JPH0438986A | 1992-02-10 | |||
JPH0193391A | 1989-04-12 | |||
US5176939A | 1993-01-05 |
1. | I claim: L A method of transferring metal leaf to a substrate, comprising the steps of: creating a transfer graphic design; forming on a transfer sheet having a paper backing and a release layer a pressure sensitive adhesive design in the shape of said transfer graphic design; placing said transfer sheet containing said pressure sensitive adhesive design on a substrate; transferring said pressure sensitive adhesive design by removing said transfer sheet so that said pressure sensitive adhesive design adheres to said substrate; and applying metal leaf to said pressure sensitive adhesive design on said substrate. |
2. | The method of transferring metal leaf to a substrate as recited in claim 1, wherein said pressure sensitive adhesive is ESPS 500 brand automotive adhesive. |
3. | The method of transferring metal leaf to a substrate as recited in claim 1 , wherein said pressure sensitive adhesive is colored with a water soluble pigment. |
4. | The method of transferring metal leaf to a substrate as recited in claim , wherein said pressure sensitive adhesive is thinned with water up to 20%. |
5. | The method of transferring a metal leaf to a substrate as recited in claim 1 , wherein said creating a transfer graphic design step further comprises the steps of: creating a transfer graphic design on a computer; printing said transfer graphic design on a printer; and screen printing said transfer design in a silk screen unit. |
6. | The method of transferring metal leaf to a substrate as recited in claim 1 , wherein said transfer sheet is a Chromaslick brand transfer sheet. |
7. | The method of transferring metal leaf to a substrate as recited in claim 1 , wherein said transfer sheet is a water release decal type transfer sheet. |
8. | The method of transferring metal leaf to a substrate as recited in claim 1 , further comprising after said forming step, the additional step of flash drying said pressure sensitive adhesive design. |
9. | The method of transferring metal leaf to a substrate as recited in claim 1 , wherein said transferring step further includes the step of rubbing said transfer sheet with a burnisher. |
10. | The method of transferring metal leaf to a substrate as recited in claim 1 , wherein said metal leaf is gold leaf. AMENDED CLAIMS [received by the International Bureau on 9 December 1997 (09.12.97; original claims 110 replaced by new claims 121 (6 pages)] 1 (Amended) A method of transferring metal leaf to a substrate, comprising the steps of: creating a transfer graphic design; forming on a transfer sheet having a [paper] backing and a release layer a pressure sensitive adhesive design in the shape of said transfer graphic design; placing said transfer sheet containing said pressure sensitive adhesive design on a substrate; transferring said pressure sensitive adhesive design by removing said transfer sheet so that said pressure sensitive adhesive design adheres to said substrate; and applying metal leaf to said pressure sensitive adhesive design on said substrate 2 (Amended) The method of transferring metal leaf to a substrate as recited in claim I , wherein said pressure sensitive adhesive is [ESPS 500 brand] an automotive adhesive 3 The method of transferring metal leaf to a substrate as recited in claim 1, wherein said pressure sensitive adhesive is thinned with water up to 20% 4 (Amended) The method of transferring metal leaf to a substrate as recited in claim 1 , wherein said transfer sheet is a [Chromaslick brand] dry transfer sheet. ' * 5 The method of transferring metal leaf to a substrate as recited in claim 1, wherein said transferring step further includes the step of rubbing said transfer sheet with a burnisher fe The method of transferring metal leaf to a substrate as recited in claim 1 , wherein said metal leaf is gold leaf. ? The method of transferring a metal leaf to a substrate as recited in claim 1 , wherein said creating a transfer graphic design step comprises the additional steps of placing a burnedin silk screen template in a silk screen unit; placing the transfer sheet below said burnedin silk screen template, placing a pressure sensitive adhesive on top of the burnedin silk screen template; and silk screening said transfer sheet by allowing said pressure sensitive adhesive to flow through small holes in the burnedin silk screen template. δ A method of transferring metal leaf to a substrate, comprising the steps of: creating a transfer graphic design; forming on a water release decal type transfer sheet, the transfer sheet having a backing and a release layer, a pressure sensitive adhesive design in the shape of said transfer graphic design, placing said transfer sheet containing said pressure sensitive adhesive 1 design on a substrate; 2 transferring said pressure sensitive adhesive design by removing said 3 transfer sheet so that said pressure sensitive adhesive design adheres to said 4 substrate; and 5 applying metal leaf to said pressure sensitive adhesive design on said 6 substrate. 7 8 9 The method of transferring metal leaf to a substrate as recited in 9 claim 12, wherein said metal leaf is gold leaf 1 10. A method of transferring metal leaf to a substrate, comprising 2 the steps of 3 creating a transfer graphic design; 4 forming on a transfer sheet having a backing and a release layer a 1 5 pressure sensitive adhesive design in the shape of said transfer graphic design, 16 drying said pressure sensitive adhesive design, 17 placing said transfer sheet containing said pressure sensitive adhesive ι v design on a substrate; 19 transferring said pressure sensitive adhesive design by removing said 0 transfer sheet so that said pressure sensitive adhesive design adheres to said 21 substrate; and 22 applying metal leaf to said pressure sensitive adhesive design on said 23 substrate. *& 24. |
11. | The method of transferring metal leaf to a substrate as recited in claim 14, wherein said metal leaf is gold leaf 1i A method of transferring metal leaf to a substrate, comprising the steps of: creating a transfer graphic design; forming on a transfer sheet having a backing and a release layer, a pressure sensitive adhesive design in the shape of said transfer graphic design, wherein said pressure sensitive adhesive is colored with a water soluble pigment, placing said transfer sheet containing said pressure sensitive adhesive design on a substrate; transferring said pressure sensitive adhesive design by removing said transfer sheet so that said pressure sensitive adhesive design adheres to said substrate, and applying metal leaf to said pressure sensitive adhesive design on said substrate 15 The method of transferring metal leaf to a substrate as recited in claim 16, wherein said metal leaf is gold leaf 1H A method of creating a graphic design, comprising the steps of: creating a graphic design on a computer system; transferring the computer graphic design to a template; forming on a transfer sheet having a backing and a release layer a pressure sensitive adhesive design in the shape of said graphic design on said template so that when said transfer sheet containing said pressure sensitive adhesive design is placed on a substrate, said pressure sensitive adhesive design is transferred by removing said transfer sheet so that said pressure sensitive adhesive design adheres to said substrate thereby allowing the application of metal leaf to said pressure sensitive adhesive design on said substrate. 15 The method as recited in claim 18, wherein said pressure sensitive adhesive is colored with a water soluble pigment 16 The method as recited in claim 18, wherein said transfer sheet is a water release decal type transfer sheet \f The method as recited in claim 18, wherein said metal leaf is gold leaf. 4%. The method as recited in claim 18, wherein said template is porous thus allowing the pressure sensitive adhesive to be applied through said template and onto said transfer sheet . |
12. | The method as recited in claim 22, wherein said pressure sensitive adhesive is silk screened through said template and onto said transfer sheet 2c. A method of transferring metal leaf to a substrate, comprising the steps of: creating a transfer graphic design; forming on a transfer sheet having a backing and a release layer a pressure sensitive adhesive design in the shape of said transfer graphic design; placing said transfer sheet containing said pressure sensitive adhesive design on a substrate; transferring said pressure sensitive adhesive design by removing said transfer sheet so that said pressure sensitive adhesive design adheres to said substrate and so that metal leaf may be applied to said pressure sensitive adhesive design on said substrate 11 A method of transferring metal leaf to a substrate, comprising the steps of: placing a transfer sheet having a backing and a release layer on a substrate, said transfer sheet having a pressure sensitive adhesive design in the shape of a created transfer graphic design; transferring said pressure sensitive adhesive design by removing said transfer sheet so that said pressure sensitive adhesive design adheres to said substrate; and applying metal leaf to said pressure sensitive adhesive design on said substrate. |
FIELD OF THE INVENTION
This invention relates to a method of transferring metal leaf to a substrate, and in particular, to creating a pressure sensitive adhesive in the shape of a graphic transfer,
applying the transfer to the substrate and then applying the metal leaf to the adhesive on a
substrate.
BACKGROUND OF THE INVENTION
Transfer size is used in the process of high quality leafing, such as gold leaf,
bronze leaf or other forms of metal leaf, upon a substrate. Gold leaf, for instance, has been
traditionally applied to interior and exterior surfaces by first applying a substance known as transfer size. Conventional transfer size is a sticky gluelike substance which can either be
purchased or manufactured by the person performing the metal leafing. Transfer size is
traditionally available in a slow type and a fast type. The difference between slow and fast
size is the period of time necessary for the size to become tacky or to attain a desired
stickiness. Fast size become tacky very quickly, but has a short "open" time or time during
which it retains its stickiness. Slow size takes longer to become tacky but has a longer
"open" time depending on the formulation of the size. Both fast and slow size are, however,
are applied as a wet substance which may be extremely messy. Transfer size is also available as an aerosol spray and generally tacks quickly. Spray transfer size may, however, run after
sprayed upon the desired surface.
Size must be first applied wherever one would want to apply metal leaf . The
size may be stenciled or painted on an object of substrate that is to receive the metal leaf.
Generally, size is applied in register over an undercolor which gives character to the final
leafing. However, the undercolor is often not visible because of the wetness of the size or the
formulation of which it is composed. When the size is applied to an object or substrate and
reaches the proper tack, the metal leaf is gently lowered on to the tacky size and very
carefully smoothed over. A brush or fabric is then moved back and forth over the leaf such that the abrasive action causes the leaf not attached to the size to break away, leaving the
areas coated in size to be metal leafed. Producing fine details using this method is, however,
extremely difficult, time consuming, and requires a skilled artisan. Additionally, the
chemicals and solvents used in the size formulation can be flammable and hazardous if used in a closed area, and in addition, may be harmful to the environment.
Accordingly, there is a need for a transfer size which is dry, clean, safe for
both users and the environment, which is easy to prepare and which can be used by an
individual with little or no training in the art of metal leafing.
OBJECTS AND SUMMARY OF THE INVENTION
It is thus a general object of the present invention to provide a metal leaf
transfer size which is safe to use by a user as well as safe for the environment, and which
permits high quality metal leafing by all individuals.
A more specific object of the present invention is to provide a transfer size
which is dry and eliminates the need for application of a wet or spray size prior to applying
metal leaf to a desired surface.
An additional object is to eliminate the use of graphic stencils which must be
cut out or fabricated in order to apply wet or spray size in the desired areas. A further object is to eliminate the hand painting of wet or spray size on a desired surface.
It is another object of the present invention to provide a dry transfer size which
tacks quickly, has a relatively long "open" time, and which eliminates the mess associated
with wet transfer size. It is a further object of the present invention to provide a dry transfer size
which is clear in color and which permits the addition of colored pigment for providing back
up color. It is still a further object of the present invention to provide a dry transfer size
which is clear in color and which permits viewing of an undercolor on the substrate or surface
to which the size is applied.
In accordance with one aspect of the present invention, a method of
transferring metal leaf is provided which eliminates the need in the prior art for a wet or spray size to be applied prior to applying metal leaf to a substrate or surface.
The method of transferring metal leaf to a substrate according to the present
invention, includes the steps of first creating a transfer graphic design. Next, utilizing a
release sheet, which may be a dry release sheet or a water release decal type paper, a pressure
sensitive adhesive design in the shape of the transfer graphic design is formed on the release
sheet by a suitable process such as silk screening. The release sheet is allowed to dry and
then allowed to cure. Use of the pressure sensitive adhesive is environmentally safe, and
does not contain any harmful or flammable solvents or chemicals. After curing, the transfer
sheet on which the transfer graphic is retained is placed against the substrate or surface upon which it is to be applied. If a dry transfer sheet is being used, the adhesive and graphic may
be transferred to the substrate by rubbing the back of the transfer sheet. The transfer sheet is
then removed to leave the adhesive on the substrate in the form of a dry transfer size. If a
water release transfer paper is used, the back of the release paper is wet with water. After approximately one minute, the release paper is removed and the adhesive size which remains
is allowed to dry. Metal leaf, such as gold leaf or bronze leaf or any other finely ground
powder, pigment or even flock may then be applied in the traditional manner to the adhesive
which is applied on the substrate.
The above description sets forth rather broadly the more important features of
the present invention in order that the detailed description thereof that follows may be
understood, and in order that the present contributions to the art may be better appreciated.
Other objects and features of the present invention will become apparent from the following
detailed description considered in conjunction with the accompanying drawings. It is to be
understood, however, that the drawings are designed solely for the purposes of illustration
and not as a definition of the limits of the invention, for which reference should be made to
the appended claims.
DETAILED DESCRIPTION OF THE DRAWINGS
In the drawings in which like reference characters denote similar elements
throughout the several views:
FIG. 1 illustrates a transverse sectional view of a transfer sheet having
pressure sensitive adhesive disposed thereon for transferring a transfer graphic design to a
substrate for application of metal leaf;
FIG. 2 illustrates a transverse sectional view of a transfer sheet having
pressure sensitive adhesive disposed thereon for transferring a transfer graphic design to a
substrate and having a protective sheet covering the transfer graphic design for storage or
shipping; FIG. 3 illustrates an exploded side view of the transfer graphic design adhered
to a substrate after removal of the release paper; and
FIG. 4 illustrates a schematic illustration of the preferred process for creating a transfer graphic design and printing it on a transfer sheet according to the present invention.
DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENT
With reference to FIG. 1 , there is shown one embodiment of the leaf adhesive
transfer sheet 10 according to the present invention. Leaf adhesive transfer sheet 10 of the
present invention comprises a design formed from a pressure sensitive adhesive 18 on a
transfer sheet 40 having a paper backing 12 and a release layer 14. The preferred method of
forming a design from pressure sensitive adhesive 18 on a transfer sheet 12 is illustrated in
FIG. 4, wherein a graphic transfer design 16 must first be created and, and which may be an
illustrative design, a drawing or words such as a company name, for example. Graphic
transfer design 16 is advantageously created using a computer system 22, although other
methods such as stenciling may be used. Once the graphic transfer design 16 is created on
the computer 22, a black film 24 having the desired design is created by printer means 26, such as an ink jet printer which is connected to the computer 22. Once the black film 24 is
outputted from the printer means 26, the black film 24 is applied to a silk screen 28 with a
photographic emulsion (not shown) so that wherever there is an image, the silk screen 28 is
exposed or "burned in", thus creating a burned-in silk screen template 30 having small holes
on the silk screen 28 which correspond to the graphic transfer design 16 created by computer
22. Since the words, drawing, or design created of the graphic transfer design 16 will later
be attached to a substrate and viewed from in front of the substrate, the black film 24 is
flipped or reversed before being placed on silk screen 28. Although, this is the preferred
method of creating the graphic transfer design 16, any other method, as known by those
skilled in the art of creating graphic transfers on a silk screen may be utilized such as hand
painting, the scope of the invention not being limited to how graphic transfer design 16 is
created on the silk screen.
The bumed-in silk screen template 30 is then placed in a silk screen unit 32. A
transfer sheet 40 having a paper backing 12 and a release layer 14 thereon is placed below the
burned-in silk screen template 30. Thereafter, a pressure sensitive adhesive 18 is placed on top of the burned in silk screen 30 in the silk screen unit 32. The transfer sheet 40 is then silk
screened allowing the pressure sensitive adhesive 18 to flow through the small holes in the
burned in silk screen 30 template. Accordingly, adhesive 18 is screen printed onto release
layer 14 of transfer sheet 40 in the shape of graphic transfer design 16 which was originally created by computer 22 and printed by printer means 26.
Pressure sensitive adhesive 18 is preferably an automotive pressure sensitive
adhesive such as ESPS 500, manufactured by Electrocal, S. Windsor, CT. 06074. However, the invention is not limited in this respect and other contact adhesives may be used. Adhesive
18 is preferably thinned up to 20 % with water and is clear in color so that one may inspect
the graphic transfer. Advantageously, the pressure sensitive adhesive may be colored with
water soluble pigments to provide a backup color for use in the later addition of metal leaf as
well as to ensure that the adhesive is visible on transparent surfaces. Transfer sheet 40 upon
which graphic transfer design 16 is placed, is preferably any dry transfer sheet 40 known in
the art such as Chromaslick brand release paper from Chromotek Inc., 196 Wicksteed Ave., Toronto, Ontario M4G 286. As an alternative, a water release decal type transfer sheet such as Twincal and Photocal manufactured by Brittains T.R. Limited — Ivy House Paper Mills,
Commercial Road, Hanley, Stakeon-Tret ST1 3QS, England, and described in U.S.
Application No. 08/654,448 to Zemel filed May 28, 1996, the disclosure of which is
incorporated herein by reference, may be used instead of a dry transfer sheet 40. The method of transferring metal leaf to a substrate comprises the steps of first
creating the graphic transfer design 16 on a computer 22 as discussed hereinabove. Next, a
design comprised of pressure sensitive adhesive 18 in the shape created by transfer graphic
design 16 is formed on release layer 14 of transfer sheet 40 according to the silk screening
procedure discussed hereinabove. The forming step further comprises the step of drying
adhesive 18 and transfer sheet 40 for about 20 seconds after adhesive 18 has been screen
printed on to transfer sheet 40, and then allowing transfer sheet 40 and adhesive 18 to cure in
open air, such as on a table, for 24-48 hours. A conventional hair dryer is preferably used for
drying adhesive 18 and transfer sheet 40, although other methods of drying may be used.
After the forming step is completed, transfer sheet 40 having the adhesive 18
thereon, is placed on a substrate 34, as illustrated in FIG. 3. If Chromaslik or another brand
of dry transfer sheet 40 is used, the transfer sheet 40 with adhesive 18 thereon is placed upon a substrate 34 or surface with adhesive 18 facing the substrate 34. The reverse side or back
12a of paper backing 12 is then rubbed or brushed with a burnisher (not shown). Other
objects such as a finger nail may also be used. Paper backing 12 is then peeled away leaving
adhesive 18 on substrate 34. Adhesive 18 shaped in the design created by design transfer
graphic 16 is now prepared for the application of metal leaf (not shown) thereon. If adhesive 18 was screen printed onto a water release decal type transfer sheet 40, the water release
decal type transfer sheet 40 is pressed onto the desired substrate 34 or surface after having
been dried and allowed to cure. While pressed against the substrate 34 for transfer, reverse
side or back 12a of water release decal type transfer sheet 40 is wetted with water. After
about one minute, the water release decal type transfer sheet 40 is removed and the adhesive
18 which remains upon the substrate 34 is allowed to dry without handling for approximately
15-20 minutes. After adhesive 18 has dried, metal leaf may be applied thereto. Accordingly,
metal leaf, such as gold leaf or bronze leaf or any other finely ground powder, pigment or
even flock may then be applied in the traditional manner to the adhesive 18 which subsists on
the substrate 34.
It is to be noted that transfer sheet 40 with adhesive 16 need not be
immediately transferred to a substrate after drying with the hair dryer. Instead, transfer sheet
40 with adhesive 18 thereon may be covered with a protective sheet 18, as shown in FIG. 2,
for storage and later usage. Protective sheet 20 may be a wax sheet, a silicon sheet, or a parchment sheet. Furthermore, after metal leaf has been applied to adhesive 18 on the
substrate, a non-solvent based top coat may be applied thereto to protect bronze or copper
leaf.
Thus, while there have been shown and described and pointed out fundamental novel features of the invention as applied to preferred embodiments thereof, it will be
understood that various omissions and substitutions and changes in the form and details of the
disclosed invention may be made by those skilled in the art without departing from the spirt
of the invention. It is the intention, therefore, to be limited only as indicated by the scope of
the claims appended hereto. It is to be understood that the drawings are not necessarily
drawn to scale, but that they are merely conceptual in nature.
Next Patent: DEVICE AND METHOD FOR DUSTING SMOOTH OR SHEET-LIKE PRODUCTS