Cover material having trademark-like mark and method of applying trademark-like mark

Abstract

The invention relates to a covering material with a trademark-like mark and a method for applying the trademark-like mark. An article includes a leather segment, and a color layer comprising a color coating mixed with an irreversible thermochromic dye applied to the leather segment. The irreversible thermochromic dye includes a first portion and a second portion combined to produce a graphical image on the leather segment, the first portion being activated to provide a visible indicia on the leather segment, the second portion being not activated. The disclosed method comprises: conditioning a section of cover material with an undercoat; applying a color coating comprising an irreversible thermochromic dye and a pigmented paint to the cover material segment; applying a top coat to the color coat; and embossing the graphic image in the color coating with an embossing tool, the embossing tool being heated to a temperature that causes a color change of the irreversible thermochromic dye by applying pressure to a first portion of the color coating.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0001] Figure 1 is a top plan view of a brand-like graphic marking on a segment of cover material.

[0002] Figure 2 is along Figure 1 A cross-sectional view taken along line 2-2 in FIG.

[0003] Figure 3 is a process flow diagram illustrating one example of a process for manufacturing a segment of cover material having a brand-like graphic indicia.

[0004] Details

[0005] As required, detailed embodiments of the present invention are disclosed herein; however, it should be understood that the disclosed embodiments are merely illustrative of the present invention that can be embodied in multiple and alternative forms. The drawings are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, the specific structural and functional details disclosed herein should not be interpreted as limiting, but merely as a representative basis for teaching those skilled in the art to variously employ the present invention.

[0006] Reference Figure 1 and Figure 2 , a covering material segment 10 is illustrated, which includes a leather segment, a vinyl sheet material, a polyurethane or a thermoplastic polyolefin sheet material. A color layer 12 includes a pigmented coating mixed with an irreversible thermochromic dye applied to the leather segment (dye / pigment system).

[0007] Colored coatings include water-based polyurethane, solvent-based polyurethane or vinyl resin coatings. Irreversible thermochromic dyes include leuco dyes, which are color-changing materials that change visible color when reaching a transition temperature. Irreversible thermochromic dyes cannot be reversed by returning the material to its original temperature state after changing color due to applied pressure and a selected series of temperatures. They are typically a combination of leuco dyes, color developers / activators, and molten materials (usually waxes) that are blended and then micronized to reduce particle size. Leuco dyes are incorporated into carriers to form aqueous concentrates that are permanently colored from off-white when heated to temperatures higher than their rated temperatures. When the temperature applied to the leuco dye increases, color density increases. In the present application, the dye / pigment system used is a material that changes from transparent, white, or cream tones to black or brown when reaching the temperature transition point of the molten material sealant.

[0008] In one example, the tinted coating comprises 40% by volume of tinted coating mixed with 60% by volume of leuco dye. (As mentioned herein, the stated percentages are by volume) It is contemplated that the tinted coating in the mixture may range from 5% to 40% of the composition, and the leuco dye may range from 40% to 100% of the composition. An example of an irreversible thermochromic dye includes a material currently from LCR Hallcrest, named Kromagen WB Silk Ink Black, which has an activation temperature range between 115°C and 170°C.

[0009] The mixture containing the irreversible thermochromic dye comprises a first part 14 which is activated after being heated to its activation temperature and pressure is applied to provide a visible mark on one surface of the leather. A second part 16 is not activated so that the first part and the second part produce a graphic image 17 on a length of covering material 10 such as leather.

[0010] Reference Figure 2 In one example, the covering material constitutes a covering material segment 10 that can be used to cover a seat of a vehicle or the like. If the covering material is leather, a base layer 18 is used for padding, sealing and bonding, such as an acrylic coating system or a polyurethane coating system with microspheres or foam, which is applied to the leather to provide a consistent appearance. The covering material segment can then be embossed using a texture embossing tool (see Figure 31) to provide or improve the appearance of texture on the leather. After the texture embossing step, a color layer 12 is applied to the cover material section 10 on the base layer 18. A top layer 22 is applied to the cover material section 10 over the color layer 12. The top layer 22 (more than one top layer 22 may be applied) is transparent or may contain less than 10% color pigment, but may be in the range of from 0% to 8%. Leuco dyes may be included in these coatings to enhance visibility.

[0011] As will be referred to below Figure 3 As depicted, a hot embossing tool 24 heated to a temperature between 140° C. and 200° C. is pressed against the covering material section 10. The hot embossing tool includes raised areas 26 and recessed areas 28. The raised areas 26 form the first portion 14, which is activated to provide a visible mark on one surface of the covering material section 10. The recessed areas 28 form the second portion 16, which is not activated and does not provide a visible mark on one surface of the covering material section 10.

[0012] Reference Figure 3 , the manufacturing process is described with reference to the process flow chart. The process begins at 30 by selecting a covering material segment 10. As previously mentioned, the covering material may include leather, a vinyl resin sheet, a polyurethane or a thermoplastic polyolefin sheet.

[0013] A base coating is applied to the cover material section 10 at 32, forming a base layer 18. The base layer 18 includes a filler material, such as foam or microspheres in a solution of acrylic, polyester or polyurethane.

[0014] The covering material section 10 with the base layer 18 is then heated in an oven at a temperature between 100° C. and 120° C. to dry the base layer 18 at 34. This process step may be omitted if the covering material section 10 is not leather, such as a thermoplastic polyolefin sheet, a polyurethane sheet, or a vinyl sheet, or if the leather is unblemished.

[0015] If desired, the cover material section 10 is embossed at 36 using an embossing tool to provide a textured appearance on the cover material section 10. If the cover material section is smooth in appearance, this step is omitted.

[0016] At 38, a color layer 12 comprising a mixture of a colored paint and a leuco dye is applied to the covering material segment 10. The colored paint is, for example, a water-based polyurethane, a solvent-based polyurethane, or a vinyl resin paint. As previously described, the leuco dye is an irreversible thermochromic dye. The ratio of the colored paint to the leuco dye can be varied depending on the desired appearance of the graphic image 17 to be provided on the covering material segment 10. The color layer 12 is applied on the base layer 18, or directly to the covering material segment 10.

[0017] After the color layer 12 is applied, the cover material section 10 with the color layer 12 is placed in an oven at 40 to dry the color layer 12 .

[0018] At 42, a top coating is applied over the color layer 12 to form the top layer 22 which protects the cover material section 10 and the previously applied coatings.

[0019] The top coating is dried in an oven at a temperature between 100° C. and 120° C. to form the top layer 22 .

[0020] At 46, the leuco dye is embossed using a hot embossing tool that is heated to a temperature between 140°C and 180°C to activate the leuco dye in the first portion 14 of the graphic image, wherein the embossing tool 20 applies pressure to the covering material segment, which changes the color of the leuco dye. Less pressure is applied to the second portion of the graphic image, and the leuco dye does not change color in the second portion. The color change occurs in the first portion because the leuco dye is encapsulated in a wax or other microencapsulation material to cause a phase change when the pH buffer solution mixes with the leuco dye component in the area where pressure is applied while being heated, thereby causing the color change in the first portion 14.

[0021] According to a first aspect of the present disclosure, an article is disclosed that includes a covering material segment 10 and a color layer 12 that includes a colored coating mixed with an irreversible thermochromic dye applied to the covering material segment 10. The irreversible thermochromic dye includes a first portion 14 that is activated to provide a visible mark on one surface of the covering material segment 10 and a second portion 16 that is not activated, wherein the combined first portion 14 and second portion 16 produce a graphic image 17 on the covering material segment 10.

[0022] Other concepts that may be combined with the first aspect of the present disclosure include one or more of the following:

[0023] The article may further include a topcoat layer 22 comprising at least one of a solvent-based polyurethane, a water-based polyurethane, and a vinyl resin applied over the color layer.

[0024] The top coating 22 may be a translucent tinted paint or a leuco dye.

[0025] A primer layer 18 may be applied to the length of covering material 10. An embossed texture pattern may be formed on the length of covering material 10.

[0026] The color layer 12 may contain a mixture of 40% by volume of a pigmented color coating and 60% by volume of a leuco dye. Alternatively, the mixture may contain from 40% to 0% of a pigmented color coating and 60% to 100% of a leuco dye.

[0027] According to a second aspect of the present disclosure, an article is disclosed, comprising a covering material section 10 coated with a color layer 12, the color layer 12 comprising a pigmented coating and an irreversible thermochromic dye. A top coating 22 is applied to the color layer 12. The irreversible thermochromic dye comprises a first portion 14 and a second portion 16, the first portion 14 providing a visible mark 17 when activated, and the second portion 16 being unactivated.

[0028] Other concepts that may be combined with the second aspect of the present disclosure include one or more of the following:

[0029] A base layer 18 is applied to the length of covering material 10 , wherein the color layer 12 is applied on top of the base layer 18 .

[0030] The color layer 12 also contains a mixture of a pigmented color coating and a leuco dye.

[0031] The color layer 12 also contains a mixture of 40% of a pigmented color coating and 60% of a leuco dye. Alternatively, the mixture may contain from 40% to 0% of a pigmented color coating and 60% to 100% of a leuco dye.

[0032] Color layer 12 is applied indirectly to covering material section 10 on base coating 18 .

[0033] The top coating layer 22 is a clear coating layer of at least one of a solvent-based polyurethane, a water-based polyurethane, or a vinyl resin.

[0034] The covering material segment 10 is selected from the group consisting of leather, vinyl or polyurethane.

[0035] According to a third aspect of the present disclosure, a method is disclosed that includes conditioning a segment of cover material with a primer at 32, applying a color coating comprising an irreversible thermochromic dye and a coloring paint to the segment of cover material at 38, applying a top coating to the color coating at 42, and embossing a graphic image in the color coating at 46. A heat embossing tool 24 is heated to a temperature that causes a color change in the irreversible thermochromic dye by applying pressure to a first portion 14 of the color coating 12. In the area where reduced pressure is applied by the heat embossing tool 24, a color change in the irreversible thermochromic dye does not occur in a second portion 16 of the color coating 12.

[0036] Other concepts that may be combined with the third aspect of the present disclosure include one or more of the following:

[0037] A primer layer 18 is applied to the length of cover material 10 .

[0038] A filler coating is applied to the cover material section 10 at 32 and a textured pattern is embossed onto the cover material section.

[0039] The color coating 12 includes a mixture of a pigmented color coating and an irreversible thermochromic dye (eg, a leuco dye).

[0040] The pigmented color coating 12 contains 40% of the color coating and 60% of the leuco dye. Alternatively, the mixture may contain from 40% to 0% of the pigmented color coating and 60% to 100% of the leuco dye.

[0041] The step of embossing the graphic image 17 in the color coating is performed using a hot embossing tool 24 that is heated to a temperature above the curing temperature of the curing oven and below a temperature that would be detrimental to the top coating.

[0042] A product is made according to the method of claim 14.

[0043] Although exemplary embodiments are described above, this does not mean that these embodiments describe all possible forms of the present invention. More specifically, the wording used in this specification is descriptive rather than restrictive, and it should be understood that multiple changes can be made without departing from the spirit and scope of the present invention. In addition, the features of the embodiments of multiple implementations can be combined to form other embodiments of the present invention.

Claims

1. An article comprising: leather segments; as well as A color layer comprising a pigmented coating mixed with an irreversible thermochromic dye applied to the leather segment, wherein the irreversible thermochromic dye comprises a first part that provides a visible mark on one surface of the leather when activated and a second part that is not activated.

2. The article of claim 1, further comprising: A top coating layer comprising at least one of a solvent-based polyurethane, a water-based polyurethane, and a vinyl resin is applied over the color layer.

3. The article of claim 2, wherein the topcoat comprises a translucent pigmented paint.

4. The article according to claim 1, comprising: A base coat is applied to the leather segment.

5. The article according to claim 1, comprising: An embossed grain pattern is formed on the leather segment.

6. The article of claim 1, wherein the color layer comprises a mixture of 40% pigmented color coating and 60% leuco dye.

7. An article comprising: Covering material segment; a color layer comprising an irreversible thermochromic dye applied to the length of cover material, wherein the irreversible thermochromic dye comprises a first portion that provides a visible indicia when activated and a second portion that is not activated; as well as A top coat is applied over the color layer.

8. The article according to claim 7, comprising: A base layer is applied to the length of cover material, wherein the color layer is applied over the base layer.

9. The article of claim 7, wherein the color layer further comprises a mixture of a pigmented color coating and a leuco dye.

10. The article of claim 7, wherein the color layer further comprises a mixture of 40% pigmented color coating and 60% leuco dye.

11. The article of claim 7, wherein the color layer is applied indirectly to the length of covering material over a base coat.

12. The article of claim 7, wherein the topcoat is a clearcoat of at least one of a solvent-based polyurethane, a water-based polyurethane, or a vinyl resin.

13. The article of claim 7, wherein the covering material segment is selected from the group consisting of: leather, Vinyl resin, Thermoplastic polyolefins, and Polyurethane.

14. A method comprising: conditioning the covering material segment with a primer layer; applying a color coating comprising an irreversible thermochromic dye to the length of covering material; applying a top coat to the color coat; as well as A graphic image is embossed in the color coating using a heat embossing tool that is heated to a temperature that causes a color change of the irreversible thermochromic dye in a first portion of the color coating without causing a color change of the irreversible thermochromic dye in a second portion of the color coating.

15. The method according to claim 14, comprising: A primer layer is applied to the length of cover material.

16. The method of claim 14, wherein the length of covering material is leather, and the method further comprises: applying a filler coating to the section of cover material; as well as A textured pattern is embossed into the length of cover material.

17. The method of claim 14, wherein the color coating comprises a mixture of pigmented color coatings, and wherein the irreversible thermochromic dye is a leuco dye.

18. The method of claim 17, wherein the pigmented color coating comprises 40% color coating and 60% leuco dye.

19. The method of claim 14, wherein the step of embossing a graphic image in the color coating layer is performed using a hot embossing tool that is heated to a temperature above the curing temperature of a curing oven and below a temperature that is detrimental to the top coating layer.

20. A product made according to the method of claim 14.

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