GB2438177A

GB2438177A - A method of forming a sign

Info

Publication number: GB2438177A
Application number: GB0609250A
Authority: GB
Inventors: Graham Green
Original assignee: LEAWOOD Manufacturing Ltd
Current assignee: LEAWOOD Manufacturing Ltd
Priority date: 2006-05-10
Filing date: 2006-05-10
Publication date: 2007-11-21
Also published as: GB0609250D0

Abstract

A method for forming a sign comprises utilising a recessed structure 21 or 31, and applying a resin into a recess through a needle 33 wherein, the resin is chosen by a combination of a clear resin and a colorant for a particular recess and the needle is arranged to provide a pressurised resin flow to the recess for wash distribution spread across the recess. A ledge 28, (34 - figure 3b not shown) to a periphery of a recess prevents overspill.

Description

A Method of Forming a Sign The present invention relates to a method of

forming a sign and more particularly to signs such as beer plaques attached to handles of a beer engine in order to identify that brand of beer.

Traditionally, and previously, some signs have been vitreous enamelled onto metal structures. In such circumstances a base structure material such as a suitable metal must be utilised in order to allow the process with regard to forming the vitreous enamel at elevated temperatures. Clearly, metals can be relatively expensive and the enamelling process itself which requires high temperatures of at least 600 C can also be expensive.

Alternatively, materials such as plastic materials may be used but it is not possible to enamel such plastics materials in view of the temperatures necessary to glassify the vitreous enamels. However, signs such as beer plaques have traditionally been formed by an enamelling process. Enamel signs for beer plaques have therefore become an expected solution so plastic materials based signs should at least emulate a vitreous enamel format. This is impossible to achieve with known methods of forming plastic materials signs.

In accordance with aspects of the present invention there is provided a method for forming a sign comprising utilising a recessed structure, the method comprising defining a plurality of recesses in the structure and applying a resin through a needle, the resin chosen by a combination of a clear resin and a colorant for a particular recess and the needle arranged to provide a pressurised resin flow to the recess for wash distribution spread across the recess.

Generally, the method includes provision of a ledge to a periphery of each recess of sufficient depth to prevent overspill and/or provide edge definition.

Generally, the method includes choosing a needle dependent upon recess size and/or regulating air pressure flow.

Typically, the recesses are provided by moulding the structure.

Normally, the recessed structureis formed from a plastics material.

Typically, the method includes selection of a necessary colorant from a range of pigments and/or dyes to achieve the desired final colour field in the recess.

Possibly, the recess includes a flow trap edge. Normally, the flow trap edge comprises a ledge to prevent upward creep or smearing up the recess wall.

Also in accordance with aspects of the present invention there is provided a sign made by the above method. Typically, the sign is a beer plaque for securing to a beer engine handle.

Typically, the recess has a depth of up to 1mm Embodiments of the present invention will now be described by way of example and with reference to the accompanying drawings in which:-Ag. 1 is a schematic plan view of a sign in accordance with aspects of the present invention; Fig. 2 is a cross-section of a recessed structure in accordance with aspects of the present invention; and, Fig. 3 illustrates steps with regard to the method in accordance with aspects of the present invention for forming a badge such as a beer plaque for attachment to a beer engine handle.

As indicated above, vitreous enamelled badges are attractive due to their lustre and viewed depth of colour. However, vitreous enamelling is a relatively expensive process and, as indicated above, requires use of metals to withstand the temperatures of the manufacturing process which will normally be in excess of 600 C.

In situations such as with regard to promotional signage and badging 1 5 the cost associated with creating relatively large signs such as beer plaques for association with beer engine handles can be expensive when using an enamelling process. Moulded recessed plastic structures would be a cheaper alternative, but such plastics materials will not be able to withstand the enamelling temperatures.

Aspects of the present invention provide a method of creating a sign which emulates an enamelled sign but without the necessary vitreous enamelling process to enable a plastics material to be utilised. A particular feature of vitreous enamelled badges and other signs is the lustre and depth of colour provided by such enamelling. This lustre is achieved through surface tension during the cooling process as the melted vitreous glass powder cools and shrinks and creates surface tension and reflectivity.

Aspects of the present invention utilise an epoxy resin material incorporating an appropriate colorant and hardener to simulate such shrinkage after application inducing the high gloss surface tension reminiscent of vitreous enamel. In such circumstances, in accordance with the method described below, the recess is substantially flood filled through a wash process of introduction of epoxy resin into the recess and then as that epoxy cures the surface tension effects create a desired high gloss lustre as required.

Initial stages of the method comprise analysing artwork for a sign such as a beer handle plaque in order to identify the necessary colour fields to create the overall badge representation. These colour fields will be defined by recesses in a structure. This structure may be curved or flat dependent upon sign requirements. It will be understood that the recessed structure, as described above, will generally be formed from a plastics material appropriately moulded but other materials such as compressed cardboard may be used. Furthermore, metal structures may be used simply to avoid the vitreous enamelling process.

The recessed structure, as indicated will typically be moulded although, 1 5 where possible, the recesses may be specifically machined with an appropriate routing tool. Generally the depth will be as required but typically be in the order of up to 1mm. The recess structure will include a number of recesses into its surface to allow an artistic representation to be provided as well as words, letters and numbers as appropriate signage.

Fig. I provides a schematic illustration of a recess structure 1 in accordance with aspects of the present invention. The structure I incorporates a number of different features 2, 3, 4 representative of a wider range of different recess shapes and sizes to provide an aesthetic distribution on the structure 1. Thus, recess 2 simply comprises a trough in order to create a bar across the structure 1. Recess 3 comprises a ledge recess into the structure 1 in the shape of a triangle, whilst recess 4 again has a ledge periphery to a circular shaped depression. These feature recesses 2, 3, 4, as indicated above, can be moulded using an appropriate mould tool or press formed into a base material 5 from which the structure 1 is created. It will be understood in terms of the method a mould process reduces the amount of waste material in forming the structure I whilst press forming of the recesses will cause deformation of the base material 4 which may over stress the structure 1 or cause distortion whilst machining processes in addition to being expensive with regard to removal of the excess material in the recesses are also wasteful of that material.

As discussed above, the base material 4 of the structure I will typically comprise a plastics material. This plastics material replaces the metal cast structures utilised with respect to previous vitreous enamel signs and badges.

The plastics material is generally more malleable and lighter so that the necessary mountings (not shown) for securing the badge in use and attached during a complete manufacturing process in accordance with present invention, may be less robust and cheaper than previous arrangements. The use of the plastics material will allow a greater adaptability with respect to the moulding or other process for creating the recesses in accordance with aspects of the present invention.

Fig. 2 provides a schematic illustration of a number of recesses 22, 23, 24 in accordance with aspects of the present invention. These recesses 22, 23, 24 are formed within a recessed structure 21 manufactured using a plastic or other suitable material.

Recess 22 is a simple trough type recess in which, in accordance with aspects of the present invention, a resin 25 (shown in broken line) is introduced in order to emulate an enamelled appearance. The resin in accordance with aspects of the present invention will typically comprise a base clear resin to which colour dyes and/or pigments are added for colour along with an activator or hardener for the resin. The resin is thus relatively fluid and therefore a simple trough recess 22 may be susceptible to leakage and over flow of the injected resin. It will be understood that in order to provide the clean lines necessary for a sign emulating a vitreous enamelled badge or other component, leakage or smearing of the coloured resin from a recess will be unacceptable. In accordance with aspects of the present invention the resin combination is forcefully ejected from a hollow needle into the recesses for wash distribution, that wash may overflow unless care is taken. Furthermore, generally the walls of the recess will be coloured or plated so that capillary action or surface tension creep up these walls may not detract from the appearance of the sign.

Recess 23 is similar to recess 22, except that within the trough a raised island or a plafform 26 has been provided. This island 26 may extend above the surface 27 of an injected resin/colour so that the top of the island is visible or the island 26 can act to reduce the amount of resin necessary to fill the recess 23. The island 26 may form lettering or another shape in a colour field created by the resin in the trough of the recess about the island 26 Recess 24 illustrates a further option in that the recess 24 includes a 1 5 peripheral ledge 28 such that a resin flow 29 as a result of surface tension creep will not smear over an upper wall surface 30 in the recess. Thus, there is a well defined resin infill within the recess 24 for good colour definition within the recess 24 in order to create the desired signal or badge appearance. The structure in terms of the recess defining letters and shapes is sharply presented between the colour fields in the recess and the colour of exposed parts of the structure distinctly shown. The edge will typically be in the order of a fraction of a millimetre in depth to prevent creep upwards by surface tension effects. The ledge acts as a brake to wash distribution and gives an operator more leeway with respect of forced resin flow proportioning.

Aspects of the present invention particularly relate to provision of a method of creating a badge or other sign which emulates a vitreous enamel badge as produced traditionally using cast metal recessed structures. These structures may be curved or flat or include angular elements, but nevertheless, the use of a resin having an appropriate hardener colour combination ensures that each colour area will emulate an enamelled area as viewed. The resin is typically an epoxy resin and the dye/pigment any appropriate colorant chosen for colour and desirability.

Aspects of the present invention initially require definition of a required recess structure such that each recess can be filled with an appropriate resin.

The injected resin comprises a clear epoxy resin with a colour dye and/or pigment addition of less than 10% by weight dye and/or pigment in order to create the necessary deep lustre and glow to emulate vitreous enamel.

Bottom parts of the recess may incorporate reflective or roughened surfaces dependent upon requirements in order to facilitate the desired enamel emulating effect. The particular depths and wall thicknesses between the cavities for recesses and wells into the moulding will be varied dependent upon requirements to form the final sign shape and distribution.

The composition of the resin, as indicated, will incorporate a dye and/or pigment but also more importantly a hardener such that over an acceptable period of time in an ambient temperature and atmosphere or possibly slightly elevated temperature and reduced ventilation pressure the resin will harden to create a lustre reminiscent of vitreous enamel. The hardener will be added to the resin in the manufacturing method proportionally to achieve the desired hardening rate. Typically, the resin should still be operationally workable after about twenty minutes, and practically hard after 24 hours.

Fig. 3 illustrates the resin injection stages as Fig. 3a and Fig. 3b in accordance with the method of aspects of the present invention. As can be seen in Fig. 3a a recessed structure 31 includes a recess 32. Resin 35 is presented to the recess 32 through a hollow needle 33 and is propelled through a syringe comprising a hollow cylinder 36 driven by compressed air pressure 38. This air pressure 38 is generally created through release of a compressed air supply under the control of a regulator valve 39. The valve 39 will be arranged to allow adjustment in the presented pressure between 1 to psi in order that there can be accurate presentation of the resin 35 through the hollow needle 33 in terms of its rate and distribution.

In accordance with the method of aspects of the present invention the diameter and size of the needle 33 as well as the regulated propelling pressure for the resin presented through the needle 33 are particularly chosen for the size of the recess 32 and/or compressed air pressure. Generally the available needles 33 will be sized in terms of fine, medium and high diameters to allow an appropriate amount of resin to be presented to the recess 32 but in any event a range of sizes will be provided, It will be understood, as indicated, that the resin as presented within the syringe has a finite period during which the resin can be presented to the recess 32 in view of the hardening effects of the activator or hardener added to the base resin and colour combination. Typically, the syringe will be loaded with the activated resin, that is to say resin, colour and hardener and then coupled to the regulator valve for the compressed air. In such circumstances, through the needle 33, accurate presentation of the resin to the recess 32 is achieved at an appropriate flow rate for the size of that recess 32 without over edge spilling and smudging which, as indicated above, will diminish from the acceptability of the final sign.

Generally, the needle 32 will be manipulated by an operative within the recess 32 in order to fill that recess 32. Advantageously, as indicated above, the recess 32 will incorporate a peripheral ledge 34 so that the resin will be notionally only incorporated into the inner part 32a of the recess 32 leaving the upper wall parts of the recess exposed to contribute to the overall sign appearance.

The basic steps of the method in accordance with aspects of the present invention comprise:-a) moulding the recessed structure to have recesses in a desired distribution for colour fields in terms of recesses filled with resin in accordance with aspects of the present invention then; b) introducing specifically that resin into those recesses through a hollow needle of an appropriate size such that the coloured resin remains within the colour field defined by the recess so that an appropriate high quality distribution of colour within the recesses creates the desired final sign distribution and finally; c) allowing the resin to harden in that format.

Typically, as indicated above, the hardener will be arranged to result in a still workable resin after approximately twenty minutes, and a practically hard resin in an acceptable time period, but this will also be achieved normally through provision of an elevated curing temperature in the order of 40 -50 C.

Other hardening periods may be specified.

Accurate colour fields produced by the method in accordance with aspects of the present invention will create an overall sign which is reminiscent of a vitreous enamel sign produced previously. The plastics base material which forms the recessed structure formed by the present method will generally be metallised by surface plating to induce the desired light reflections for lustre in the resin/colorant combination utilised in accordance with the method of the present invention. These plated parts will also remain exposed between the infilled recesses as part of the sign design. As indicated above, solid particles in the form of pigments can be added to the resin in accordance with the method with a transparent dye added to the resin utilised to create the desired lustre, It will also be understood combinations of solid pigments and transparent dyes can be utilised within the resin provided there is no significant degradation in the base resin to hardener activation process. As indicated, this limits the colorant content within the resin to less than 10% by weight in most situations.

The peripheral ledges act as flow traps to control creep up the side waIls of the recess and limit the resin to the desired colour field defined by a recess within the final sign In such circumstances the method in accordance with aspects of the present invention also includes defining an appropriate width for these peripheral ledge edges such that a flow trap is created to prevent smearing and overspill of the resin beyond the desired recess acting as a well for a colour field within the sign or badge.

It will be understood that generally the needle presenting the resin in accordance with aspects of the present invention will be manipulated within the recess in order that the resin will wash flow or flood towards the peripheral ledges. In such circumstances, as indicated, the method comprises incorporating peripheral ledges which act as traps to stop creep of the resin upwards in the recess.

Typically, the needle utilised in accordance with the present method will be of a hypodermic type associated with an appropriate syringe which is disposable after single use. The syringe will be operated through an air pressure varied utilising a regulator valve under specific operator control.

Thus, the width of the needle aperture, as well as the regulated air pressure driving resin flow and movement to force resin through the needle, will be determinant of resin flow rate but also it will be understood that resin viscosity will be a factor. In such circumstances the hardener, as indicated, will generally act to vary the viscosity of the resin over a filling cycle in accordance with aspects of the present invention. By utilising a regulator valve in the method to specifically adjust the air pressure, it will be understood that an operator can therefore increase the air pressure as the viscosity of the resin increases with hardener effect upon the base resin/colorant combination.

During early stages of resin introduction to the recess the resin/colorant will be relatively fluid as the hardener will not have taken much effect in terms of its chemical reaction or other activating process with respect to the resin. In such circumstances a relatively low air pressure will be required to drive resin flow whilst, as the resin becomes harder and therefore its viscosity increases, an operator through the regulator valve can apply greater air pressure to force resin flow as required. As indicated, ideally the method also includes provisions of a peripheral ledge to act as an in-situ flow trap should this variability with respect to resin viscosity cause an excessive wash flow distribution but more normally to inhibit smudging due to surface tension creep up an edge rendering the sign malformed and therefore unacceptable.

The present invention relates particularly to forming signs for use as beer plaques attached to beer engine handles in public houses. Thus, these signs will typically take the form of a brewer's base logo with particular lettering in appropriate colours and distributions to define the nature or brand of the beer identified by the beer plaque. By aspects of the present invention the method provides a sign in the form of a beer plaque which emulates previous vitreous enamel formed beer plaques which appear to have a metal form.

Whilst endeavouring in the foregoing specification to draw attention to those features of the invention believed to be of particular importance it should be understood that the Applicant claims protection in respect of any patentable feature or combination of features hereinbefore referred to and/or shown in the drawings whether or not particular emphasis has been placed thereon.

Claims

c:!ains 1. A method for forming a sign cortiprising uttlising a

recessed structure, the method comPflSifl9 defining a plurality of recesses in the structure and applying a resin through a needle, th resin chosen by a combination of a clear resin and a colorant for a particular recess and the needle arranged to provide a pressurised resin flow to the recess for wash distribution spread across the recess 2 A method as claimed in claim I wherein the method includes provision of a ledge to a periphely of each recess of sufficient depth to prevent overspill and/or provide edge definition. 4* * . .

S S. *

1 5 3. A method as claimed in claim I or claim 2 wherein the method includes * . . choosing a needle dependent upon recess size and/or regulating air pressure *S* flow.

S *

4 A method as claimed in any preceding claim wherein the recesses are provided by moulding the structure. * . S

S

5. A method as claimed in any preceding claim wherein the recessed structure is formed from a plastics material.

6. A method as claimed in any preceding claim wherein the method includes selection of a necessary colorant from a range of pigments and/or dyes to achieve the desired final colour field in the recess 7 A method as claimed in any preceding claim wherein forming the recesS includes forming a flow trap edge 8. A method for forming a sign substantially as hereinbefore described with reference to the accompanying drawings 9. A sign made in accordance with a method as claimed in any preceding claim.

A sign as claimed in claim 9 wherein the sign is a beer plaque for securing to a beer engine handle.

11. A sign as claimed in claim 9 or claim 10 wherein the recess has a depth of up to 1mm.

12 A sign as claimed in any of claims 9 to 11 when dependent upon claim 7 wherein the flow trap edge comprises a ledge to prevent upward creep or * Sb 1 5 smearing up the recess wall. s.* 13. A sign substantially as hereiribefore described with reference to the accompanying drawings. ii' * 14. Any novel subject matter or combination including novel subject matter disclosed herein, whether or not within the scope of or relating to the same invention as any of the preceding claims.