ed Gla-bord- panel
1 8 C Inventive proceis- on embo~ed Gla-bord- panel
1 9 N Inventive proce-- on mooth Tile board
2 0 L Vinyl wallpaper on mooth Gla~bord- panel
2 1 M Inventive process on smooth Formica- panel
2 1 ~ Vinyl wallpaper on embo--ed Gla~bord- panel
2 2 A Inventive proce-a on smooth Gla~bord- panel
2 2 C Inventive proce~i on ~imooth Glasbord- panel
2 2 K Vinyl wallpaper on ~mooth Gla-bord- panel (w~th iqealer)
2 2 K Vinyl wallpaper on embos~ed Gla-bord- panel ~with aealer)
2 5 F Acryllc/urethane palnt sprayed on mooth Gla~bord- panel
2 5 F Acrylic/urethane paint ~prayed on embos~ed Gla~bord- panel
3 0 J Vinyl contact paper on mooth Gla-bord~ panel
3 0 G Sprayed enamel on embo-aed Gla~bord- panel
3 3 G Sprayed enamel on ~mooth Gla-bord- panel
3 3 J Vinyl contact paper on ~mbo-sed Glasbord- panel
3 3 D Screen pr~nt on embo~-ed Gla~bord- panel
3 7 D Scre-n print on mooth Glaabord- panel
3 7 I Lat-x palnt bru-hed on smooth Gla-bord~ panel
3 7 H Latex paint bru-hed on mooth Glai~bord- panel (with primer)
m~ 3 7 I Latex paint bru-hed on embos~ed Gla-bord- panel
3 8 H Lat-x paint bru-hed on embosi-ed Gla-bord- panel (with primer) -
Hot Stamping ~E ) wa- not included becau-e there wa~ not enough
material to put through the ~taining and chemical re~i~tance te~ts ~ -~
However, con-id ring ju-t cratch and abra-ion re~istance, hot ~tamping ~ i
p~rformed very~poorly )
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','
72g
Base on these tests, the inventive panels performed
better as a group than panels decorated using any other
techniques. In particular, other than Glasbord~ panels
decorated using vinyl wallpaper (which is clearly
unsuited to mass production), the inventive process
performed better than any other decorating technique,
and significantly better than any technique in which
coatings are applied to the surface of a panel.
Of course, it will be appreciated that the invention
may take forms other than those specifically described,
and it will be clear to those skilled in the art that
changes and modifications other than those specifically
pointed out may be made without departing from the
spirit and scope of the invention, which is to be
determined by reference to the appended claims.
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