MXPA00005521A - Flexible grand format reflective sign and materials and methods for making - Google Patents

Abstract

A flexible outdoor sign (10) being comprised of a flexible substrate layer (18) and a flexible reflective layer (16), wherein the sign (10) is of a grand format dimension, that is, greater than 48 inches wide, and further being most applicable to outdoor billboards, truck curtains, and other large outdoor venues. Due to its flexible nature, this sign (10) can be rolled up and transported easily, as it does not depend on heavy plywood backing to support it. Upon being delivered, the sign (10) can be unrolled and winched around a billboard, for example. The sign (10) is then anchored with trucking straps, or the like. This invention is also a flexible sign material made into grand format dimensions, as well as a method for making this material.

Description

LETTER REFLECTOR OF LARGE FLEXIBLE FORMAT AND MATERIALS AND METHODS TO MANUFACTURE IT Cross-reference to related requests This application claims the benefit of the provisional application for USES. No. 60 / 098,982, filed on September 2, 1998.

FIELD OF THE INVENTION This invention pertains generally to exterior signage and spectacular advertisements used for advertising purposes, and, more specifically, to a flexible large-format reflector sign and methods and materials for making a flexible large-format reflector sign.

BACKGROUND OF THE INVENTION Spectacular ads have been a common vehicle for advertising goods and services outdoors for more than seventy years. Spectacular ads carry a message related to a product or service to captive audiences in cars and casual passers-by. In the early days of making spectacular advertisements, a paper sign was glued to a laminated wood backing, or other rigid substrate, and assembled by pieces to comprise a full advertisement. Those initial spectacular paper ads were designed for temporary use, since they usually deteriorate in the environment in less than three months. If a more permanent advertisement was desired, this involved painting by hand a spectacular advertisement directly on the laminated wood, in which case said sign could last several years. The initial spectacular advertisements were limited to use only during daylight, because the old painted signs could not be seen during the night. When electric light became commonplace in large cities, spectacular commercials began to incorporate lighting systems for night use. However, in the surrounding areas where there was no electricity, or it was too expensive to place power lines, the signs placed in those areas were still limited to use only during the day. As a result, the advertising capacity of those outdoor billboards was terminated during the afternoon. A solution to illuminate signs not accessible to electricity came with the arrival of reflective materials. These reflective materials made it possible to use the front lights of passing cars to serve as a source of light to illuminate the reflective signs. These reflective materials are classified according to a "luminaire power" standard measured in candelas per light per square meter (cpl). A synopsis of several reflective materials currently known for use with signs, and their cpl classification comes next: Lens Vinyl Enclosed-90 cpl This reflective material is commonly used for commercial signage, vehicle graphics, and safety markings. This material is manufactured from glass beads (lenses) enclosed (embedded) in polyvinyl chloride compounds. The material is built to become a layer of film and adhesive, and as such it can be cut into graphic shapes and letters. The surface is printable on the screen, paintable, and digitally printable, and the product commonly has an adhesive backing to fix to rigid laminate such as laminated wood or aluminum. This type of product can not withstand bending or grooving without impairing the properties of light reflection. The enclosed lens films are angularly restricted in that they have a narrow entry and angle of observation, requiring almost a direct approach of a light source and observer to reflect the light and be seen. They are further limited by a reduction in reflective capacity due to the fact that the lenses are embedded in the vinyl structural layer. Spectacular signage of enclosed lenses must be placed within approximately 4.57 meters of the edge of a roadway, or otherwise they will not reflect light adequately. Typical spectacular signage is fabricated with encased lens material by adhering the material to a laminated wood substrate, or backing.

Encapsulated lens film-250 cpl This material is manufactured by encapsulating glass spheres under tightly sealed "cells" that maintain an air gap to allow the lenses to reflect at full capacity. The sealing of the lenses protects them from the elements, since the lenses will not reflect if they are dirty or wet. The film of encapsulated lenses 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 signs, but imparts an undesirable 10 to 15% change in colors that is undesirable for the spectacular ad technique. The current digital technology can not print directly to encapsulated lens films, as they have a layer of acrylic or polycarbonate coating the encapsulation layer. The same layer creates a rigid yet brittle structure that requires the material to be adhered onto a supporting substrate such as laminated wood or aluminum. Encapsulated lens films offer classifications c.p.l. higher when compared to enclosed lens films, and offer wider viewing and viewing angles. This film is occasionally used to make spectacular advertisements by cutting the film in the form of graphic elements, and applying them as individual pieces to eventually form a complete sign.

Rigid formed sheet.- This film is made by forming a sheet of acrylic material or the like to have a layer of microprisms under a surface of an optically transparent material, or by joining hard prisms on rigid laminate. The 3M Diamond Grade film is typical of this type of formed sheet, and uses hermetically sealed chambers in small diamonds (± 0.63cm) that are backed by a layer of vinyl and adhesive. This film is stiff, rigid, and not printable by current digital media. This film requires a substrate such as laminated wood or aluminum to be exposed in an outdoor environment.

Flexible bonded sheet.- It is manufactured by joining semi-hard micro-prisms on flexible substrate substrate such as polyvinyl chloride combined with nylon or polyester network. Flexible bonded sheet constructions are relatively new materials that have gained considerable acceptance in flexible street signage, clothing, and sports goods manufacturing. For clothes, the material is typically sewn into a garment to create a semi-sealed cell. For signaling, the sealed cell construction (air bag) is used, with the support substrate typically of the desired color of the sign in its finished use, ie orange, yellow, red, white. These materials are digitally printable. This material can be seen in direct and indirect angles of view. This material offers bright reflection and white environments and reflective energy that works in daylight as well as at night. Graphically, it is ideally suited for spectacular flexible reflector ads. However, this material suffers from the following four disadvantages for spectacular advertisement uses, namely: 1) that it is not manufactured in widths larger than 121.92 cm and; 2) can not be quickly converted into larger widths, and; 3) to create larger widths with supply items, a layer of adhesive (and subsequent silver color) would be required and; 4) It would require hand application of laminate with adhesive coating to fix it to a standard face of spectacular vinyl ad. Additionally, current manufacturers recommend that this material be fixed only to rigid materials, such as laminated wood, thereby increasing the transportation costs associated with shipping a sign to its point of use.

Prismatic Films-300-900cpl.- Prismatic films (or cube corner microprisms (CCMR)) offer the highest reflection angles and widest observation and entrance angles. Because all prismatic layers are transparent by design, they offer non-opaque reflection to make a white background in daylight, and offer minimal structural integrity for exterior function. This material requires a support layer for structural integrity and graphic appearance for the desired end use. To be useful, this material requires maintaining the mirror surface of the prisms as reflective facets of light. This can be accomplished by reflecting the prisms on the film by depositing some form of silver to create a mirror finish, or by creating a sealed chamber under the prisms to allow the prisms to reflect with their natural polish. In mirror construction, adhesives may be applied to the backing of the prismatic film, since the mirror coating acts to reflect light, and the reflective properties are not diminished. The silver or reflective deposition is gray (approximately 30%) and looks similar to stainless steel. This material is manufactured by manufacturers that include Reflexite Corp, Stimsonite Corp, and 3M Corp, and is comprised of a flexible reflector material that can be manufactured with an adhesive coating for hand pressure applications. Because the CCMR can be printed digitally on top of it, it makes an excellent choice for large-format signage such as billboard advertisements and truck curtains. The CCMR and the flexible bonded sheet are flexible, unlike the more rigid flexible materials described above. Smaller signs of less than 121.98 cm2 have been created, using flexible bonded sheet, which can then be rolled and transported easily. So far, no one has contemplated any material or method by which a flexible large-format reflector sign could be created for such applications on spectacular signs and truck curtains. The aforementioned discussion reflects the most advanced of the technique of which the inventor is aware, and is presented in order to discharge the recognized sincerity obligation of the inventor in describing information that may be relevant in relation to the patentability of the present invention. . It is stipulated in a respectful manner, however, that the information described does not teach or becomes obvious, uniquely or when considered in combination, the invention claimed by the inventor.

BRIEF DESCRIPTION OF THE INVENTION In its broadest sense, this invention applies to any flexible large-format reflector sign consisting of a flexible reflective layer bonded to a flexible structural substrate layer. This invention relates to the creation of flexible large-format reflector signs by two methods: 1) by hand applying flexible reflector sign material to a flexible substrate by adhesive means; and 2) modifying flexible bonded sheet sections for purposes of joining sections to create a large format sign. This invention further relates to a material consisting of a modified flexible bonded sheet that can be used to create large format signage. Finally, this invention relates to large format signs produced by the two methods described herein. Accordingly, the following objects and advantages will be achieved by this invention: It is an object of this invention to provide a modification to existing flexible bonded sheet signage materials and use them to create large format reflective signage; this modification is designed to effect the easy and complete joining of said sign materials by machine manufacture so that a 100% reflective quality and a 100% structural integrity are maintained across the surface of a sign. It is an object of this invention to provide a reflector sign in a large format size using a light weight substrate material which can be rolled and shipped to an installation location with minimum shipping cost. It is a further object of this invention to provide a reflector sign in a large format size that can be rolled and installed on a spectacular advertisement structure or other hanging surface, using ropes or pulleys, and four, or less, workers. The additional objects and advantages of this invention will be brought into the following portions of the specification, in which the detailed description is for purposes of fully describing preferred embodiments of the invention without placing limitations thereto.

BRIEF DESCRIPTION OF THE DRAWINGS The invention will be more fully understood by reference to the following drawings which are for illustrative purposes only: Figure 1 is an exploded perspective view of a large format signboard in which adhesive CCMR is used in a hand-applied method. Figure 2 is a cut-away end view of a section of flexible bonded sheet material. Figure 3 is a cut-away end view of a section of flexible bonded sheet material prepared according to the preferred method for making a large format sign as described herein. Figure 4 is a cut-away end view of adjacent sections of flexible bonded sheet material, prepared according to the method described herein, placed for RF welding. Figure 5 is a cut-away end view showing the substrate layers of adjacent sections of flexible bonded sheet being "RF bar" welded with a sealing bar, according to the method described herein. Figure 6 is a cut-away end view showing the substrate layers of adjacent sections after RF bar welding. Figure 7 is a cut-away end view showing a pattern duplicating die welding the reflective layer on the previously welded substrate layers of adjacent flexible bonded sheet sections, as a final step to the process described herein.

Figure 8 is a cut-away end view showing a complete joint engaging two adjacent flexible bonded sheet sections. Figure 9 is a bottom perspective view of a disposable pattern duplicating die for use in practicing the method described herein. Figure 10 is a bottom view of a permanent pattern duplicating die for use in practicing the method described herein.

DESCRIPTION OF THE PREFERRED MODALITIES The present invention relates to flexible large format reflector signs and materials and methods for manufacturing said signs. The retroreflective film of microprism of corner of cube (CCMR) has the following superior qualities: 1) it can be printed digitally; 2) can be attached to a light weight flexible substrate such as PVC / nylon net; 3) is flexible, and therefore compares in flexibility to substrates, such as PVC / nylon, thereby reducing problems associated with the lamination; 4) can be viewed from direct and indirect angles of view. However, large-format signs have not been produced ("large format" means broader signs of 121.92 cm) using CCMR. In the first embodiment of this invention, a method is described for hand-applied CCMR backed with adhesive to a PVC / nylon net substrate to create a large format size sign, such as a spectacular 3.04 X 14.63 m (44.50 m) advertisement. m2). This type of large-format sign 10 produced according to this method is shown in Figure 1. This method requires CCMR sections 12 to be applied by hand to a vinyl substrate (PVC) and nylon network having the dimensions adequate 3.04 X 14.63 m of a typical spectacular ad. A flexible substrate 18, such as vinyl and nylon network, of a large format scale, is fabricated by radio frequency (RF) bar welding of adjacent sections 14 of substrate material 18 together until a large format dimension, as 3.04 X 14.63 m is achieved. Next, the CCMR with adhesive backing should be printed in sections 12, with the appropriate announcement and background. Digital printing is a known method for applying words, logos, and photographs or other signs 15 to sections of CCMR. The respective adhesive sections 12 are then accurately aligned, and hand-applied to the substrate 18. Two skilled workers require approximately 4 hours to produce a single large-format 44.50 m2 sign using this hand-applied method. Although a presentable sign 10 is produced with this method, which can be rolled and transported, this method is slow and labor-intensive; air bubbles may also occur under the CCMR, or if inadequate adhesion at points does not occur, thereby affecting the uniform visual quality of the finished sign product. As an alternative to the hand application of the CCMR material in large format size signs, flexible bonded sheet material is used according to a second method to produce a large format sign as described herein. In the prior art, small signage having a maximum width of 121.92 cm has been created using flexible bonded sheet material. This material typically comes in rolls that are up to 121.92 cm wide, maximum, but that have a variable length, sometimes as long as 1524 m. This 121.92 cm wide material is machine made using RF welding guided by a computer and patterned. The die with pattern is a series of sunken square air pads of approximately 2.54 square cm. Where there are depressions in the die, there is no contact, and therefore welding does not occur. At the edges of each frame, the die contacts and welds the reflective layer to the flexible vinyl substrate and nylon net. The result is a sign material having a plurality of square air pads barely visible through its surface and having a width of up to 121.92 cm. It has been discovered that due to the flexible nature of the reflective layer, and the flexible nature of the substrate layer, precise machine registration is difficult at widths above 121.92 cm, and therefore, this width limit is currently the limit of the latest technique for this material. Currently, the development of a machine to produce pre-filled sign material in widths of more than 121.92 cm has not been achieved. The present invention is a sign material comprising modified flexible bonded sheet so that adjacent sheet sections can be easily welded together in a large format dimension. This material can then be used as a large format preform (without signs) that can be shipped to a sign manufacturer to print signs and create a large format finished sign. This material and the procedure for using it to make a flexible large-format sign maintain a 100% uniform structural integrity and a 100% uniform visual appearance across the entire surface of a large format signage. Although the hand-applied method using CCMR, described above, creates a presentable flexible large format sign, the level of visual appearance is superior with the second method described herein, which uses flexible bonded sheet material. For purposes of this invention, the term "flexible" means the ability of a placard fabricated from the materials and methods described herein to be rolled up for seizure, without damage or slippage of the different layers, and subsequently unrolled. , for installation. Although the CCMR and the flexible bonded sheet are discussed herein as two reflective materials capable of meeting this definition of flexibility, any other reflective material that meets this definition is also included within the scope of the invention.

In a representative embodiment, flexible bonded sheet of the type already described herein is used to produce a sign material according to the present invention. The flexible bonded sheet provides flexibilities that almost equalize with the network substrate layers so that the final sign product can be rolled, and unrolled, without problems associated with lamination. Additionally, the flexible nature of the two layers allows the sign to be produced in large format sizes, and subsequently rolled and shipped to any location for installation. A large format sign fabricated from network substrate and flexible bonded sheet, in a standard spectacular ad size of 3.04 X 14.63 m weighs approximately 54.43 kg, which is one tenth of the typical weight of a 3M Diamond Grade size sign similar that weighs approximately 544.30 kg, due to its dependence on a laminated wood substrate. Hence, significant savings are provided by the present invention in terms of shipping costs. The flexible bonded sheet material includes a flexible reflective layer bonded to a flexible substrate layer such as vinyl and nylon net, using an RF welding method and a computer guided welder having a die forming a plurality of air pads 2.54 cm2 across the surface of the flexible bonded sheet. These air pads 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 their reflective properties and to retain their ability to be seen at indirect angles. Figure 2 represents a cut-away end view of a standard flexible bonded sheet section which is not modified in any way. Here the flexible bonded sheet 11, has a reflective layer 16, a layer of substrate 18 and associated air pads 20 and air bags 22. Figure 3 depicts a flexible bonded sheet section 11 modified in a manner to present the material of sign which is the present invention. In Figure 3, a first end 24 and a second end 26 of the material section have been prepared so that the first end 24 comprises only one layer of substrate 18, devoid of any reflective layer 16 and the second end 26 retains a reflecting layer in the form of a loose end flap 28. The ends 24 and 26 have been prepared in this manner so as to be treatable for joining the adjacent sections of sign material for purposes of fabricating a full-size large sign 10. Figure 4 illustrates adjacent sections 11a, 11b of flexible bonded sheet being joined by overlapping the first end 24 below the end flap 28 of the second end 26. Figure 5 illustrates a sealing bar 30 of an RF welder joining the layers 18 of respective substrates of adjacent material sections 11a, 11b. Figure 6 illustrates the substrate layers 18 joined after welding and before joining the end flap 28. Figure 7 illustrates the final step of the process involving coupling a pattern duplicating die 32 which duplicates the air pads to Along the weld seam 34. This final step is achieved by RF welding and creates a surface of uninterrupted air pads through the large format sign material, thus retaining 100% visual and 100% uniformity across the material surface of the large format sign. When the sign material is printed digitally on top, the signs printed on the finished sign appear clear and uninterrupted. This final step provides a sign material that is wider than the 121.92 cm limitation of standard flexible bonded sheet; that is, the edge perpendicular to the weld seam in the finished material is wider than 121.92 cm, making large format sizes possible in a flexible sign. The step of applying the reflective flap 28 may be achieved by using other bonding materials, such as a reflective flap with adhesive backing which could be applied on top of the weld seam 34 of the substrate layers. However, although said reflective layer with adhesive backing is within the scope of this invention, it has been found that it is less preferable to use adhesives, due to problems of air bubbles, and a reduction in the reflective quality at the point of adhesion to the adhesive. along the weld seam, which degrades the final appearance of the large format sign. It has been discovered that by using a pattern duplicating die 32 to duplicate the surface of the flexible bonded sheet at the point of the weld seam 34, problems with adhesives are avoided and that 100% and 100% reflective quality can be maintained. % structural integrity across the surface of a large format sign. Figure 8 illustrates the final product produced by the method described so far, showing the weld seam 34 with air pad 20 and suitable air pockets 22 located on the weld seam 34 as created by the duplication die 32 Pattern. The doubling die 32 is shown in two embodiments in Figures 9 and 10. While the sealing bar 30 sealing the substrate layers is simply an iron with a flat surface, which is heated with RF waves, the 32 of pattern duplication incorporates a plurality of rectangular cavities 36. The edges 38 of the cavities 36 contact the surface of the layer 16 of reflective material and weld it to the substrate layers 18 creating the edges 40 of the air pads, when heated by contact with the sealing bar. The cavities 36 create the air bag 22 of the air cushion 20 allowing the layer of reflective material to advance upwardly in the cavity 36 without contacting the substrate layer 18 and welding it. Figure 9 depicts a disposable die 32 made of machined metal having cavities 36 and edges 38, as previously described. Figure 10 shows a permanent die 32 having a non-conductive insert 42 mounted on top of the cavity 36 and a non-conductive coating 44 surrounding the outside of the die 32. The non-conductive materials are preferably glass fiber, epoxy, or silicone rubber The rectangular edges 38 surrounding the cavity 36 remain of an RF conductive material, such as metal. The method of machine fabrication of the sign material from the modified flexible bonded sheet shown in Figure 3 allows a spectacular advertisement size material of 3.04 m X 14.63 m to be manufactured in 10-20 minutes with a bar sealer of RF and die of pattern duplication. The method of application by hand described here requires two people and four hours to complete. The sign installation method described herein takes advantage of its flexible nature. As part of the fabrication of the sign it is preferred that corner sacks or metal eyelets are installed for the purpose of placing traction belts so that the sign can be clamped tight from various attachment points in the installation. Upon being delivered to a spectacular advertisement location for installation, a sign fabricated from the two methods described herein may be unrolled, deployed around a spectacular advertisement structure, and subsequently be tensioned, and engaged with four or more traction straps This method of installation can be achieved using a staff of as few as four people for a spectacular announcement sign of 3.04 X 14.63 m, and can be completed in a fifth of the typical time it takes to install a spectacular advertisement sign using laminated wood, 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. Accordingly, this invention provides a sign material made from modified flexible bonded sheet, which can be used to machine make a flexible large format sign material having superior properties not seen heretofore. This material can be shipped to a sign manufacturer in a "blank" large format size, at which point, the sign can be completed by printing several signs on the sign by digital printing, for example. Additionally, the invention provides a method for machining this blank material from the modified flexible bonded sheet previously described. In the alternative, this invention also provides a method for manufacturing a flexible large-format sign using hand-applied CCMRs and a flexible substrate such as PVC nylon netting. This invention is also a flexible large-format sign fabricated from flexible sign material that can be rolled up and shipped to a location for installation, unwinding, and installation. Finally, although the above description contains many specifications, these should not be considered as limiting the scope of the invention but simply as providing illustrations of some of the presently preferred embodiments of this invention.

Claims (17)

NOVELTY OF THE INVENTION CLAIMS

1. - A flexible large format sign designed to be rolled for transport, comprising: a flexible substrate layer and a reflective layer attached to said substrate layer; the reflecting layer and the substrate layer measured in a large format dimension; and printed signs placed on the signboard so that said signs are reflected by said reflective layer in a manner that retains uniform visual appearance through a surface that visually appears from said sign.

2. The large format sign according to claim 1, further characterized in that the substrate layer comprises a vinyl substrate and nylon net.

3. The large format sign according to claim 2, further characterized in that the reflecting layer is retroreflector microprism film of cube corner.

4. The large format sign according to claim 3, further characterized in that the reflective layer is adhesively applied to the substrate layer.

5. The large format sign according to claim 1, further characterized in that it additionally comprises adjacent sections of flexible bonded sheet, said adjacent sections share a layer of welded substrate, forming a weld seam, said weld seam joined to a layer of reflective material formed in air pads along said welding seam.

6. The large format sign according to claim 1, further characterized in that it additionally comprises adjacent sections of flexible bonded sheet, said adjacent sections share a layer of welded flexible substrate forming a weld seam, said weld seam being joined Adhesively to a layer of reflective material placed on top of the weld seam.

7. A flexible bonded sheet material modified for the manufacture of large format signs, said material comprises: a section of flexible bonded sheet material; a first edge skirting the section of bonded sheet material, said first edge comprising a layer of bare flexible substrate; and a second edge skirting said section of bonded sheet material, said second edge comprising a layer of flexible substrate superimposed by a fin of flexible reflective material.

8. A signage material for the manufacture of large format signage, comprising: a first section of flexible bonded sheet material, said section includes a bare substrate layer edge; a second section of flexible bonded sheet material, said section includes a substrate layer edge superimposed with a fin of reflective material; said uncovered substrate layer edge of the first section being welded to the substrate layer edge of the second section, said substrate layer edges welded together forming an edge seam; said flap of reflective material being attached to the edge seam to complete a joint between the first and second sections of the bonded sheet material.

9. The material according to claim 8 further characterized in that the fin of reflective material is adhesively attached to the weld seam.

10. The material according to claim 8 further characterized in that the fin of reflective material is attached to the weld seam to form a plurality of air pads along the weld seam.

11. The material according to claim 8, further characterized in that the first and second sections of bonded sheet material are wider than 121.92 cm along an edge perpendicular to said weld seam.

12. A method for manufacturing a material for creating large format signs, comprising: overlapping layers of flexible substrate from two adjacent sections of flexible bonded sheet material; welding said flexible substrate layers together to form a weld seam; coating said welding seam with a fin of flexible reflector material; joining the reflective material to the weld seam to form the reflective material on a visual appearance surface that is uniform across the sign material.

13. The method according to claim 12, further characterized in that said flexible substrate layers are welded with a bar sealer using RF energy to form said weld seam.

14. The method according to claim 12, further characterized in that said adjacent sections of bonded sheet material are wider than 121.92 cm along an edge perpendicular to said weld seam.

15. The method according to claim 12, further characterized by additionally comprising the attachment of the reflective material to said weld seam forming first the reflector material in a plurality of air pads and secondly joining the reflector material to said seam welding, said air pads creating a visual appearance surface that is uniform across the sign material.

16. The method according to claim 14, further characterized in that it further comprises forming the reflective material in air pads using a pattern duplicating die and attaching the reflective material to said welding seam using RF energy.

17. A method for the manufacture of large format sign, the method comprises: a) providing a flexible substrate layer having a large format dimension; b) supplying adjacent sections of flexible reflective material having signs printed thereon; c) adhesively applying the adjacent sections of flexible reflective material to the flexible substrate layer such that said signs are aligned to form a complete sign message, said flexible substrate layer being covered by the flexible reflective layer.