Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Reexamination Certificate
1999-04-06
2001-04-24
Aftergut, Jeff H. (Department: 1733)
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
C156S153000, C156S154000
Reexamination Certificate
active
06221188
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is generally concerned with providing an article having a three-dimensional decorative appearance, particularly in producing an article having a continuous or discontinuous pattern simulating a reproducible natural ice crystal formation for use in the decorative glass industry, and most particularly for use on doors and windows.
2. Description of the Prior Art
Frosting articles, particularly those made of glass or plastic, for aesthetic reasons, has long been known and used in -many diverse industries. These industries include architecture/construction, packaging, display systems and furniture making. Conventional frosting of these substrates is achieved either chemically by an etching liquid such as an acid solution, or mechanically by abrading such as by sandblasting. Another method known in the prior art which is utilized to provide a textured surface on glass, comprises the steps of applying animal hide glue to the surface of the glass which has been sandblasted, then heating the glue and allowing it to dry. This causes the glue to pull chips from the surface, thereby producing a random frosting pattern with an overabundance of fern-like surface patterns. For these reasons, the conventional glue chip process does not yield an ice crystal formation which closely simulates a natural pattern. Such a glue chip process is discussed in U.S. Pat. No. 5,631,057 to Carter, which is directed to yet another method of providing a decorative appearance that involves adhering appliques to the surface of the glass.
The aforementioned methods produce articles that are primarily decorative or advertising in nature, are frequently unique and are difficult to reproduce in exactly the same pattern on a commercial scale. In attempting to reproduce an intricate pattern such as natural ice formation, the problem is magnified. The use of a natural ice crystal formation pattern for imparting the illusion of a very cold environment for beverage dispensing machines and other refrigerated products that are displayed and merchandised behind glass in various refrigerated commercial equipment is very desirable from a marketing standpoint.
None of the prior art techniques discussed above provides a satisfactory three dimensional ice crystal effect on two dimensional optically transparent substrates, which can be duplicated in high volumes. Therefore, there exists a need in the decorative glass industry to provide a process which produces a translucent three-dimensional optical effect which closely simulates natural ice crystal formation on a suitable substrate, wherein the pattern can be reproduced in large quantities.
SUMMARY OF THE INVENTION
In its broadest aspect, the present invention provides a three-dimensional optical effect simulating the appearance of a natural ice formation on the surface of a glass. It is preferred that the glass substrate is optically transparent, although translucent and opaque substrates can be used. The ice crystal formation produced by the present process closely resembles ice crystal formations found in nature by controlling the configuration and number of the fern-like surface patterns associated with the prior art methods discussed. In accordance with the present invention in its broadest aspect, the process for producing a glass article having a three dimensional optical effect pattern comprises the steps of:
a. applying a screen pattern onto a glass substrate;
b. screen printing a masking agent coating composition on the substrate to provide an exposed area to form an outline of the natural ice crystal formations;
c. curing the masking agent coating composition;
d. cooling the coated substrate;
e. sandblasting the exposed area with a medium grit;
f. cleaning the sandblasted surface area;
g. applying an animal hide glue composition to the sandblasted glass surface;
h. dehumidifying the glue composition coated on the substrate;
i. heating said coated substrate to provide a first shrink of the glue composition to chip the glass substrate and initiate formation of a natural ice crystal pattern thereon;
j. removing the chipped glass, glue composition and masking agent residues from the glass substrate;
k. reheat the glass substrate having a natural ice crystal pattern to provide a final shrink of the glue composition on the substrate; and
l. recovering a glass substrate having a translucent simulated ice crystal formation containing from about
20
to 50 percent of a fern-like surface pattern within said formation based on the total surface area of the ice crystal formation.
The masking agent coating composition is selected from vinyl resins, which can be cured by thermally initiated polymerization. Vinyl plastisols are the preferred masking agents. Plastisols are liquid compositions produced by spray-drying latices obtained from the emulsion polymerization of vinyl chloride. The latex particles are dispersed into plasticizers, such as phthalate esters, phosphate esters, adipates, azelates, oleates and sebacates, epoxy plasticizers, fatty acid esters , and glycol derivatives. The polymer particles do not dissolve in the liquids, but remain dispersed until the mixture is heated. Fusion then yields a final plastic film.
The process yields an article of manufacture which possess high standards of quality control regarding the reproducibility of the ice crystal formation.
It is therefore a primary object of this invention to provide a simulated resembling a natural ice crystal formation which has a three dimensional translucent appearance on a glass substrate.
Another object of this invention is to provide a clear glass substrate with a simulated ice crystal formation that closely resembles a natural ice crystal formation by controlling the configuration and number of the fern-like patterns and that can be reproducible in a commercial process. Another related object of this invention is to provide a decorative ice crystal effect on optically transparent glass substrates.
A more particular object of this invention is to provide a process which imparts a translucent three-dimensional simulated ice crystal formation on transparent glass substrates, such as doors and panels of refrigerated units.
An associated particular object of this invention is to provide a process which produces a three-dimensional simulated translucent ice crystal formation on translucent and opaque glass substrates such as drinking glasses, mugs, panels and bottles.
A further particular object of this invention is to provide a three dimensional appearance simulating a natural ice crystal formation on a suitable glass substrate wherein the pattern is continuous.
Yet another particular object of this invention is to provide a three dimensional appearance simulating a natural ice crystal formation on a suitable glass substrate wherein the pattern is discontinuous.
REFERENCES:
patent: 495375 (1893-04-01), Savary
patent: 4199358 (1980-04-01), Parsons
patent: 4323423 (1982-04-01), Schrunk
patent: 4427729 (1984-01-01), Messer
patent: 4436776 (1984-03-01), Wojcik
patent: 4451329 (1984-05-01), Batchelor et al.
patent: 5721013 (1998-02-01), Pratt
Chubb Richard A.
Grant, Jr. Thomas
Aftergut Jeff H.
John Lezdey & Assoc
Thermoseal Glass Corp.
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