MECHANICAL EMBOSSING ON PIGMENTED ORGANIC SUBLIMATABLE COATING FOR BOTH FLAT PANELS AND EXTRUSIONS

FIELD OF THE INVENTION

[0001] The invention relates to a system and method for embossing a powder coating that can accept sublimation printing techniques. In particular, the invention relates to dimensional coatings for metal or other substrates, such as“wood-look” railings and fences or other products.

BACKGROUND OF THE INVENTION

[0002] Digitally created embossed surfaces for building materials, such as wall and flooring panels, are popular alternatives to natural products. U.S. Patent No. 10,029,484 summarizes the various techniques used to create such synthetic materials and discloses a press matrix and method for forming an embossed structure on a panel by providing a press matrix having hard pressed particles arranged in a pattern to a carrier paper or foil and pressing the foil to a surface to create an embossed structure. These panels are not sublimated.

[0003] Dye sublimation is a process that uses heat to transfer dye onto materials such as metal, plastic, card, paper, or fabric. Heat and pressure are applied to a solid, turning it into gas through an

endothermic reaction without passing through the liquid phase. In sublimation printing, unique sublimation dyes are transferred to sheets of“transfer” paper via liquid gel ink through a piezoelectric print head or by rotogravure techniques. The ink is deposited on these high-release inkjet papers, which are used for the next step of the sublimation printing process. After the digital design is printed onto sublimation transfer sheets, it is placed on a heat press along with the substrate to be sublimated.

[0004] In order to transfer the image from the paper to the substrate, it requires a heat press process that is a combination of time, temperature and pressure. A heat press applies this special

combination, which can change depending on the substrate, to “transfer” the sublimation dyes at the molecular level into the substrate. The most common dyes used for sublimation activate at 350 degrees Fahrenheit. However, a range of 380 to 420 degrees Fahrenheit, or 180 to 220 degrees Celsius, is normally recommended for optimal color.

[0005] The end result of the sublimation process is a nearly permanent, high resolution, full color print. Because the molecules of sublimation pigments are transforming in gas inside the polymer layer and then becoming solid again, rather than applied at a topical level (such as with screen printing and direct to garment printing), the prints will not crack, fade or peel from the substrate under normal conditions.

[0006] For these reasons, it is desirable to use sublimation to apply designs onto objects and articles for building and outdoor use. Accordingly, nowadays many building materials and outdoor products, such as panels, fences, railings, lawn chairs, tables and decking are made of hard plastics or metal. There is a desire for these more durable sublimated products to mimic the look and feel of traditional materials used for these products, such as wood. Many wood-look products are available on the market.

[0007] For instance, Decora Powder Coatings Ltd. provides wood grain finishes on aluminum and steel. A pretreatment of chemical conversions gets applied to a raw aluminum surface, creating thin layers of amorphous oxide with a coating. A 2.5 mils layer of powder paint (non hazardous) is applied with electrostatic guns. Polymerization is then performed utilizing a 400°F temperature for up to 30 minutes. In the next stage of the powder coating process, a pre-printed film transfer (that contains organic photosensitive pigments and cellulose resin) is wrapped around the product, which is set on the surface of a trolley. A vacuum suction system removes air, and in turn, produces a thermo print. The trolley is placed within a specialized oven, affecting the decoration by converting ink pigments from solid, into gas and back again to solid within the paint layer. In the last step of the powder coat process, the film is removed upon cooling.

[0008] These films visually look like wood grain, but are smooth and do not provide the texture of a natural wood grain. There is a desire for durable textured materials that are printed by sublimation.

[0009] U.S. Patent No. 9,956,814 discloses a method of decorating a substrate wherein subliming is combined with the step of embossing the substrate. Embossing is achieved by printing and curing a curable substance on a carrier that is then laminated and embossed onto the substrate at the same time. A continuous machine for achieving such materials employs 4 steps: embossing, curing, printing, and curing. The sublimation is done at the same time as embossing.

[0010] New and improved and/or alternative processes to apply pattern and texture to substrates that can be sublimated are desired. In particular, there is a desire to have a process for applying texture to a product for sublimation printing where the sublimation can take place at a later point in time from the step of embossing.

SUMMARY OF THE INVENTION

[0011] It is an object of the invention to provide for embossing and sublimation printing on a variety of materials, and more particularly metal materials. [0012] It is further an object of the invention to provide an efficient process for embossing substrates which can be sublimated.

[0013] In accordance with the foregoing, the present invention provides a method for manufacturing an embossed substrate suitable for sublimation comprising the steps of applying a primer to a substrate; coating the primed substrate; heating the coated substrate to at least partially cure the coating; pressing a body having relief depressions on the at least partially cured coating to form depressions in the powder coating; removing the body having relief depressions to yield an embossed substrate. In certain aspects, the body is a wheel and in others the body is a plate. In preferred aspects, the coating layer which includes both the primer and coating is fully cured before embossing and the primer is a softer material than the coating. In other preferred aspects, the primer is not used. In other preferred aspects, the coating is receptive to sublimation in others, the coating is not receptive to sublimation.

[0014] In certain aspects the method includes heating the substrate, during or after the step of pressing. In other aspects the method includes heating the substrate before the step of pressing to a higher temperature than the heating to at least partially cure the coating. In yet other aspects the body is a flat plate. In other aspects the body is a flexible paper material. In still other aspects the body is a wheel. In yet other aspects the wheel is heated during the pressing step. In still other aspects the wheel is metallic. In other aspects the method includes feeding the embossed substrate through a sublimation press to apply sublimation decoration to the coating. In certain aspects the wheel is metallic and the roller of the sublimation press is a rubber material. In certain aspects the coating is a powder coating selected from the group consisting of an epoxy polyester, polyester and polyurethane. In certain aspects, the coating is made of organic compounds.

[0015] In still other aspects, during the pressing step, the coating is maintained at a temperature in the rage of 180-270 deg C. In other aspects the temperature is in the range of 220-260 deg C. In other aspects the temperature is approximately 230 deg C.

[0016] In other aspects the pressing step is maintained for a time of 40-500 seconds. In certain aspects the time is 60-300 seconds.

[0017] Other objects are achieved by providing a method of manufacturing a sublimated substrate comprising the steps of: providing a coated substrate with a coating which is a powder coating selected from the group consisting of epoxy polyester, polyester and

polyurethane; pressing a body having relief depressions on the at least partially cured coating to form depressions in the coating; removing the body having relief depressions from contact with the coated substrate to yield an embossed substrate; and sublimating the embossed substrate with a print decoration, wherein the step of sublimating occurs after the substrate is embossed and wherein the coating is receptive to sublimation ink of the print decoration.

[0018] In certain aspects the method includes heating the substrate, during or after the step of pressing. In other aspects the method includes pre-heating the substrate before the step of pressing.

In other aspects the coating is heated to a temperature in the range of 180-260deg c and the pressing step is maintained for a time of 20-500 seconds.

[0019] Other objects are achieved by providing an embossed and printed substrate including a substrate of a first material and a coating applied to an exterior of the first material wherein the coating is of a thickness of 40-300 microns (more particularly 50-250 microns or more particularly 60-200 microns) and is selected from the group consisting of: epoxy polyester, polyester and polyurethane. Depressions are provided in the coating such that the depressions have a depth in the range of 0-80% of the thickness. Sublimation ink is applied to the coating such that a sublimated decoration is applied to the coating. In certain aspects a primer layer is between the coating and substrate and the primer layer is a different material than the coating.

DESCRIPTION OF DRAWINGS

[0020] The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.

[0021] Fig. 1 shows a flat press machine suitable for use in certain methods of the invention.

[0022] Fig. 2 shows a regular powder coated surface without embossing.

[0023] Fig. 3 shows an embossed substrate made in accordance with present invention.

[0024] Fig. 4 shows an embossed, sublimated substrate made in accordance with the inventive methods, in which the embossing is a hexagonal pattern.

[0025] Fig. 5 shows an embossed, sublimated substrate made in accordance with the inventive methods, in which the embossing is a different pattern from that of Fig. 4.

[0026] FIG. 6 shows another exemplary pattern for an embossed and decorated substrate of the invention. [0027] FIG. 7 shows a side view of a process for preparing the embossed and decorated substrates.

[0028] FIG. 8A-C shows front views of the machine used in FIG.

7 and embodiments thereof.

[0029] FIG. 9 and 10 are perspective views of an alternative embossing process.

[0030] FIG. 1 1 is a perspective view of an unembossed substrate

[0031] FIG. 12 is a perspective view of the substrate of FIG. 1 1 with embossing.

DETAILED DESCRIPTION OF THE INVENTION

[0032] The present invention provides methods for manufacturing an embossed substrate suitable for sublimation, such as the ones shown in Figs. 3- 6 and 13. The present invention also provides for methods of manufacturing embossed substrates which include curved or otherwise undulating or varied surfaces/cross sections.

[0033] Suitable substrates are able to withstand temperatures of 500°F and can be selected from metals, such as aluminum, steel, copper, bronze and stainless steel. Preferably, the substrate is metal, such as an aluminum panel or extruded metal such as aluminum of varied shapes. Another set of suitable substrates is selected from the group consisting of one or more of polyamide or nylon 66 or glass, or MDF or other materials which have a melting point above 180 deg Celsius.

[0034] The first step involves applying a primer to a substrate. The primer can be liquid or solid. Preferably, the primer is a white coating. The primer is partially or totally cured. The temperature to cure or partially cure will depend on the treatment selected and can be readily adjusted by those of skill in the art. Preferably, the primer is fully cured.

[0035] After a primer is applied, a coating is applied to the primed substrate. Coatings can be selected from powders or liquids. Suitable coatings include, but are not limited to sublimatable coatings. In preferred embodiments, the coating is a sublimation ink receptive material.

[0036] In some embodiments, the coating can be selected from polyesters, including epoxy polyesters, and polyurethanes. In certain embodiments, the coating is preferably polyurethane.

[0037] The coated substrate is heated to at least partially cure the coating. In preferred embodiments, the coating is fully cured. The temperature to cure or partially cure will depend on the coating selected and can be readily adjusted by those of skill in the art.

[0038] An example of a coated substrate is shown in Fig. 2.

[0039] Subsequent to coating, a pressing a plate having relief depressions is placed on the coated substrate (with the relief going out faced the coated substrate) to form depressions in the powder coating.

[0040] The pressing plate can be made of paper or metal.

[0041] The relief depressions can take any configuration. It is desirable to have relief patterns that mimic the patterns of natural building materials, for instance wood. Other desirable patterns include geometric or random patterns, such as those shown in Figs. 3-5. Fig. 4 shows a substrate which has both a white primer and a clear coating thereon where the clear coating is sublimated to change the color thereof and the white of the primer layer is visible through the clear coating where sublimation is not applied in that sublimation does not ordinarily allow for the application of white color and rather the absence of printing in that location provides for the white color of the primer to be visible. It should be understood that although certain specific relief patterns are shown, the invention is not limited to the specific relief patterns herein.

[0042] The pressing plate is pressed into the coated substrate by application of pressure. A flat press machine, as shown in Figure 1 , can be used. Alternately, vacuum bagging (FIG. 9-10) or a continuous process shown in Figures 7-8(A-C) can be used. When a flat press machine is used in some embodiments the coated substrate faces up and the pressing plate faces down towards the coating layer. The reverse arrangement is also contemplated and it is also contemplated that both sides can be embossed with the pressing plate on both sides facing inwards.

[0043] Optionally, heat can be applied during or after the pressing step. If heat is used during the pressing step, it can include

temperatures of about 200-500°F or 100-250°C. Optionally, the heating can include a pre-heat at around 300-450°F of the metal sheet for few seconds (60-500 seconds first) with or without pressure and then generating high heat (300-500° F) and high pressure (50-150 PSI) for few seconds (60-500 seconds).

[0044] Alternatively, the heating temperature is in the range of about 100°C to about 260°C, preferably 170-260°C, more preferably about 180-260°C, most preferably around 230°C.

[0045] After pressing, the plate is removed to yield an embossed substrate, such as is shown in Fig. 3. The substrates can be sublimated using conventional techniques known in the art. Examples of embossed substrates having sublimation printing are shown in Figs. 4 and 5. Fig.

6 shows a three dimensional profile which a surface thereof is embossed using the vacuum bagging system (FIG. 9-10) described herein or through the roller machine (FIG. 7, 8A-C).

[0046] An alternative method of manufacturing embossed extruded substrates and sheets in a continuous process is shown in Fig. 7 and 8A-C. The process builds an embossing process into applicant’s continuous sublimation printing process disclosed in U.S. Patent No. 6,676,792, the contents of which are incorporated herein.

[0047] Applicant’s novel previously disclosed sublimation process involves preheating an aluminum profile, send into oven stage for few minutes at 200°C, comes out of oven and a high temperature silicone wheel creates pressure and heat at same time for print. Electric resistance elements may heat the silicone wheel. A sublimation film is applied on the bottom of wheel and a rerolling system rolls up the film.

[0048] This process can be modified as shown in FIG. 7, 8A-C to include an embossing step.

[0049] As shown in FIG. 7 and 8A-C, the substrate 2 which in 8A is in an oval profile or in 8B-C is a parallelogram profile is fed along rollers 14 which feed the substrate 2 through the machine. The substrate is primed and coated 5. Pre-heating 4 is applied to bring the substrate to the appropriate temperature. It is also understood that the heat can be a combination of curing and pre-heating with different temperatures. It is also contemplated that the priming, coating and curing (or partial curing) can be accomplished on a separate machine from the embossing. Next, the embossing wheel 6 is used to apply pressure to the surface of the substrate that is to be embossed. Relief pattern/texture T is cut in the wheel 6 which has concave 32 sections designed to match the convex substrate 2. It is understood that although concave 32 sections are shown, this is only because the particular substrate being matched is convex. It is understood that a variety of profiles can be used in the embossing which may result in a variety of cutout 32 shapes on the wheel 6 or that the wheel may be flat as shown in 8B-C. What is important is that the cutout 32 or underlying pressing surface matches the shape of the substrate 2 which is to be embossed and that the cutout 18 of the wheel 14 matches the bottom surface of the substrate 2. Although a single side embossing is shown in FIG. 8A, it is understood that roller 14 may be replaced by another wheel 6 in order to apply the texture T (or a different texture) to the other surface of the substrate as shown in FIG. 7 (677’). It is also contemplated that in certain situations that wheels 6 could be positioned to push in from the sides in order to apply the texture/embossing T to the edges of the substrate and that the wheel 6 can tilt/rotate to accommodate different substrate shapes and orientations. A

combination of multiple wheels 6 is contemplated. Alternately, wheel 14 could include the embossing texture T as shown in FIG. 8B-C. Wheel 6 is also provided with heating in that the wheel itself may have a heating coil embedded in or attached to it or a heater may be placed close to wheel 6. This ensures that the coating on the substrate which is to be embossed will react appropriately to the pressure P and the texture T relief cuts in the wheel 6 in order to provide the embossing on the substrate 2. As can be seen, wheel 6 is supported by arms 20 which support shaft 28. These arms allow the distance A to be adjusted and pressure P to be applied. In addition, it is contemplated that the wheel 6 may be changed and that rollers 14 may be changed to match different shaped substrates 2.

[0050] In one embodiment where profiles made of a number of flat shapes, it is useful to be able to utilize identical wheels to provide the same embossing pattern but then tilt the wheels to match the surface to be embossed. FIG. 8B shows a setup similar to FIG 8A where the top surface is being embossed and the bottom surface is also being embossed. The roller 6 shown in FIG. 8C is not shown in FIG.

8B. Next in the feed line, the roller of FIG. 8C is provided and as shown, this roller has been tilted to match the angled surface of substrate 2. In FIG. 8C, roller 14’ may be a rubber roller (or a more flexible/less hard material) than roller 6 which is less likely to damage the already embossed. Particularly embossed roller 14 in FIG. 8B is preferably metal or another suitably hard material like wheel 6 in order to transfer the embossing to the substrate 2. After embossing has occurred on a particular surface, subsequent support rollers may be made of a softer material than the material used for embossing to avoid these subsequent rollers modifying the embossing pattern. It is understood that roller 14’ is slightly forward or behind wheel 6 to avoid interference or that roller 14’ may alternately be provided with cutouts to avoid interference with wheel 6.

[0051] Although one tilting roller is shown, it is understood that numerous tilting (or fixed) rollers can be provided on the machine in order to provide for embossing of substrates of various shapes and configurations and that the wheels may be removable from the machine so that they can be replaced to emboss a specifically shaped substrate.

[0052] The underlying substrate surface is not modified by the embossing, rather it is the coating layer on that substrate surface which is modified to provide the texture/patterns contemplated herein.

[0053] In preferred embodiments wheel 6 is made of a relatively hard material which can withstand relatively high temperatures without deforming. For example, the wheel 6 will need to withstand at least the temperatures to which the substrate 2 is heated as described herein without deforming under pressure such that the embossing pattern T can be transferred to the substrate. In certain aspects, the wheel 6 is designed to withstand temperatures at least 50% more than those the substrate 2 is heated to, more particularly at least twice those temperatures is preferred. In preferred embodiments, the wheel 6 is made of a metallic material such as aluminum, steel or other

appropriate alloys. In certain aspects, the substrate 2 material and the wheel 6 material are the same type of metal. As the substrate 2 moves through the process, the wheel 6 will press the substrate’s coating to emboss it and the wheel will progressively be removed from contact with the substrate in the locations pressed to provide a continuous process of pressing with the wheel and removing the wheel as the wheel presses new sections of the substrate 2.

[0054] The next step in the process is use of a sublimation roller 8 which will have the same cutout 32 shape as wheel 6 or may provide a series of wheels to sublimate on different surfaces. It is understood that the sublimation process may be on a separate machine from the embossing or that one or more of the processes described herein may be combined into one continuous machine. Sublimation roller 8 will optionally not have the embossing pattern T and will be made of a softer material compared to wheel 6. In preferred embodiments, the wheel 6 is made of silicone rubber or another rubber or rubber like flexible material which can withstand temperatures commonly found in sublimation printing. Rollers 10/12 hold transfer sheet 15 which includes the sublimation ink/printing which is to be transferred to the substrate 2. Roller 8 will apply pressure and heat to activate the sublimation inks in the transfer sheet 15. Typically, the pressure exerted by roller 8 on the substrate 2 will be less than that of wheel 6. More particularly, the pressure applied by roller 8 is 75% or less than that applied by wheel 6 and more preferably 50% less or even more preferably 25% or less.

[0055] Decoration may be applied on the surface of said embossed and pre-treated and possibly pre-painted section, by a thin layer of glue, which co-operates with said temperature and/or pressure action, and contributes to fixing the decoration to the embossed substrate.

[0056] According to another embodiment of the present invention, a transparent, decoration-protecting paint layer is applied on said decoration applied to the surface of said pre-treated and possibly pre painted and pre-heated and embossed substrate, always through the co-operation of temperature and/or pressure.

[0057] After said possible sublimation and fixing step, the decorated section according to the process subject matter of this invention may be submitted to a further protection treatment by means of the application of a transparent, possibly fluid paint and subsequent air-, hot air-, UV- or IR radiation oven drying.

[0058] Said transfer sheet 15 is preferably a strip-like flexible support is constituted, according to this invention, by a continuous strip from paper, fabric, plastic materials or the like, carrying the pattern to be transferred on the side which will get in touch with the surface of the section to be decorated.

[0059] According to another embodiment of the present invention, said strip-like flexible support is constituted by a continuous strip from paper, fabric, plastic materials or the like, carrying on the side which will get in touch with the surface of the section to be decorated a first thin layer of glue and a second layer constituted by the decoration or the pattern to be transferred.

[0060] According to a further embodiment of the present invention, said strip-like flexible support is constituted by a continuous strip from paper, fabric, plastic materials or the like, carrying on the side which will get in touch with the surface of the section to be decorated a first thin layer of glue, a second layer constituted by the decoration or the pattern to be transferred, and a third layer constituted by a transparent, decoration-protecting film.

[0061] The decoration is automatically applied, through the combined action of heat and pressure, on the section to be decorated during its translation on a horizontal plane (on chain or rollers). The decoration is transferred on a strip from paper, fabric, plastic materials or the like, continuously pressed by a rotary nip roller from silicon material, on the surface of the section. The roller is suitably heated by a casing provided with electric resistors. Such temperature is kept constant and is controlled by an electronic controller. When the decoration is associated to a glue layer and/or a protecting paint layer, also these layers are transferred onto the section by rolling.

[0062] Sections from deformable materials (plastic materials, composite fibreglass-reinforced materials, etc.) or sections from metal having easily bruisable or damageable areas (low thicknesses, cantilever-flanges, etc.) may also be decorated on prior reinforcement of the delicate areas by means of suitable pads (from wood, plastic materials, metals, etc.).

[0063] According to the complexity of the section to be decorated several rollers may operate at the same time. Each of these rollers may be suitably inclined to work in a well defined area of the section's cross- section, and it will be shaped according to the same shape as the partly decorated area. Due to the rollers being of a relatively soft/elastic material, preferably silicone rubber, the surface of the rollers can deform to match the embossing and thereby ensure that the

decoration/sublimation is applied along the entire surface, including the depressions and surface variations caused by the embossing process. [0064] After the transfer step, the decoration-comprising strip from paper, fabric or plastic material is automatically recovered through a system of unwinding and rewinding coils. After the possible sublimation and fixing step, the whole cycle can be completed by the stay of the decorated sections in a ventilated air-, UV- or IR radiation oven. This step allows to achieve the ideal conditions to perform the complete sublimation of the decoration inks on the surface of the sections and their complete fixing. Sections remains in the oven for a time comprised between 1 and 30 minutes at temperatures comprised between 100 and 300. degree. C.

[0065] The process according to the invention proved particularly advantageous to obtain sections from aluminum alloy with imitation wood or imitation marble decorations, comprising a first layer of primer forming the basic color, and a second layer constituted by the decoration. Besides, according to the final use of the sections, there may be a third layer constituted by a veil of decoration-protecting paint.

[0066] Thus, it is also understood that like wheel 6, additional rollers 8 may be added to decorate the bottom and/or sides of the substrate 2 with additional feed rollers 10/12 and their corresponding transfer sheets 15.

[0067] As a result of the process shown in FIG. 7, the embossed and sublimated substrates 2 can be created using a continuous process with high throughput.

[0068] In certain situations, the substrate 2 may not lend itself well to the wheel 6 based embossing. For example the shape may be complicated or may otherwise require embossing in a manner that the wheel 6 based process of FIG. 7-8 is not appropriate. In this scenario, a vacuum based process can be used. FIG. 9-10 depict this vacuum based process where the substrate 2 is provided and an embossed sheet 34 is rolled over the substrate 2. This embossed sheet in preferred embodiments is flexible and made of paper. As is understood, this substrate has already been coated with the appropriate primers and coatings to enable embossing and sublimation. This substrate with the sheet 34 around it is placed in a vacuum bag 40 which is sealed and then vacuum is applied through hose 38 and vacuum pump 36. The vacuum bag 40 may be sealed using heat sealing or any other known sealing system. For example, vacuum bagging is used regularly in the manufacture of composites and similar technology can be used. It is also contemplated that a reusable vacuum system can be employed to make the process more repeatable. With the sheet 34 applied around and preferably taped or otherwise attached to the substrate 2, vacuum is drawn and heat of preferably 230°C is applied (the ranges described previously as to other embodiments apply to this temperature as well). This heat and vacuum when applied for 10 minutes produces some embossing but sometimes not enough. Temperature of 230°C for 20 minutes has been shown to be more effective. The reason for the longer cycle time as compared to e.g. the flat plate press or the continuous process is that vacuum pressure is limited to on atmosphere or 1 bar. After the end of the cycle time, the sheet 34 is removed and sublimation is applied at 200°C to transfer the design to the substrate 2. In other optional embodiments, the vacuum bag can be placed in an autoclave in order to provide increased pressure and thus produce a corresponding reduction in cycle time. In the ordinary vacuum system, at least 8 minutes and preferably at least 15 minutes of application of vacuum is indicated and if the pressure is doubled (e.g. by an autoclave), at least 6 minutes of vacuum is indicated or more preferably at least 10 minutes.

[0069] A flat press example is shown at FIG. 1 and 1 1 with plates 42/40 which squeeze sheet 34 on top of substrate 2. In certain embodiments, sheet 34 is paper and in others, sheet 34 is metallic. Optionally, sheet 34 may be integrated into plate 42 in that the embossing relief cuts are directly in plate 42. Plates 42/40 are also able to apply heat to the substrate 2 to enable the embossing. The temperatures and ranges in the other manufacturing techniques apply equally to the flat plate. Preferably pressure of 45-70 bar is applied by the plates 42/40 in order to reduce the cycle time.

[0070] EXAMPLES

[0071] Example l : 12” x 12” aluminum panels were

manufactured on a small press at 120 psi.

[0072] A PE 41 1 Powder Coating was applied to the aluminum panels followed by DS 810 powder coating. A metal or other hard material plate having relief depressions was pressed on the coated panels. After pressing, the panels were sublimated using conventional sublimation methods.

[0073] Images of the final products are shown in Figs. 4 and 5.

[0074] Larger 4’ x 8’ panels have been shown to require greater force in order to reduce cycle time.

[0075] Example 2: Production Parameters for Cold Panels

Item _ Min _ Max

Temp 25°C/77°F 50°C/122°F

Force 1 Ton/sf 4 Ton/sf

[0076] Example 3: Production Parameters for Heated Panels

Item Min Max

Temp 100°C/212°F 250°C/482°F Force 0.5 Ton/sf 1 Ton/sf

[0077] The step of sublimating can occur after the substrate is embossed.

[0078] In some embodiments, the step of pressing is performed with a 50-ton to 100-ton sheet stamping press. In some preferred embodiments, the pressing is performed with a 50 ton sheet stamping press. In other preferred embodiments, the pressing is performed with a 100-ton sheet stamping press. In some of those embodiments, a pressure of 0.5 ton/sf to 4 ton/sf is applied. In some of those

embodiments, 1 Ton/sf to 4 Ton/sf is applied. In other of those embodiments 0.5 T on/sf to 1 T on/sf is applied.

[0079] In other embodiments, the step of pressing is performed at 45-75 bar pressure on a heat press.

[0080] In some of embodiments, the pressing is performed using temperatures of about 100°C to about 260°C, preferably 170-260°C, more preferably about 180-260°C, most preferably around 230°C.

[0081] In certain embodiment, the methods further comprise the step of heating the substrate having the depressed coating to a curing temperature for the coating. In some of those embodiments, the heating temperature is in the range of about 100°C to about 260°C, preferably 170-260°C, more preferably about 180-260°C, most preferably around 230°C. In some of those embodiments, the heating occurs for 60-500 seconds. In other embodiments the heating occurs from 300-400 seconds, preferably around 360 seconds.

[0082] In certain embodiments, the substrate is comprised of metal. In some of those embodiments, the substrate consists essentially of metal. In certain of those embodiments, the substrate consists of metal. The metal can be selected from the group consisting of aluminum, steel, copper, bronze and stainless steel.

[0083] In some embodiments, the step of coating comprises applying a first coating; curing the first coating by applying heat at a curing temperature for the first coating; and applying a second coating on top of the cured first coating.

[0084] In some embodiments, the coating is a powder coat. In other embodiments, the coating is a liquid coat.

[0085] In certain embodiments, the coating is white or other colors. In other embodiments the coating is clear. In yet other embodiments the coating comprises a white coating or other colors and a clear coating.

[0086] In some embodiments, the coating comprises a sublimation ink receptive layer.

[0087] In certain embodiments, the coating is a powder coating in the range of 20-120 microns thick, more particularly 40-1 10 microns thick or even more particularly that about 50-100 microns thick or more specifically about 70 microns thick. It is understood that variances in the measurements are inherently in existence due the application process of powder coating. One such application process involves spraying the powder coating. In certain aspects, the primer described herein can be of the same thickness ranges as described in this paragraph. In particular aspects, both the coating and the primer are powder coatings and in certain aspects when the embossing occurs it embosses the primer and/or coating or in some cases primarily the primer layers.

[0088] The combination of the coating and the optional primer layer makes up the coating layer for the substrate which in one aspect has a combined thickness of 60-400 microns, more particularly 80-300 microns or more particularly 100-200 microns. Typically in a two layer system, the primer and coating layers will be made of different materials with the coating layer being a harder material which is receptive to sublimation, for example polyurethane. The primer in this example may be polyester or epoxy which is softer than the polyurethane, especially when heated in order that the primer will deform to enable embossing as described herein. This primer layer may not be sublimation receptive in that the sublimation will be applied to the harder polyurethane layer.

In particular aspects, the primer is a white color and the polyurethane (coating) layer is clear. This choice of colors is specifically used since sublimation is commonly unable to sublimate in white color, thus the primer provides the white coloring where needed and the clear coating receives the colored sublimation ink. Most of the deformation which results from embossing in this embodiment will occur in the softer primer layer, for example 50% or more of the deformation due to embossing, more particularly 60% or more of the deformation and even more particularly 70% or more of the deformation. The result of this unequal deformation is that the thickness of the primer will vary more as a result of the embossing as compared to the coating which does not deform as much and maintains a more uniform thickness. Typically, the primer and coating when initially applied and cured each account for roughly half the overall thickness of the coating layer. It is understood that in general powder coatings like the ones used herein can have natural variances in initial thicknesses due to the nature of how these coatings are applied.

[0089] In single layer embodiments, the coating layer will often be of the softer materials such as polyester or epoxy and in this case the polyester/epoxy chosen will be sublimation ink receptive whereas the two layer embodiment the primer layer which receives most of the sublimation deformation does not necessarily need to be sublimation receptive. It is also contemplated that the non-sublimation receptive layer is applied to the substrate in a monochromatic manner and is then embossed in order to provide a single color embossed substrate which is not decorated with sublimation.

[0090] In some embodiments, the plate or wheel having relief depressions comprises paper. In some of those embodiments, the plate having relief depressions consists essentially of paper.

[0091] In other embodiments, the plate or wheel having relief depressions comprises a metal material. In some of those

embodiments, the plate or wheel consists essentially of metal.

[0092] In some embodiments, the step of heating the coated substrate occurs at a temperature in the range of 200-500°F. In some of those embodiments, the heating occurs for 60-500 seconds. In other embodiments the heating occurs from 300-400 seconds, preferably around 360 seconds.

[0093] In certain embodiments, the step of heating the coated substrate includes applying pressure of 50-150 psi. In certain of those embodiments, the pressure is applied for 60-500 seconds. In other embodiments the heating occurs from 300-400 seconds, preferably around 360 seconds.

[0094] The depth of the depressions are limited by the depth of the coatings (coating and optionally primer) in that the embossing is designed to emboss the coatings which can be sublimated. Thus, the depth of the depressions is typically 0%-90% of the total coating thickness or more particularly 0%-75% or even more particularly 0%- 50% of the total coating thickness (including coating and optional primer layers). In this way the portion of the coating layer which is most pressed down or thinned due to the embossing still provides some coating over the substrate which coating can be sublimated and also may provide protection for the substrate against corrosion. In preferred embodiments, the embossing depressions are at maximum depth 1 mm less than the maximum coating thickness.

[0095] In another aspect, the invention provides a process for embossing and variously decorating sections from metal, plastic materials, and composite materials which comprises the following steps: pre-treating by submitting the sections to at least one step of surface preparation selected from the group consisting of degreasing, cleaning, anodic oxidation, neutralization, chromate treatment, phosphochromate treatment, phosphating, nitrocobalt treatment, treatment with chrome- free products and mechanical polishing; coating the pre-treated sections; embossing by transfer from a strip-like support developing from at least a first coil, through the action of temperature and pressure generated by a first roller from a first roller material, said first roller having relief depressions; and decorating by applying onto a surface of the embossed sections, a decoration by sublimation transfer from a strip-like flexible support developing from at least a first coil, through the action of temperature and pressure generated by at least a second roller formed of a second roller material, said roller being suitable inclined in a well defined area of the section to be decorated and being shaped according to the same shape as the decorated area.

[0096] In some embodiments, the temperature generated by the first roller is 180°C to 260°C.

[0097] In some embodiments, the pressure generated by the first roller is 45-70 bar.

[0098] In certain embodiments, the first roller material is a rigid suitably shaped, heated and thermo-stated material. In some of those embodiments, the first roller material is paper; in other of those embodiments, the first roller material is metal. In some of those embodiments, the material is steel.

[0099] In some embodiments, the second roller material is an elastically complying and suitably shaped, heated and thermo-stated material. In some of those embodiments, the second roller material is a rubber material such as silicone rubber.

[00100] In certain embodiments, the coating is selected from epoxy polyester, polyester or polyurethane powder coats. In certain preferred embodiments, the coating is polyester powder.

[00101] In some embodiments, the method further comprises pre heating by submitting said powder coated sections to heating at a temperature of 100° C-250° C;

[00102] In certain embodiments, the method further comprises fixing by submitting said pre-painted sections comprising said decoration, at a temperature of between 100° C and 300° C for 1 to 30 minutes.

[00103] In some embodiments, the method comprises applying said decoration to the surface of said embossed sections by means of a thin layer of glue, which co-operates with said temperature and pressure action and contributes to the fixing of said decoration.

[00104] In certain embodiments, the process comprises applying a layer of transparent decoration-protecting onto said decoration. In some embodiments, the method includes a subsequent drying selected from the group consisting of air-drying, hot air-drying, UV radiation, and IR radiation oven drying. In some of those embodiments, the transparent paint is a fluid paint. [00105] In some embodiments, the strip-like flexible support is constituted by a continuous strip of material selected from the group consisting of paper, fabric and plastic material and carrying the decoration or pattern to be transferred on the side that will touch the surface of the section to be decorated. In certain embodiments, the strip-like flexible support is a disposable strip.

[00106] In certain embodiments, the substrate is kept at the same temperature post embossing for sublimation or the substrate is brought to 180-200 deg Celsius between embossing and sublimation in order to prepare for sublimation. It is understood that cooling devices and/or heaters may be added at FIG. 7 to facilitate temperature control. When sublimation and embossing are separate, the substrate will typically be allowed to cool to room temperature to facilitate handling and then pre heated again in the sublimation machine. In particular aspects, the sublimation temperature is roughly the same as the embossing temperature and in certain cases, the two temperatures vary within 10% and more particularly lower than the embossing pre-heat/heating temperature vary by less than 20%.

[00107] It is contemplated that many different embossing patterns can be use such as the hexagon pattern in FIGS 3-5 or the other patterns shown. One pattern shown in FIG. 13 is a wood grain pattern which is provided on the substrate of FIG. 12 (which has been coated with the coatings described herein). As can be seen, the wood grain generally wraps around the entire substrate which can be accomplished using the roller 6 such that the cutout 32 is designed to emboss around the edges and/or provide additional rollers 6 which press inwards rather than downwards in order to emboss the sides of the substrate of FIG.

12. In certain aspects this can be used as a deck board substitute which is exceptionally durable in that it can be made of extruded aluminum which is embossed with the wood pattern. Once embossed, sublimation over the pattern can be provided in order to provide the color/contrast combined with the embossing in order to provide a metal replacement for deck boards that look more like real wood.

[00108] In each of the embodiments disclosed herein, the embossing is accomplished without deforming or otherwise modifying the underlying substrate in the sense that the embossing depressions and surface variations supplied are done on the coatings on the outside of the substrate. Thus, it is the underlying coating which is deformed to cause the surface variations/embossing.

[00109] It is understood that the methods, compositions and products described and illustrated herein represent only some embodiments of the invention. It is appreciated by those skilled in the art that various changes and additions can be made to without departing from the spirit and scope of this invention. While a number of different processes have been described, it is understood to be within the scope of this disclosure to use the processing parameters described for one process in the other processed(s).