WO2000012301A1 - Flexible grand format reflective sign and materials and methods for making - Google Patents
Flexible grand format reflective sign and materials and methods for making Download PDFInfo
- Publication number
- WO2000012301A1 WO2000012301A1 PCT/US1999/020050 US9920050W WO0012301A1 WO 2000012301 A1 WO2000012301 A1 WO 2000012301A1 US 9920050 W US9920050 W US 9920050W WO 0012301 A1 WO0012301 A1 WO 0012301A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- flexible
- weld seam
- sign
- reflective
- substrate layer
- Prior art date
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
- B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
-
- G—PHYSICS
- G09—EDUCATION; CRYPTOGRAPHY; DISPLAY; ADVERTISING; SEALS
- G09F—DISPLAYING; ADVERTISING; SIGNS; LABELS OR NAME-PLATES; SEALS
- G09F13/00—Illuminated signs; Luminous advertising
- G09F13/16—Signs formed of or incorporating reflecting elements or surfaces, e.g. warning signs having triangular or other geometrical shape
-
- G—PHYSICS
- G09—EDUCATION; CRYPTOGRAPHY; DISPLAY; ADVERTISING; SEALS
- G09F—DISPLAYING; ADVERTISING; SIGNS; LABELS OR NAME-PLATES; SEALS
- G09F15/00—Boards, hoardings, pillars, or like structures for notices, placards, posters, or the like
- G09F15/0006—Boards, hoardings, pillars, or like structures for notices, placards, posters, or the like planar structures comprising one or more panels
- G09F15/0025—Boards, hoardings, pillars, or like structures for notices, placards, posters, or the like planar structures comprising one or more panels display surface tensioning means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2590/00—Signboards, advertising panels, road signs
Definitions
- This invention pertains generally to outdoor signs and billboards used for advertising purposes, and, more specifically, to a flexible grand format reflective sign and methods and materials for making a flexible grand format reflective sign.
- Billboards have been a common vehicle for advertising goods and services outdoors for over seventy years. Billboards convey a message relating to a product or service to captive audiences in automobiles and to casual passerbys.
- a paper sign was glued to a plywood backing, or other rigid substrate, and assembled piecemeal to comprise an entire advertisement. These early paper billboards were designed for temporary use, as they usually deteriorated in the environment in less than three months time. If a more permanent board was desired, this involved hand-painting a billboard advertisement directly onto the plywood, in which case such a sign could last for several years.
- Typical billboard signs are manufactured with enclosed lens material by adhering the material to a plywood substrate, or backing.
- Encapsulated Lens Film is often used on street signs, and has a silver base color derived from a mirror coating under the lenses. The silver color is acceptable for street sign uses, but imparts an undesirable 10% to 15% shift in colors that is undesirable for billboard art.
- Encapsulated Lens Films offer higher c.p.l. ratings when compared to enclosed lens films, and offer broader entrance and observation angles. This film is occasionally used to make billboards by cutting out the film in the form of graphic elements , and applying them as individual pieces to eventually comprise an entire sign.
- Rigid formed sheet - This film is manufactured by forming a sheet of acrylic or similar material to have a layer of micro prisms under one surface of an optically clear material, or bonding hard prisms onto rigid sheeting.
- 3M Diamond Grade film is typical of this type of formed sheet, and uses hermetically sealed chambers in small sized (.25"+-) diamonds that are backed by a layer of vinyl and adhesive.
- This film is stiff, rigid, and not printable by current digital means.
- This film requires a substrate like plywood or aluminum to be displayed in an outdoor environment.
- Flexible Bonded Sheet - is manufactured by bonding semi-hard micro prisms onto flexible support substrate layer such as polyvinyl chloride combined with nylon web or polyester. Flexible Bonded Sheet constructions are relatively new materials which have gained considerable acceptance in flexible street sign, apparel, and sporting goods manufacture
- the material is typically sewn into a garment to create a semi- sealed cell
- the sealed cellular (air pocket) construction is used, with the support substrate typically the desired coloi of the sign in its finished use, i e orange, yellow, red, white
- the support substrate typically the desired coloi of the sign in its finished use, i e orange, yellow, red, white
- This material offers bright reflected and ambient whites and reflecting power which works in the daylight as well as the night Graphically, it is ideally suited for flexible reflective billboards
- this material suffers from the following four drawbacks for billboard uses, namely 1 ) that it is not manufactured in widths greater than 48" and, 2) it could not be readily converted into larger widths, and, 3) to create larger widths with stock items, an adhesive layer ( and subsequent silver color) would be required and, 4) hand application of the adhesive coated sheeting would be required to affix it to a standard billboard vinyl face
- present manufacturers recommend that this material be affixed only to rigid materials, such as plywood, thereby increasing transportation costs related to shipping a sign to its point of use
- Prismatic Films - 300-900cpl. -Prismatic (or cube corner micro prism (CCMR)) films offer the high reflectance and widest entrance and observation angles Since all of the prismatic layers are clear by design, they offer no opaque reflectance to make a white colored background in daylight, and they offer minimal structural integrity for exterior function This material requires a support layer for structural integrity and graphical appearance for the desired end use. To be serviceable, this material requires maintaining the mirror surface of the prisms as light reflective facets. This can be accomplished by mirroring the prisms on the film by depositing some from of silvering to create a mirror finish, or by creating a sealed chamber under the prisms to allow the prisms to reflect with their natural polish.
- CCMR cube corner micro prism
- adhesives can be applied to the back of the prismatic film, as the mirror coating acts to reflect light, and the reflective properties are not diminished.
- the silvering or mirroring deposition is grey (about 30%) and appears similar to stainless steel. This material is manufactured by manufacturers which include Reflexite Corp,
- Stimsonite Corp and 3M Corp, and is comprised of a flexible reflective material which can be manufactured with an adhesive coating for hand- pressure applications. Because CCMR can be digitally printed upon it makes an excellent choice for grand format signs such as billboards and truck curtains.
- CCMR and flexible bond sheet are flexible, unlike the more rigid flexible materials previously described. Smaller signs under 48" square, using flexible bonded sheet have been created, which can then be rolled up and easily transported. So far, no one has devised any materials and methods by which a flexible grand format reflective sign could be created for such applications on billboards and truck curtains.
- this invention applies to any flexible grand format reflective sign comprised of a flexible reflective layer bonded to a flexible structural substrate layer.
- This invention relates to creating flexible grand format reflective signs by two methods: 1) Hand applying flexible reflective sign material to a flexible substrate by adhesive means; and 2) modifying sections of flexible bonded sheet for purposes of adjoining sections to create a grand format sign.
- This invention further relates to a material comprised of a modified flexible bonded sheet which can be used to create grand format signs.
- this invention relates to grand format signs produced by the two methods described herein.
- FIG. 1 is an exploded perspective view of a grand format sign wherein adhesive CCMR is used in a hand application method.
- FIG. 2 is an end cutaway view of a section of flexible bonded sheet material.
- FIG. 3 is an end cutaway view of a section of flexible bonded sheet material prepared in accordance with the preferred method of making a grand format sign as described herein.
- FIG. 4 is an end cutaway view of adjacent sections of flexible bonded sheet material, prepared in accordance with the method described herein, positioned for RF welding.
- FIG. 5 is an end cutaway view showing the substrate layers of adjacent sections of flexible bonded sheet being RF "bar welded" with a sealing bar, in accordance with the method described herein.
- FIG. 6 is an end cutaway view showing the substrate layers of adjacent sections following RF bar welding.
- FIG. 7 is an end cutaway view showing a pattern replicating die welding the reflective layer over the previously welded substrate layers of adjacent flexible bonded sheet sections, as a final step to the process described herein.
- FIG. 8 is an end cutaway view showing a completed joint coupling two adjacent flexible bonded sheet sections.
- FIG. 9 is a perspective bottom view of a throw-away pattern replicating die for use in practicing the method described herein.
- FIG. 10 is a bottom view of a permanent pattern replicating die for use in practicing the method described herein. DESCRIPTION OF THE PREFERRED EMBODIMENTS
- the present invention relates to flexible grand format reflective signs and materials and methods for making said signs.
- Cube Corner Microprism Retroreflective Film has the following superior qualities: 1) It can be digitally printed; 2) It can be bonded to a lightweight flexible substrate such as PVC/nylon web; 3) It is flexible, and therefore compares in flexibility to substrates, such as PVC/nylon, thereby reducing problems associated with delamination; 4) It can be viewed from direct and indirect viewing angles. However, no grand format signs ("grand format" meaning signs wider than
- CCMR complementary metal-oxide-semiconductor
- a method for hand-applying adhesive-backed CCMR to a PVC/nylon web substrate to create a grand format size sign, such as a 10' X 48' (480 square feet) billboard is described.
- This type of grand format sign 10 produced in accordance with this method is shown in FIG. 1.
- This method requires that CCMR sections 12 be hand-applied to a vinyl (PVC) and nylon web substrate 18 having the appropriate 10' X 48' dimension of a typical billboard.
- a flexible substrate 18, such as vinyl and nylon web, of a grand format scale, is made by radio frequency (RF) bar welding adjacent sections 14 of substrate material 18 together until a grand format dimension, such as 10' X 48' is achieved.
- RF radio frequency
- the adhesive-backed CCMR must be printed in sections 12, with the appropriate advertisement and background.
- Digital printing is one known method for applying words, logos, and photographs and other indicia 15 to sections of CCMR.
- the respective adhesive sections 12 are next aligned precisely, and hand-applied to the substrate 18. Two skilled laborers require about 4 hours to produce a single 480 square foot grand format sign using this hand application method. While a presentable sign 10 is produced with this method, which can be rolled up and transported, this method is slow and labor intensive; also air bubbles can occur under the CCMR, or else improper adhesion occurs in spots, thereby affecting the uniform visual quality of the finished sign product
- flexible bonded sheet material is used in accordance with a second method of producing a grand format sign as described herein.
- small signs having a maximum width of 48" have been created using flexible bonded sheet material.
- This material typically comes in rolls which are up to 48 inches wide, maximum, but which have a variable length, sometimes as long as 5000 yards.
- This 48" wide material is machine manufactured using an RF computer indexed welder and patterned die.
- the die pattern is a series of depressed square air pillows of approximately 1 inch square. Where there are depressions in the die, no contact, and therefore, no weld occurs.
- the present invention is a sign material comprised of modifying flexible bonded sheet in a manner so that adjacent sheet sections can be readily welded together into a grand format dimension.
- This material can then be used a grand format blank (without indicia) which can be shipped to a sign maker for printing indicia and creating a finished grand format sign.
- This material and the process for using it to make a flexible grand format sign maintains 100% uniform structural integrity and 100% uniform visual appearance across the entire surface of a grand format sign. While the hand application method using CCMR, described previously, creates a presentable flexible grand format sign, the level of visual appearance is superior with the second method described herein, which uses 12301
- flexible bonded sheet material For purposes of this invention, the term "flexible” means the ability of a sign made from the materials and methods described herein to be rolled up for shipping, without damage or delamination of different layers, and subsequently unrolled, for installation.
- CCMR and flexible bonded sheet are discussed herein as two reflective materials capable of meeting this definition of flexibility, any other reflective material which meets this definition is also hereby included within the scope of the invention.
- flexible bonded sheet of the type already described herein is used to produce a sign material in accordance with the present invention.
- Flexible bonded sheet provides near matching flexibilities with the web substrate layer such that the final sign product can be rolled, and unrolled, without problems associated with delamination. Additionally, the flexible nature of the two layers allows the sign to be produced in grand format sizes, and subsequently rolled up and shipped to any location for installation.
- a grand format sign manufactured from web substrate and flexible bonded sheet, in a standard billboard size of 10' X 48' weighs about 120 pounds, which is one-tenth the typical weight of a 3M Diamond Grade sign of similar size which weighs about 1200 pounds, due to its dependence on a plywood substrate.
- Flexible bonded sheet material includes a flexible reflective layer bonded to a flexible substrate layer such as vinyl and nylon web, using an RF weld process and a computer index welder having a die which forms a plurality of 1 inch square air pillows across the surface of the flexible bonded sheet. These air pillows provide air space between the reflective material and the substrate layer for purposes of maintaining reflective qualities. These air spaces must be maintained in the flexible bonded sheet to retain its reflective properties and to retain its ability to be viewed at indirect angles.
- FIG. 2 represents a cutaway end view of a section of standard flexible bonded sheet which is unmodified in any way.
- the flexible bonded sheet 11 0/12301
- FIG. 3 represents a section of flexible bonded sheet 1 1 modified in a manner to represent the sign material which is the present invention.
- a first end 24 and a second end 26 of the material section have been prepared so that first end 24 is comprised of a substrate layer 18 only, devoid of any reflective layer
- FIG. 4 illustrates adjacent sections 11a, l ib of flexible bonded sheet being joined by underlapping first end 24 beneath end flap 28 of second end 26.
- FIG. 5 illustrates a sealing bar 30 of an RF welder joining the respective substrate layers 18 of the adjacent material sections 11a, l ib.
- FIG. 6 illustrates the joined substrate layers 18 after welding and prior to joining end flap 28.
- FIG. 7 illustrates the final step of the process which involves coupling a pattern replicating die 32 which replicates the air pillows along the weld seam 34.
- This final step is accomplished by RF welding and creates an uninterrupted air pillow surface across the grand format sign material, thereby preserving 100% visual appearance and 100%) uniformity across the surface of the grand format sign material.
- the sign material is digitally printed upon, the indicia printed on the finished sign appear clear and uninterrupted.
- This final step provides a sign material which has a width greater than the 48 inch limitation of standard flexible bonded sheet; that is the edge perpendicular to the weld seams in the finished material is wider than 48 inches, making grand format sizes possible in a flexible sign.
- the step of applying the reflective flap 28 could be accomplished using other bonding methods, such as an adhesive-backed reflective flap which would be applied atop weld seam 34 of the substrate layers.
- FIG. 8 illustrates the final product produced by the method heretofore described, showing the weld seam 34 with appropriate air pillow 20 and air pockets 22 located atop weld seam 34 as created by pattern replicating die 32.
- the pattern replicating die 32 is shown in two embodiments in FIGS. 9 and
- the sealing bar 30 which seals the substrate layers is merely an iron with a planar surface, which is heated with RF waves
- the pattern replicating die 32 incorporates a plurality of squarish cavities 36.
- the edges 38 of the cavities 36 contact the surface of the reflective material layer 16 and weld it to the substrate layers 18 creating the edges 40 of the air pillows, upon being heated through contact with the sealing bar.
- the cavities 36 create the air pocket 22 of the air pillow 20 by allowing the reflective material layer to advance upwards into cavity 36 without contacting the substrate layer 18 and welding to it.
- FIG. 9 represents a "throw-away" die 32 made of machined metal having cavities 36 and edges 38, as previously described.
- 10 represents a permanent die 32 having a non- conductive insert 42 mounted in the top of cavity 36 and a non-conductive cladding 44 surrounding the exterior of die 32.
- the non-conductive materials are preferably fiberglass, epoxy, or silicone rubber.
- the squarish edges 38 surrounding the cavity 36 remain an RF conductive material, such as metal.
- the method of machine manufacturing sign material from the modified flexible bonded sheet shown in FIG. 3 allows a standard 10' X 48' billboard size material to be made in 10-20 minutes with an RF bar sealer and pattern replicating die.
- the hand application method described herein requires two personnel and four hours to complete. /12301
- the method of installation of the sign described herein takes advantage of its flexible nature. As part of the sign's manufacture it is preferred if corner pockets or grommets be installed for purposes of placing trucking straps so that the sign can be winched tight from several winching points upon installation.
- a sign manufactured from the two methods disclosed herein can be unrolled, stretched around a billboard frame, and subsequently pulled taught, and hooked with four or more trucking straps.
- This method of installation can be accomplished using a crew of as few as four people for a typical 10' X 48' billboard sign, and can be completed in one-fifth the typical time it takes to install a billboard sign which used plywood, or other rigid material as a substrate. Therefore, added savings are presented by this invention in terms of labor costs and time saved in installation.
- this invention provides for a sign material made from modified flexible bonded sheet, which can be used to machine-manufacture a material for making flexible grand format signs having superior properties not heretofore seen.
- This material can be shipped to a sign maker in a "blank" grand format size, at which point, the sign can be completed by printing various indicia upon the sign by digital printing, for example. Additionally, the invention provides for a method for machine manufacturing this blank material from the modified flexible bonded sheet previously described. In the alternative, this invention also provides for a method of making a flexible grand format sign using hand applied CCMR and a flexible substrate such as PVC nylon web.
- This invention is also a flexible grand format sign made from flexible sign material which can be rolled up and shipped to a location for installation, unrolled, and installed.
Abstract
Description
Claims
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP99945391A EP1027215A4 (en) | 1998-09-02 | 1999-09-01 | Flexible grand format reflective sign and materials and methods for making |
CA002312835A CA2312835A1 (en) | 1998-09-02 | 1999-09-01 | Flexible grand format reflective sign and materials and methods for making |
AU57994/99A AU5799499A (en) | 1998-09-02 | 1999-09-01 | Flexible grand format reflective sign and materials and methods for making |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US9898298P | 1998-09-02 | 1998-09-02 | |
US60/098,982 | 1998-09-02 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2000012301A1 true WO2000012301A1 (en) | 2000-03-09 |
Family
ID=22271842
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US1999/020050 WO2000012301A1 (en) | 1998-09-02 | 1999-09-01 | Flexible grand format reflective sign and materials and methods for making |
Country Status (4)
Country | Link |
---|---|
EP (1) | EP1027215A4 (en) |
AU (1) | AU5799499A (en) |
CA (1) | CA2312835A1 (en) |
WO (1) | WO2000012301A1 (en) |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4231830A (en) * | 1978-10-17 | 1980-11-04 | Ferro Corporation | Process for preparing reflecting sheeting having wide angle response |
US5303492A (en) * | 1992-10-21 | 1994-04-19 | Dan Nishio | Retroflective road sign having translucent border around legend segments |
US5491586A (en) * | 1993-07-19 | 1996-02-13 | Reflexite Corporation | Elastomeric retroreflective structure |
US5753344A (en) * | 1993-12-22 | 1998-05-19 | Jacobsen; Gary A. | In-line printing production of three dimensional image products incorporating lenticular transparent material |
US5759671A (en) * | 1994-12-16 | 1998-06-02 | Nippon Carbide Kogyo Kabushiki Kaisha | Ultraviolet luminescent retroreflective sheeting |
-
1999
- 1999-09-01 EP EP99945391A patent/EP1027215A4/en not_active Withdrawn
- 1999-09-01 WO PCT/US1999/020050 patent/WO2000012301A1/en not_active Application Discontinuation
- 1999-09-01 AU AU57994/99A patent/AU5799499A/en not_active Abandoned
- 1999-09-01 CA CA002312835A patent/CA2312835A1/en not_active Abandoned
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4231830A (en) * | 1978-10-17 | 1980-11-04 | Ferro Corporation | Process for preparing reflecting sheeting having wide angle response |
US5303492A (en) * | 1992-10-21 | 1994-04-19 | Dan Nishio | Retroflective road sign having translucent border around legend segments |
US5491586A (en) * | 1993-07-19 | 1996-02-13 | Reflexite Corporation | Elastomeric retroreflective structure |
US5753344A (en) * | 1993-12-22 | 1998-05-19 | Jacobsen; Gary A. | In-line printing production of three dimensional image products incorporating lenticular transparent material |
US5759671A (en) * | 1994-12-16 | 1998-06-02 | Nippon Carbide Kogyo Kabushiki Kaisha | Ultraviolet luminescent retroreflective sheeting |
Non-Patent Citations (1)
Title |
---|
See also references of EP1027215A4 * |
Also Published As
Publication number | Publication date |
---|---|
EP1027215A1 (en) | 2000-08-16 |
EP1027215A4 (en) | 2001-05-16 |
AU5799499A (en) | 2000-03-21 |
CA2312835A1 (en) | 2000-03-09 |
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