LINK E
PATENTE DO ERLEI NOS ESTADOS UNIDOS
Inventor - Erlei Moreira
Parte
02
2. The process of
claim 1, wherein the decorative design is on a transparency,
paper, cloth, plastic wood, metal, or leather, and wherein the
decorative design contains characters, pictures, photographs,
graphs, or signatures, and wherein the decorative design was
generated by computer, by hand, or by another kind of printing.
3. The process of claim 1, wherein step (h) is immediately
followed by step (j).
4. The process of claim 1, wherein steps (m) and (n) impart a
smooth finish to the laminate.
5. The process of claim 1, wherein the trimming substep of step
(p) produces a planar, spherical, or cylindrical form, and wherein
the finishing substep of step (p) produces a trophy, medal, award
plate, sign plate, or panel.
6. The process of claim 1, wherein a first layer of catalyzed
resin (d) is polymerized to touch point (e) before the application
of additional layers.
7. A process of manufacturing trophies, medals, or award plates
from polyester, estervinylic, or epoxy resins, comprising:
applying an organic alcohol in four or five transverse layers;
drying the alcohol layers; applying a first catalyzed resin layer
on the dried alcohol layer; allowing the resin layer to become
tacky; applying second and third catalyzed resin layers; placing
fiberglass in textile or roving form into the resin and roulleting
the fiberglass until the fiberglass is totally absorbed by the
resin and there are no more air bubbles; placing a decorative
object face down onto the impregnated fiberglass; applying a
fourth catalyzed resin layer; placing another layer of fiberglass
in textile or roving form onto the fourth resin layer and
roulleting the fiberglass layer; placing a plastic film on the
laminate; roulleting the laminate until all air bubbles are
expelled; allowing the resin layers to polymerize for at least
twenty-four hours; and dismolding and cutting the finished pieces.
Description
The present patent refers to the process of manufacturing the
laminate in plain, spherical, cylindrical or another geometrical
form, that is useful as basic raw material to manufacturate
trophies, medals, award plates, indicative plates, panels, et al;
being obtained by means of the insertion of polychromies
containing characters, pictures, photographies, graphs,
signatures, et al; made in transparencies, papers, cloths,
plastics, wood, metals, leather, et al; generated by computer,
manually, or by any other kind of printing; in the lamination of
polyester, estervinylic or epoxy resins, reinforced with
fiberglass.
The polyester, estervinylic or epoxy resins, reinforced with
fiberglass, have nowadays too many applications in industries.
Because they provide high mechanical properties, lightness, high
dieletrical rigidness, dimensional stability, corrosion resistence,
an simple molds with low maintenance cost, these fiberglass
reinforced resins are applicated basically in: general structures,
automotive, bodywork, boats, surfboards, tables, chairs, water
containers, tanks, vans, automotive and industrial parts, et al.
However, it's noticed that, given the versatility of these resins
and the easiness to manufacturing them by the mold process, even
by manually lamination, hand-held gun lamination, rolling,
pultrusion, injection molding, presses, RTM, et al, the objective
of their use has been: after the cure or polymerization of the
resin, to get a piece in its final dimension, in other words, a
finished piece. To improve the visual finishing of this piece,
normally are used the resin pigmentation processes or even the
traditional superficial painting. In special cases, by means of
rolling process, tubes and cylinders are produced which once
manufactored shall produce wads for application in machines. In
the field of art manufacturing, it's noticed some utilization of
the pure resin, without fiberglass reinforcement, applicated as
superficial finishing in pieces like jewelleries, et al,
nevertheless without insertion of these objects inside the resin.
With the purpose of enlarging the utilization field of the
polyester, estervinylic or epoxy resins, reinforced with
fiberglass, nor for the obtention of a final product after the
polymerization of the resin, neither to obtain a simple
superficial finishing, but to obtain a inviolately involucre of
resin and fiberglass in polychromies, from which there will be
manufacturated products like trophies, medals, award plates,
indicative plates, panels, et al, it was developed the present
manufacturing process. By means of insertion of polychromies in
transparencies, papers, cloths, plastics, wood, metals, leather,
et al; containing characters, drawings, paintings, pictures,
photographies, signatures, et al; generated by computer, manually
or by. any other kind of printing; in the lamination of polyester,
estervinylic or epoxy resins, reinforced with fiberglass are
obtained plates in plain; spherical, cylindrical or any other
geometrical form that, cut out, glued, rivetted or assembled will
originate trophies, medals, award plates, indicative plates,
panels, et al.
The process in question consists on the following stages: (a)
cleaning of the glassy surface or polished base, that must be
totally. dried, (b) application of a organic alchool in four or
five transverse layers, (c) drying of the surface, (d) initial
application of a first catalysed resin layer over the dried
alchool layer, (e) a wait for the attaining touch point, (f)
application of two other catalysed resin layers, (g) placing the
fiberglass in woven forms, textile forms, or roving forms,
rouletting it until when the fiberglass is totally absorbed by the
resin and there are no more airbubbles, (h) placing the
polychromies with their faces turned to the base, (i) application
of another catalysed resin layer, spreading it well, (0) placing
the cloth on the plate and the polychromies, (k) new application
of a catalysed resin layer, (l) placing the fiberglass in woven
forms, textile forms, or roving forms, (m) placing the plastic
film, stret alhed and pressed on the laminate, (n) roulleting the
laminate with a cylinder or pipe, from center to border, until
expelling all airbubbles, (o) allow the joint to polymerize for,
at least, twenty-four hours and, finally, dismold, cut out and
finish the pieces.
The present manufacturing process can be better understood through
the detailing below, where will be taken, just as an example, and
without any limitative character, the insertion of a transparency
with polychromies in a plain laminate of polyester resin with
woven forms fiberglass application.
Raw materials: polyester resin, reference (#) 10203, from Resana;
polyvinylic alchool; woven forms 300 g/m.sup.2 fiberglass; MEK
M-50 catalyser; styrenics monomer; white microfiber peach skin
twill cloth; cellophane film.
Mixtures to be done: mix up the polyvinylic alchool with water, at
50%; put 4,5% of the styrenics in the polyester resin and mix it
up; at the moment of its usage, put 0,7% of MEK M-50 catalyser to
the polyester resin, mixing it up quite well.
Process Detailing
On the well cleaned and dried glass or polished base, apply the
polyvinylic alchool, in four or five transverse layers, using
nylon sponge. Allow it to dry naturally in a 60.degree. C. stewpot
for 30 minutes, verifying if the surface does not have faults. On
the polyvinylic alchool, apply a first layer of catalysed resin at
the rate of 400 ml/m.sup.2. A wait about 1.5 hour until this layer
attains the touch point, in other words, until this layer is
sticky, but not clinging to fingers. When it is at the touch
point, apply a layer of catalysed polyester resin using a brush,
at the rate of 150 ml/m.sup.2. Brush it over quite well in all
directions. Afterwards, scatter a layer of catalysed resin at the
rate of 1600 ml/m.sup.2 on the glass or polished base. Place the
woven forms 300 g/m.sup.2 fiberglass on the resin and roulette it
using a specific roulette for lamination, until the resin absorb
totally the woven forms 300 g/m.sup.2 fiberglass and there are not
airbubbles anymore. Place the transparency with polychromies faced
to the base. The transparency must to be cut off pretty close to
the polychromies. On the polychromies, place a layer of catalysed
resin at the rate of 400 ml/m.sup.2, spreading it well. Place the
white microfiber peach skin twill cloth on the plate and the
transparency. On the cloth, place a catalysed resin layer at the
rate of 600 ml/m.sup.2, spreading it well. Place the woven forms
300 g/m.sup.2 fiberglass on the cloth, rouletting it until there
are no more airbubbles. Add more catalysed resin, if necessary, in
order that all the joint becomes well moist. Over the joint, place
the cellophane film, stret alhed and pressed on the laminate.
Using a cylinder or a 3/4" plastic pipe, roulette from center to
borders, aiming to remove all air still existing inside the joint,
All this process can not last more than 10/12 minutes. Let product
polymerizing for 24 hours. After this time, dismold the plate from
the glass or base. Cut out the pieces, leaving a plate margin over
the boundaries of the transparency. Finish the edges with
sandpaper and automotive wax and assemble what will be a trophy,
medal, award plate, indicative plate or panel.
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