Method for producing an image in a surface of a consumer article

Abstract

Method for producing a color-stable or color-resistant image (10) in a surface (21) of a consumer article (20), in particular a sanitary article, such as a shower tray, bathtub, washbasin, toilet lid, seat ring, floor or wall panel, apron for bathtubs, bathroom furniture or household article, such as a chair, table, furniture, for example a sofa, the method comprising the following steps: - Providing (100) the surface (21), wherein the surface (21) comprises or is formed from a polymer material (22), in particular mineral casting, the polymer material (22) comprises at least one polymer (23) and one filler (24), and the filler (24) comprises silicon dioxide; - providing (200) a dye (30) for the image (10) to be produced; - combining (300) the surface (21) and the dye (30); and - heating (400) the dye (30), whereby the dye (30) diffuses into the surface (21) by sublimation and the image (10) is formed.

Description

[0001] The present invention relates to a method for producing a color-stable or color-resistant image in the surface of a consumer article. The consumer article, in particular a sanitary article, can be a shower tray, a bathtub, a washbasin, a toilet seat, a seat ring, a floor or wall panel, a bathtub apron, a bathroom furniture piece, or a household article, such as a chair, a table, or a piece of furniture, for example a sofa, in particular made of or comprising an at least partially polymerized plastic or polymer material.

[0002] Sanitary ware is intended to have a visual design on its surface, for example, for reasons of visibility in the peripheral field of vision and / or to blend in with the surroundings. For this purpose, it is known to provide and / or print sanitary ware, in particular, with an image, label, decoration, and / or printing. Sanitary ware is typically printed on layers close to the surface or on and / or in the surface.

[0003] Typically, the visual design on the surface of an article, such as an image, lettering, decoration, and / or printing, fades over time. This can occur due to cleaning, UV radiation, walking on it, touching it, especially chemical aging effects, or other environmental influences.

[0004] According to the current state of the art, an image on the surface of a sanitary ware can be protected with a transparent lacquer layer to ensure colorfastness and / or prevent fading. However, applying a lacquer layer is complex and can also lead to poor colorfastness if the lacquer layer is damaged.

[0005] Therefore, the object of the invention is to provide a method for producing an image in or on a surface of a sanitary article, in which the image is color-stable and protected against fading for as long as possible after production. Furthermore, the method should be economically viable.

[0006] According to the invention, the object is achieved by the method having the features of claim 1. Advantageous further developments are the subject of the subclaims.

[0007] According to the invention, there is provided a method for producing a color-stable or color-resistant image in a surface of a consumer article, in particular a sanitary article, such as a shower tray, bathtub, washbasin, toilet lid, seat ring, floor or wall panel, apron for bathtubs, bathroom furniture or household article, such as a chair, table, furniture, for example a sofa, wherein the method according to the proposal comprises the following steps, in particular wherein a sequence of the steps is given below by way of example. - Providing the surface, wherein the surface comprises a polymer material, in particular mineral casting, or is formed from such a material, wherein the polymer material comprises at least one polymer and one filler, and wherein the filler comprises silicon dioxide. - Providing a dye for the image to be produced; - Combining surface and dye; and - Heating the dye, whereby the dye diffuses into the surface by sublimation and the image is formed.

[0008] The invention is based on the idea that a surface of a polymer material comprising at least the filler silicon dioxide and initially any desired polymer is printed using a technique in which the dye is sublimated by elevated temperature and can be introduced into the surface, in particular at least partially, substantially or exclusively by diffusion. This technique is therefore particularly preferably based on the principle of sublimation or so-called sublimation printing. It has been found in particular that a sublimation print adheres particularly well to the surface thanks to the polymer material, especially because the porosity usually inherent in the polymer material with the filler containing silicon dioxide ensures good diffusion of the dye into the pores of the surface, especially at elevated temperatures.The proposed fillers increase porosity, particularly of the polymer material, at elevated temperatures or upon heating, and thus improve the diffusion capacity or absorption capacity for dyes or inks. The image can extend to a certain depth of the surface and thus be resistant to fading. Another surprising effect is that the polymer material now exhibits greater wear resistance thanks to silicon dioxide, which inherently makes the image more resistant to fading, thus making it more color-stable or colorfast because the surface with the image wears or wears less, and the dye lasts longer.

[0009] The surface comprises the polymer material and / or is formed therefrom. The surface or the polymer material can be arranged on a material component of the sanitary article that differs from the polymer material. The polymer material is preferably a cast material and / or a mineral cast, i.e. a cast material comprising minerals. A cast material can, for example, in contrast to a formed material or formed material, advantageously be shaped in a very adaptable manner. The polymer material has two essential components, namely a polymer or plastic and a filler with or made of silicon dioxide (SiO2) or based on silicon dioxide. Of course, two, three or more different polymers and / or fillers can also be used. When providing the surface, for example, a casting process can be used, preferably one that is suitable for producing mineral cast and / or sanitary articles.

[0010] If the dye is provided for the image to be produced, the dye can be loose and / or arranged on a dye carrier. For example, the dye carrier, which is in particular at least substantially planar, can carry the dye in an arrangement that corresponds to a negative of the image to be produced. The dye carrier can therefore carry the dye on one side that can be arranged facing the surface or can be arranged during the process. The dye can adhere to the dye carrier, at least on one side, in particular lightly (in particular, “lightly” means with lower adhesion capacity or lower adhesion force than on the article of use after production or after printing of an image), preferably such that the dye remains in its arrangement on the dye carrier until later heating, in particular sublimation, and / or during handling.The dye may comprise single-color or multi-color dye particles, e.g. to create cost-effective monochrome or attractive colorful images.

[0011] When the surface and the dye are brought together, the dye and the surface can come into contact. In particular, the dye and / or a dye carrier can lie flat against the surface. This creates a homogeneous image.

[0012] When the dye is heated, the image can be formed, in particular, in or on the surface. During heating, the dye can be introduced into the surface through sublimation. This means, for example, that the originally solid dye immediately transitions into a gas phase, particularly when the dye is close to the surface and / or penetrates the surface. The dye can, in particular, diffuse into, diffuse into, or penetrate the surface based on sublimation. The image can be formed, in particular printed, and / or introduced onto, onto, and / or into the surface.

[0013] Heating refers to increasing the temperature above ambient temperature, preferably above 140, 150, 160, or 165 °C. A higher temperature can increase the color fastness of the image by embedding the image deeper into the surface and / or by allowing the dye to bond better with the polymer material.

[0014] The image may extend to a depth of more than 1, 50, 150, or 200 micrometers in the topmost layer of the surface. The dye may be provided with a dye layer thickness, preferably before heating and / or on a dye carrier, of at least 1, 50, 150, or 200 micrometers.

[0015] The polymer material comprises at least one plastic as one or more polymers. Thermoplastics and / or thermosets are suitable, for example. A synthetic resin can preferably be used as the polymer. Using acrylic or acrylic resin as the polymer results in particularly good colorfastness of the image while providing equally good or even improved strength for the polymer material.

[0016] Preferably, the polymer (or polymers) forms a matrix with embedded fillers. The polymer material is preferably electrically non-conductive and / or non-magnetic or non-magnetizable. The polymer material preferably has no metallic components; alternatively, the polymer material has metallic components.

[0017] The invention is generally applicable to substantially flat or large-area objects, or to objects having such surfaces, that are suitable for images. The objects or surfaces can, but do not have to, be flat. Contoured objects or surfaces of objects are also suitable.

[0018] The type of images is not restricted. For example, abstract monochrome or grayscale geometries, colored, single- or multi-colored geometries, or pictorially represented textures can be used as images or representational images; any combination of these is also conceivable. One or more images can be applied, particularly side by side and / or on top of each other. "Image" can also be understood as "print," "representation," or "optical design."

[0019] In a preferred embodiment, the silicon dioxide of the filler is based on or comprises one or more of the following substances: cristobalite (also called cristobalite), quartz, or another silicon dioxide modification. Mixtures of the aforementioned substances can therefore be provided in or as the filler. This further enhances the inventive effect of the dye penetrating the surface or the material of the sanitary article itself. It has been found that cristobalite and quartz in particular have excellent properties for the inventive process. This allows a particularly color-stable or color-fast image to be created.

[0020] Preferably, a preferably used cristobalite comprises or consists of a tetragonal α-cristobalite and / or a cubic β-cristobalite.

[0021] Increased wear resistance of the surface is achieved if the filler has a hardness of at least 5, especially at least 6 or 7, on the Mohs hardness scale. The higher the Mohs hardness, or at least if it is at least 5, 6, 7, or higher, the more wear-resistant the surface is, but also the more resistant the image is to fading and the more color-stable the image is.

[0022] In a further embodiment, the filler can have a higher porosity than aluminum trihydroxide. This allows the dye to penetrate deeper into the surface, further improving the color stability of the image and its resistance to fading.

[0023] In particular, the diffusivity is increased by a higher porosity of a filler, in particular a porosity higher than the porosity of aluminum trihydroxide, whereby a faster process and / or a dye that penetrates deeper into the surface and an image with improved color fastness can be obtained.

[0024] Alternatively or additionally, the polymer material can contain aluminum trihydroxide. This allows the dye to penetrate primarily into the filler, for example, to avoid affecting the properties of the aluminum trihydroxide. Furthermore, the wear resistance and / or strength of the polymer material or surface can be improved.

[0025] It is further preferred if the polymer material contains at least 60 percent filler by weight, volume, or mass. The filler can constitute 60 percent filler by weight, volume, or mass of the polymer material or more. In particular, the proportion of filler is greater than the proportion of polymer. This not only allows the surface to exhibit further increased wear resistance, but also allows the image to exhibit good color fastness because the diffusion rate is increased by the higher porosity, allowing the dye to penetrate deeper, and the process can be carried out comparatively quickly.

[0026] The polymer material also preferably comprises, for example, at least and / or within a 5 percent deviation, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70 or more percent by weight, volume, or mass of filler with silicon dioxide such as quartz, cristobalite, or mixtures thereof. Alternatively or additionally, the polymer material preferably comprises, for example, at most and / or within a 5 percent deviation, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30 or less percent by weight, volume, or mass of polymer, in particular with acrylic and / or acrylic resin.

[0027] In a simple and preferred case, the polymer material comprises at least, exactly or approximately (i.e. + / - 1) 30 percent by weight, volume or mass of cristobalite and / or quartz, at most, exactly or approximately (i.e. + / - 1) 70 percent by weight, volume or mass of polymer, in particular with or made of acrylic and / or acrylic resin, and in case of doubt one or more further proportion(s) to 100 percent by weight, volume or mass of a further filler, a further polymer and / or a further dye or a further substance which has a positive influence on the strength or hardness of the polymer material.

[0028] In a further embodiment, the polymer material comprises acrylic, preferably acrylic resin. The polymer can be acrylic or acrylic resin or comprise it. It has been found that acrylic or acrylic resin is not only cost-effective and easy to process, but also has excellent resistance to fading when printed, preferably using sublimation printing.

[0029] Preferably, a combination of silicon dioxide, based on cristobalite and / or quartz, and acrylic or acrylic resin provides a polymer material or surface with good strength properties. In particular, such a surface is very well printable, preferably using sublimation printing.

[0030] In a preferred embodiment of the process, at least one process step or several process steps are carried out under vacuum, preferably where vacuum describes a pressure below ambient pressure, for example 0.9 bar, 0.75 bar, 0.5 bar, 0.25 bar, 0.1 bar, 0.01 bar, 0.001 bar, 0.1 mbar, 0.01 mbar, 0.001 mbar, or even less. A typical ambient pressure is, for example, 1 bar + / - 0.05 bar. Thanks to the vacuum, the dye can penetrate even deeper into the surface.

[0031] At least one point during the process may involve using a space in which a colorfast image is at least partially produced or the surface to be printed is arranged, wherein the space is pressurized to a pressure lower than ambient pressure or vacuum. Preferably, the dye is heated under vacuum. Alternatively or additionally, the diffusion of the dye into the surface and / or sublimation takes place under vacuum.

[0032] To increase color fastness, it has proven particularly preferable for the dye to be embedded at a greater depth into the surface, so that even if the surface wears, the dye remains visible. It can therefore be provided that the dye is at least partially worn away with the surface wear, or that the dye is arranged sufficiently deep in the surface so that wear of the surface above the dye does not impair the dye or the image. Combinations of the above are also conceivable.

[0033] A filler is a substance that can be finely distributed throughout a polymer material. The filler is preferably finely distributed throughout the polymer surface, particularly not clumped or agglomerated. The filler ensures hardness and color stability and should therefore not be agglomerated.

[0034] In a further embodiment of the method, it can be provided that during diffusion and / or heating the dye and / or a dye carrier lies at least partially, preferably flatly or fully, preferably under force and / or pressed against the surface. The dye carrier or dye carriers can carry the dye and serve to transfer the dye onto or into the surface. The dye carrier can have a shape that can lie flatly or fully against the surface, preferably in an area to be printed. It is particularly advantageous if the dye or dye carrier is arranged very close to the surface or lies against the surface, at least temporarily, in order to produce a homogeneous, i.e. clean or, corresponding to an original, uniform image in the height direction (i.e. normal to the surface) and width direction (i.e. along and parallel to the surface) of the surface.

[0035] It is advantageous if one or more process steps are carried out under pressure, preferably by means of a pressing device and / or a coating weight. Alternatively or additionally, the diffusion of the dye can take place under pressure. Pressure is preferably understood to mean air pressure in a space and / or compression, for example, of the surface, the polymer material, the dye, and / or a dye carrier. This ensures a homogeneous and color-stable image.

[0036] Preferably, a vacuum is used, while the support weight or pressing device ensures surface pressure on the surface or the polymer material. Advantageously, the vacuum expels gas or air from the pores, which is beneficial for the process, and / or the pressure or pressing improves diffusion into the surface.

[0037] Alternatively or additionally, a process step can be provided in which the surface, preferably the image on or in the surface, is covered with a preferably transparent and / or closed-pore lacquer layer in order to provide further protection.

[0038] Preferably, at least one or more process steps or process features can be repeated and / or carried out multiple times, for example two, three or more times, during the production of an image. The order of the steps or features of the process can also be arranged arbitrarily. For example, the surface can be provided only once, with the dye being provided twice, and the dye and the surface being brought together twice, preferably in the same arrangement to one another, and / or heated twice. A very color-stable or color-fast image can also be produced in this way, also because more dye can penetrate the surface.

[0039] In the context of the above and the following disclosure, the abbreviation "resp." is a short form for "respectively" and is generally intended to indicate alternative, essentially equivalent, and / or synonymous features or terms in order to convey the idea or meaning of a feature or term. "Respectively" can always be replaced with "and / or."

[0040] The invention will be explained in more detail below using exemplary embodiments with reference to the accompanying schematic drawings, in which: Fig. 1 is a plan view of an image in a surface according to the prior art, and Fig. 2 a plan view of an image in a surface in which the method according to the invention has been used, and Fig. 3 a schematic representation of a method according to the invention.

[0041] Fig. 1 shows a consumer article 20, the surface 21 of which has been printed with an image 10 according to a prior art method. Fig. Figure 1 shows the color fastness or color stability of the image 10 on the surface 21 of the article of daily use 20 by applying a circular, punctual, and continuous frictional movement on the surface 21 with respect to time and force. A so-called friction test was performed. This resulted in circular wear on the surface 21, resulting in a circular area 25 or groove 25. The image 10 has faded in a circular pattern. The article of daily use 20 is a polymer material 22 comprising aluminum trihydroxide as filler 24 and acrylic resin as polymer 23.

[0042] Fig. Figure 2 shows a consumer article 20 provided with a color-stable or color-resistant image 10 in its surface 21. Here, the image 10 was produced using the method according to the invention. This consumer article 20 also undergoes an abrasion test as with the consumer article 20 of Fig. 1, after which a circular area 25 and a groove 25 were created. In comparison of Fig. 1 and Fig. 2 shows that the image 10 on the article of daily use 20 produced by the method according to the invention of the Fig. 2 is more color-stable or color-resistant because the circular area 25 is comparatively Fig. 1 to Fig. 2 has faded more.

[0043] The commodity 20 of the Fig. 2 comprises a polymer material 22 with the filler 24 quartz and the polymer 23 acrylic resin. The filler 24 has a Mohs hardness of seven and a higher porosity than aluminum trihydroxide.

[0044] To produce image 10 of the Fig. 2, a dye carrier 40 comprising the dye 30 arranged in the form of a negative image of the image 10 has been provided. The dye carrier 40 with the dye 30 has been placed flat on the surface 21, whereby the dye 30 has come to rest against the surface 21. After heating and under pressure and with the dye 30 pressed against the surface 21, the dye 30 has sublimated and diffused into the surface.

[0045] In particular, image 10 of the article of daily use 20 is Fig. 2 after an equivalent abrasion test compared to Figure 10 on polymer material 22 or surface 21 according to the state of the art of the article of daily use 20 of the Fig. 1 with a lower abrasion or a lower fading of the image 10. Likewise, the article of daily use 20 of the Fig. 2 in the circular area 25 with abrasion or with fading a smaller amount of material removal compared to the Fig. 1; in other words, the furrow 25 is in Fig. 2 less deep than in Fig. 1.

[0046] The Fig. Figure 3 shows a method according to the invention. In the first step 100, a surface 21 is provided on a merely exemplary block-shaped or essentially cube-shaped body, which represents the consumer article or a section thereof. The surface 21 is arranged on a polymer material 22 made of mineral casting, or the body is made of it.

[0047] In the second step 200, which in this case can run parallel to the first step 100, a dye 30 for an image 10 to be produced is provided on a dye carrier 40 or applied to the dye carrier 40, essentially resulting in a negative of the image 10 to be produced on the dye carrier 40. For the sake of clarity, a bottle with dye 30 is shown, which represents, for example, a printing process during provision 100. For further clarity, the negative of the image 10 to be produced is illustrated in the form of two squares and a circle on a roll-off paper 40.

[0048] In the third step 300, the dye 30 is applied or brought together with the aid of the paper 40 or dye carrier 40 and the surface 21, in particular over as much of the surface as possible. In this case, the paper 40 is unwound and arranged so that it is in full contact with the surface 21.

[0049] Finally, in the fourth step 400, at least the dye 30, in particular the surface 21, is heated, preferably without the dye carrier 40. In the process, the dye 30 sublimates. The dye 30 penetrates at least partially into the surface 21. In particular, this is followed by a diffusion of the dye 30 into the surface 21. In other words, in step 400, a sublimation print is carried out on or at the surface 21. In particular, the ten curved, upward-pointing arrows and the outlined thermometer exemplify the increased temperature and the sublimation taking place, respectively.

[0050] Independently of this or in conjunction with this, in a further step 500, the surface 21 with the image 10 or the dye 30 can be cooled. Thus, the article of daily use 20 with the color-stable or color-resistant image 10 can be preserved and / or used. List of reference symbols 10 Image, image to be produced 20 everyday object 21 Surface 22 Polymer material 23 Polymer 24 Filler 25 circular area, furrow 30 dye 40 dye carriers, paper 100 Deployment, first step 200 Deployment, second step 300 Merge, third step 400 Heating, fourth step 500 Cooling, next step

Claims

[1] Method for producing a color-stable or color-resistant image (10) in a surface (21) of a consumer article (20), in particular a sanitary article, such as a shower tray, bathtub, washbasin, toilet lid, seat ring, floor or wall panel, apron for bathtubs, bathroom furniture or household article, such as a chair, table, furniture, for example a sofa, the method comprising the following steps: - Providing (100) the surface (21), wherein the surface (21) comprises or is formed from a polymer material (22), in particular mineral casting, the polymer material (22) comprises at least one polymer (23) and one filler (24), and the filler (24) comprises silicon dioxide; - providing (200) a dye (30) for the image (10) to be produced; - combining (300) the surface (21) and the dye (30); and - heating (400) the dye (30), whereby the dye (30) diffuses into the surface (21) by sublimation and the image (10) is formed. [2] Method according to claim 1, characterized by that the silicon dioxide of the filler (24) is based on and / or comprises cristobalite, quartz and / or another silicon dioxide modification. [3] Method according to claim 1 or 2, characterized by that the filler (24) has a hardness of at least 5, in particular at least 7, on the Mohs hardness scale. [4] Method according to one of the preceding claims, characterized by that the filler (24) has a higher porosity than aluminum trihydroxide. [5] Method according to one of the preceding claims, characterized by that the filler (24) forms 60 percent, in particular mass, weight or volume%, of the polymer material (22) or more. [6] Method according to one of the preceding claims, characterized by that the polymer material (22) comprises acrylic, in particular acrylic resin. [7] Method according to one of the preceding claims, characterized by that one or more process steps are carried out under vacuum, in particular at a pressure below ambient pressure, for example at 0.1 bar or 0.01 bar or less, and / or one or more diffusions of the dye (30) into the surface (21) are carried out under vacuum. [8] Method according to one of the preceding claims, characterized by that during diffusion and / or heating, the dye (30) and / or a dye carrier (40) lies at least partially, in particular flatly or completely, on the surface (21). [9] Method according to one of the preceding claims, characterized bythat one or more process steps are carried out under pressure, in particular by means of a pressing device and / or a coating weight, and / or that one or more process steps are carried out under pressure, and / or that one or more of the diffusion of the dye takes place under pressure.

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