Field of the Invention

The present invention relates to display structures such as a memorial for displaying an image and to methods for the preparation thereof. The image may take the form of a pattern, artistic work, written indicia or any other visually discernible form.

Background of the Invention

Display structures for displaying images are used extensively in a variety of applications. Such structures may take a diverse array of forms, ranging from for example an advertising billboard to a cemetery plot memorial. For those display structures which are exposed to an outdoor environment, the ability to maintain the quality of image being displayed is often a concern. In the case of an advertising billboard, an image is typically presented on a sheet material such as paper or plastic which is adhered to a backing board. In an outdoor location, the quality of the image being displayed quite rapidly deteriorates through exposure to weathering elements such as rain, sunlight and common airborne pollutants. Although such display structures can be used to display rather elaborate images, the legibility and/or the aesthetic appeal of the image can nevertheless be relatively short lived.

Where it is particularly important that an image being displayed is retained for a long period of time, the display structure may be provided with a more durable form of image. For example, a cemetery plot memorial often presents an image such as written indicia engraved into a durable substrate such as granite or marble. However, although providing a means to display an image for a relatively long period of time, this type of display structure is limited in its ability to present an elaborate image.

Accordingly, there remains an opportunity to design and develop display structures that can be used to display either simple or elaborate images in an outdoor environment where the quality of the image is maintained for a relatively long period of time. Summary of the Invention

In one aspect, the invention provides a display structure for displaying an image, the structure comprising a laminate and a substrate, the laminate comprising two rigid sheet members which: (i) are laminated together by at least one interlayer disposed there between, and (ii) present an edge of the laminate having an exposed laminate interface edge, wherein the image is disposed between the rigid sheet members, and wherein the substrate has a rebate that accommodates at least part of the edge of the laminate and shields the laminate interface edge from weathering elements.

In a further aspect, the invention provides a method for manufacturing a display structure for displaying an image, the method comprising: (a) providing a laminate comprising two rigid sheet members which: (i) are laminated together by at least one interlayer disposed therebetween, (ii) present an edge of the laminate having an exposed laminate interface edge, and (iii) have the image disposed therebetween, (b) providing a substrate having a rebate therein, and (c) accommodating at least a part of the edge of the laminate in the rebate such that the laminate interface edge is shielded from weathering elements.

It has now been found that an image confined within a laminate can be used as part of a display structure which is capable of displaying the image for relatively long periods of time without there being any significant deterioration in the quality of the image. Laminate systems comprising an image sandwiched between two rigid sheet members are known. However, images presented by such laminate systems are generally prone to deterioration when the laminates are exposed to weathering elements. In particular, the laminates have an exposed laminate interface edge that provides a site through which moisture, ultraviolet rays and/or pollutants can enter between the sheet members and cause delamination of the laminate and/or deterioration of the image itself. Shielding of the laminate interface edge from weathering elements has been found to render such laminates suitable for outdoor display structures.

By shielding the exposed laminate interface edge from weathering elements, it has also been found that laminate systems can advantageously be used as part of a memorial.

Accordingly, the invention also provides a memorial for displaying an image, the memorial comprising a laminate and a support structure which holds the laminate in a desired position relative to the support structure, the laminate comprising two rigid sheet members which: (i) are laminated together by at least one interlayer disposed there between, and (ii) present an edge of the laminate having an exposed laminate interface edge, wherein the image is disposed between the rigid sheet members, and wherein the laminate interface edge is shielded from weathering elements.

The invention further provides a method for manufacturing a memorial for displaying an image, the method comprising: (a) providing a laminate comprising two rigid sheet members which: (i) are laminated together by at least one interlayer disposed therebetween, (ii) present an edge of the laminate having an exposed laminate interface edge, and (iii) have the image disposed therebetween, (b) providing a support structure to hold the laminate in a desired position relative to the support structure, and (c) shielding the laminate interface edge from weathering elements.

Brief Description of the Drawings

The invention will hereinafter be described with reference to the following non-limiting drawings in which:

Figure 1 shows a schematic drawing presenting a frontal view of a display structure in accordance with the invention; Figure 2 shows a schematic cross-sectional view of the display structure shown in Figure 1;

Figure 3 shows a schematic drawing presenting a frontal view of a memorial in accordance with the invention; and

Figure 4 shows a schematic cross-sectional view of the memorial shown in Figure 3.

Detailed description of the Invention

As used herein, the term "memorial" is intended to denote a structure such as a monument, tombstone, grave marker, tablet or headstone identifying a grave or graves, crypt or niche.

The display structure and memorial in accordance with the invention advantageously have the exposed laminate interface edge of the laminate shielded from weathering elements. By shielding the laminate interface edge, the display structure and memorial have been found to be particularly effective at displaying an image for relatively long periods of time without delamination of the laminate and/or significant deterioration of the image occurring.

The image displayed by the display structure and memorial may take the form of one or more of a pattern, artistic work, written indicia or any other visually discernible form.

The construction of the laminate can vary provided that the resultant laminate has an integral structure and that the image and at least one interlayer are sandwiched between two rigid sheet members.

A function of the interlayer within the laminate is to provide means for adhering the two rigid sheet members together. One or more interlayers may be used, and they may be in the form of a thermoplastic polymer sheet material which has inherent adhesive qualities. Examples of such thermoplastic polymers include, but are not limited to, polyvinyl butyral (PVB) and polyether based aliphatic polyurethanes. Alternatively, a thermoplastic polymer sheet material having relatively poor inherent adhesive qualities may be coated with a suitable adhesive material to provide it with the necessary adhesive qualities to adhere the two rigid sheet members together. An example of such an interlayer includes, but is not limited to, a polyvinyl chloride (PVC) sheet coated with a polyester or polyurethane based adhesive.

The image used in the laminate is disposed between the two rigid sheet members. The image can be advantageously printed, for example using solvent based ink, paint or dye systems, directly onto the at least one interlayer, or onto the inner face of at least one of the rigid sheet members.

Those skilled in the art will appreciate that the expression "solvent based ink, paint or dye systems" used herein refers to a system in which a colouring agent is carried in a suitable organic solvent or solvents. In the case of ink, for example, a pigment is dispersed in an organic solvent or solvents. These inks include so called "oil based" inks.

Use of solvent based ink, paint or dye systems to form the image on the interlayer has been shown to not interfere with the bonding process between the interlayer and the sheet members.

Alternatively, the image may be provided as a decal which is then applied to either the inner face of at least one of the rigid sheet members or to the at least one interlayer.

A particularly preferred lay-up of the laminate is where the image is sandwiched between two interlayers, and this sandwich structure itself is sandwiched between the two rigid sheet members.

Laminate structures of the type mentioned above are known from WO 02/18154 and WO 2004/037532, the contents of which are herein incorporated by cross reference.

The interlayer materials may be transparent or opaque. However, where the image is to be viewed through an interlayer, the interlayer will need to be sufficiently transparent. In the case where the image is sandwiched between two interlayers, the image may be printed directly onto an opaque interlayer in order to better contrast the features of the image. A clear interlayer may then be positioned onto the image bearing face of the printed interlayer, with this sandwich structure being sandwiched between the two rigid sheet members. At least one of the two rigid sheet members will need to be sufficiently transparent to enable the image to be viewed. In some instances, it may be preferable that one of the rigid sheet members is opaque in order to better contrast the features of the image being displayed. A rigid sheet member having transparent qualities will generally be made from a polymer such as an acrylic polymer (eg. polymethyl methacrylate), or glass. An opaque rigid sheet member may be made from any suitable material, but is preferably made from polymer such as an acrylic polymer (eg. polymethyl methacrylate), or glass that has been rendered opaque.

An inherent feature of the laminate which forms part of the display structure or memorial is that it presents an edge having an exposed laminate interface edge. By an exposed "laminate interface edge" it is meant that the laminate has a cross sectional edge which at least exposes an edge of the laminate interface created by the two rigid sheet members. In other words, the laminate has a cross sectional edge which exposes an edge of the layers, such as the interlayer and image layer, which are disposed between the two rigid sheet members. Generally, the cross sectional edge will expose all of the layers which make up the laminate structures and extend around the entire outer perimeter of the laminate.

By presenting an exposed laminate interface edge, weathering elements such as moisture, UV radiation and/or airborne pollutants can enter between the rigid sheet members and cause delamination of the laminate and/or deterioration of the image itself. In order to prevent, or at least minimise this problem, the display structure of the invention comprises a substrate having a rebate which accommodates at least a part of the edge of the laminate and shields the laminate interface edge from weathering elements.

By the term "rebate" it is meant that the substrate has a channel or groove or recess cut into the face of its surface in order to receive the laminate. The rebate does not extend through the substrate, and the image presented by the display structure can therefore only be viewed from one side of the substrate. Generally the rebate will have approximately the same perimeter shape compared with that of the laminate, with the perimeter shape of the rebate being slightly bigger than that of the laminate to enable the laminate to be accommodated within the rebate. For example, if the laminate has a circular perimeter shape, the rebate will have a circular perimeter shape with a slightly bigger diameter.

The depth of the rebate will vary depending upon the nature of the laminate being used. However, the rebate will have sufficient depth to accommodate at least part of the edge of the laminate to shield the laminate interface edge from weathering elements. By this arrangement, the laminate interface edge is positioned within the rebate at approximately the same level as, or below, the non-rebated surface of the substrate. In this case, the substrate can function to shield the laminate interface edge from weathering elements.

Preferably, the rebate has a depth approximately equal to the thickness of the laminate so that the outer display surface of the laminate resides in substantially the same plane as the non-rebated surface of the substrate.

In selecting the dimensions of the rebate to allow for accommodation of a particular laminate, consideration will need to be given to the expansion/contraction properties of the materials which make up the laminate and the substrate. In particular, it will be important that a sufficient gap is provided between the edges of the laminate and corresponding edges of the rebate to ensure that both the substrate and the laminate can expand and contract without any adverse effects.

In the display structure the substrate functions to shield the laminate interface edge from weathering elements by virtue of it being placed in close proximity to the laminate interface edge. Preferably, a weatherproofing sealant such as a silicone rubber is positioned around the perimeter of the laminate such that a weatherproofing seal is created between the laminate and the substrate. The use of such a weatherproofing sealant serves to further shield the laminate interface edge from weathering elements.

The laminate may be fixed within the rebate by using an adhesive material suitable for bonding the laminate to the substrate. Where a weatherproofing sealant is used, it will often be convenient to use the sealant to also fix the laminate within the rebate. For aesthetic purposes, the weatherproofing sealant and adhesive material are preferably substantially colourless when cured. The substrate of the display structure can be made from any suitable material. However, bearing in mind the intent to shield the laminate interface edge from weathering elements, the substrate will generally be made from a relatively weather durable material such as stone, metal, polymer and/or wood. The substrate itself may be treated to promote its weather durability, for example by painting it with a weatherproofing paint. Preferably, the substrate is made from stone such as granite, marble, sandstone, bluestone, or combinations thereof.

The memorial in accordance with the invention comprises a support structure which holds the laminate in a desired position relative to the support structure. The support structure may function as a base or stand such that the memorial can be positioned on the ground at a gravesite. In this case, the laminate will be securely fixed to the base such that the laminate is held in desired position relative to the base.

Where the support structure comprises a base, such as a rectangular base, the laminate will generally stand proud from the base such that not all of the laminates perimeter edge makes contact with the base. For example, the laminate may be fixed to the base such that the plane defined by the image bearing face of the laminate presents at an angle to (i.e. is. not parallel with) the plane defined by the upper surface of the base. Generally, the laminate will be fixed to the base such that the image bearing plane of the laminate presents at an angle of about 90° through to about 45° relative to the plane defined by upper surface of the base. Generally, the plane defined by the upper face of the base will be horizontal and the plane defined by the image bearing face of the laminate will therefore present at an angle to the horizontal ranging from about 90° to about 45°. Preferably, the plane defined by the image bearing face of the laminate is substantially perpendicular to the plane defined by the upper face of the base.

In the memorial, the laminate may be held by the support structure through any appropriate means. For example, the support structure may comprise a base, such as a rectangular base, having a rebated portion in an upper face thereof. A section of the laminate edge could then be inserted into the rebated portion to hold the laminate in a desired position. However, unlike the display structure described above, a rebate in a base used as part of the support structure in the memorial will not have the perimeter shape of the laminate, but instead will be at least as wide as the thickness of the laminate and have a depth and length suitable to accommodate a sufficient portion of the laminate edge to ensure it can be adequately held in a desired position by the base.

Alternatively, or in addition to utilising a rebate portion in a base to hold the laminate, a frame for holding the edges of the laminate may be fixed to the base. In this case, the frame may extend partially or fully around the perimeter edge of the laminate. Such a frame may be made from any durable material capable of being fixed to the base and securely holding the laminate. Suitable materials include, but are not limited to, metal, wood, stone, plastic, and combinations thereof.

The laminate may be held within the rebate or by the frame using conventional fixing means such as an adhesive material suitable for bonding the laminate to the base and/or frame. As discussed above, a weatherproofing sealant may be used for this purpose.

It is important that the interface edge of the laminate in the memorial is shielded from weathering elements. This may be achieved in numerous ways. For example, a weatherproofing sealant such as a silicone rubber may be applied around the exposed interface edge of the laminate. Alternatively, or in addition to, where the support structure comprises a base having a rebated portion in an upper surface thereof, an edge section of the laminate, including a section of the interface edge, may be accommodated in the rebate to thereby shield that section of the interface edge from weathering elements.

As for the exposed interface edge of the laminate that is not accommodated within a rebate, and hence may not be shielded, this section may be shielded from weathering elements by using a weatherproofing sealant as described above. Alternatively, or in addition to, a weatherproof border may be adhered on and around the remaining exposed interface edge of the laminate. The weatherproof border may be selected from any suitable material including, but not limited to, metal, plastic, wood, stone, and combinations thereof. Generally, such a weatherproof boarder will be in the form of a relatively thin strip having a width that is approximately the same as the thickness of the laminate. Where the support structure of the memorial includes a frame which holds the laminate in a desired position, the frame may extend wholly or partially around the exposed interface edge of the laminate to thereby shield or further shield the laminate interface edge from weathering elements. In this case, the frame would serve a dual function of holding the laminate in a desired position and shielding or further shielding the laminate interface edge from weathering elements.

The support structure of the memorial will generally comprise a base which is capable of supporting the laminate in a desired position, for example substantially perpendicular to the base. Such a base will need to be capable of holding the laminate in an upright position and will generally be made from materials similar to that described above for the substrate of the display structure.

It will be appreciated that the display structure in accordance with the invention is also particularly suited for use as a memorial at cemetery plots. In particular, the image of the display structure or memorial can be designed to provide for unique and elaborate epitaphs. Through the design features of the display structure or memorial, the quality of the epitaph image can be advantageously maintained for a relatively long period of time. In particular, through use of laminates described herein, an image displayed by a display structure or memorial in accordance with the invention can advantageously be maintained without any appreciable fading for greater than 10 years.

As a memorial, the display structure in accordance with the invention may also be designed such that it stands substantially perpendicular to the ground, or alternatively, it may be designed in the form of a plaque which is positioned substantially horizontal to the ground.

The display structure in accordance with the invention can also be used for a diverse array of other display applications. For example, it can be used to present general advertising material or corporate logos. In this case, the laminate comprising the relevant image can be advantageously accommodated in a rebated portion of a building wall. Figure 1 shows a frontal view of a display structure (10) in accordance with the invention. The structure comprises a substrate (20) made from stone such as granite or marble. The substrate accommodates a laminate (30) which provides for an image (40) to be displayed. The laminate (30) is formed from two sheets from glass joined together by a PVB interlayer on which the image (40) is printed using solvent based ink (laminate structure not shown in detail). A cross-sectional perspective (X) of the display structure is described in more detail below.

Figure 2 shows a cross-section in the direction (X) of the display structure (10) shown in Figure 1. The substrate (20) has a rebate section (20A) in a surface thereof. The laminate (30) is accommodated in the rebate section (20A) such that the image (40) (not shown, but appears in the direction shown by the arrow) is displayed on the side of the substrate in which the rebate is formed. The laminate (30) comprises two glass sheets (50) adhered together by a PVB interlayer (60) on which the image (40) is printed using solvent based ink. The laminate (30) presents a laminate edge (70) which extends around the perimeter of the laminate. The laminate edge (70) has an exposed laminate interface edge (80) which extends around the entire laminate edge (70).

The rebate (20A) has slightly larger dimensions than that of the laminate (30) such that there is a minimal gap between the edge of the laminate (70) and the substrate (20) (the gap shown in Figure 2 has been exaggerated for clarity). By making the dimensions of the rebate (20A) in the substrate (20) close to that of the laminate (30), the substrate (20) can function more effectively to shield the laminate interface edge (80) from weathering elements, and the displayed surface of the laminate (90) can also be positioned in substantially the same plane as the non-rebated surface (100) of the substrate (20). To further enhance shielding of the laminate interface edge (80) from weathering elements, a silicone rubber weatherproofmg sealant (110) is positioned in the gap defined by the perimeter of the laminate (30) and the perimeter of the rebate (20A). Of course, the use of the sealant (110) can be more liberal than shown. An adhesive material (not shown) can be used to fix the laminate (30) within the rebate (20A) of the substrate (20). Advantageously, the silicone rubber sealant (1 10) can also serve as the adhesive for fixing the laminate (30) within the rebate (20A). Figure 3 shows a frontal view of a memorial (10) in accordance with the invention. The memorial comprises a support structure (20) in the form of a rectangular base made from marble or granite which has a rebated portion (30) in an upper face (40). The rebated portion (30) in the rectangular base (20) accommodates a section of a laminate (50) which provides for an image (60) to be displayed. The laminate (50) is formed from two sheets of glass joined together by a PVB interlayer on which the image (60) is printed using solvent based ink (laminate structure not shown in detail). The rebate (30) in the rectangular base (20) is sufficiently deep to accommodate a section of the laminate (50) such that the base (20) functions as a support structure to hold the laminate in a desired position. The memorial (10) also includes a weatherproof border (70, 80) which is adhered to the perimeter edge of the laminate. The weatherproof boarder therefore also functions to shield the exposed laminate interface edge from weathering elements. Accordingly, through a combination of a section of the laminate (50) being accommodated in the rebated portion (30) of the base (20) and the weatherproof border (70, 80), the entire exposed interface edge of the laminate can be effectively shielded from weathering elements. If desired, the side weatherproof borders (70), optionally in conjunction with the top weatherproof border (80), may also function as a frame to help hold the laminate in a desired position. In this case, the side weatherproof borders (70) will be securely fixed to the rectangular base (20). A cross sectional perspective (X) of the memorial is described in more detail below.

Figure 4 shows a cross-section in the direction (X) of the memorial (10) shown in Figure 3. For convenience, equivalent components of the memorial in Figure 4 have been given the same numeral references as those shown in Figure 3. The image presented by the memorial (10) may be viewed from either side of the laminate. However, the image will generally be viewable from only one side, for example, from the direction (Y). The laminate may be held by the base (20) such that it is substantially perpendicular or at an angle (90) to the base (20). Generally, the laminate will be held by the base such that the image bearing plane of the laminate presents at an angle ranging from about 45° to about 90° relative to the plane defined by the upper surface of the base (20).

Those skilled in the art will appreciate that the invention described herein is susceptible to variations and modifications other than those specifically described. It is to be understood that the invention includes all such variations and modifications which fall within its spirit and scope. The invention also includes all the steps, features, compositions and compounds referred to or indicated in this specification, individually or collectively, and any and all combinations of any two or more of said steps or features.

Throughout this specification, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

The reference to any prior art in this specification is not, and should not be taken as, an acknowledgment or any form of suggestion that that prior art forms part of the common general knowledge in Australia or elsewhere.