Record receiver having plural interactive leaves or a colorless – Having plural interactive leaves
Reexamination Certificate
2000-03-31
2001-10-09
Hess, Bruce H. (Department: 1774)
Record receiver having plural interactive leaves or a colorless
Having plural interactive leaves
C428S913000, C428S914000
Reexamination Certificate
active
06300279
ABSTRACT:
FIELD OF THE INVENTION
The invention generally relates to methods for applying decorative designs to wood substrates using sublimation dyes.
BACKGROUND OF THE INVENTION
With the widespread use of wood substrates in business and in the home, e.g., walls, countertops, furniture, etc., the need for suitably decorating wood substrates is obvious. However, wood surfaces are not as receptive as other substances, e.g., paper, to the printing of decorations directly on their surface. Decorations printed directly on wood substrates are prone to abrasion, fading, and other types of wear and tear.
It is generally known that substrates can be decorated by applying a decoration such as by printing to a transfer sheet, bringing the decorated transfer sheet into contact with a substrate, and by the application of heat and pressure, transferring the decoration from the transfer sheet to the surface of the substrate. It is also known that by using sublimation dyes which vaporize when heated, the decoration can be made to penetrate or bleed into the body of the substrate. However, a process for transferring decorative designs from transfer sheets to wood substrates such that the decoration penetrates the body of the wood substrate has been elusive.
U.S. Pat. No. 4,354,851, issued Oct. 19, 1982 to Hix et al., discloses a method for producing a decorated substrate by bringing a sheet printed with a design that is formed by a sublimable coloring agent, and transferring the design to a pre-coated rigid panel having a clear, water-resistant polymeric coating. It is preferred that the surface coating be selected from alkyl-melamine resins, polyester resins, alkyl resins and acrylic polymers. The rigid panel forming substrate may be a cellulosic formed board such as hardboard, particle board, softboard, insulation board, or it may be a coated gypsum panel or a coated plywood panel. The coated surface of the panel and the decorated surface of the printed sheet are brought into physical contact. While their surfaces are maintained in contact, light pressure and heat is applied to sublime the coloring agent and cause it to be transferred to and penetrate into the polymeric coating on the surface of the rigid panel.
U.S. Pat. No. 4,908,345, issued Mar. 13, 1990 to Egashire et al., discloses a thermal dye transfer system comprising a dye layer containing a fusible or sublimable dye, a sheet substrate and a dye receiving layer formed on at least one surface of the sheet substrate for receiving the dye. The substrate can be a natural fiber paper such as cellulose fiber paper. A specific feature of the dye receiving sheet is that the receiving layer comprises a specific modified polyester resin. As a result, it is reported that the dyeability and light resistance of the image can be improved.
U.S. Pat. No. 5,030,612, issued Jul. 9, 1991 to Uytterhoeven et al., discloses a thermal dye sublimation transfer recording element for receiving sublimable basic dye-precursors. U.S. Pat. No. 3,860,388, issued Jan. 14, 1975 to John M. Haigh, discloses a method for dye absorption into plastic sheets by placing polyethylene film between a dye transfer paper and a plastic sheet, where the application of heat and pressure causes the dye to migrate through the polyethylene on the surface of the plastic sheet.
There still remains the need for a cost-efficient process for the manufacture of decorated wall board panels that are advantageously distinguished by an improvement in properties including dyeability, weathering resistance and cleanability.
OBJECTS OF THE INVENTION
It is an object of the invention to provide a practical commercial process for producing decorative wood. Another object of the invention is to produce novel decorative wood substrates. Other objects and the advantages of the invention will appear from the following description of the preferred embodiment.
SUMMARY OF THE INVENTION
The present invention relates to a process for transferring a decorative sublimation dye design formed on a transfer sheet to a wood substrate. In accordance with the process defining the invention, a sheet of cellulose web material impregnated with a thermosetting resin, such as polyester, is applied to at least one surface of a wood substrate. Paper is an example of a cellulose web material that can be used in the invention. While the surfaces are in contact, the polyester-impregnated paper is consolidated to the wood substrate under heat and pressure such that the polyester seeps into the pores of the wood substrate to form a thermofused substrate. A transfer sheet is brought into contact with the surface of the thermofused substrate. Heat and pressure are applied to the transfer sheet and thermofused substrate to cause penetration of the design on the transfer sheet into the thermofused substrate through a sublimation process. The transfer sheet is separated from the surface of the thermofused substrate. Optionally, a protective coating is applied over the surface of the substrate showing the transferred design.
REFERENCES:
patent: 4354851 (1982-10-01), Hix et al.
patent: 4422854 (1983-12-01), Hähnle et al.
patent: 4462852 (1984-07-01), Custor
patent: 4465728 (1984-08-01), Haigh et al.
patent: 4596190 (1986-06-01), Hanstein et al.
patent: 4599259 (1986-07-01), Kobayashi et al.
patent: 4664672 (1987-05-01), Krajec et al.
patent: 4668560 (1987-05-01), Kabayashi et al.
patent: 4695286 (1987-09-01), Vanier et al.
patent: 4842613 (1989-06-01), Purser
patent: 4908345 (1990-03-01), Egashira et al.
patent: 4912085 (1990-03-01), Marbrow
patent: 5024989 (1991-06-01), Chiang et al.
patent: 5030612 (1991-07-01), Uytterhoeven et al.
patent: 5112361 (1992-05-01), Carrington et al.
Hess Bruce H.
White & Case LLP
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