Method for forming an image in a surface of a utility article

Abstract

The invention relates to a method for producing a color-stable orcolorfast image (10) in a surface (21) of a consumer product (20), in particular a sanitary ware, such as a shower tray, bathtub, washbasin, toilet seat, seat ring, floor or wall panel, apron for bathtubs, bathroom furniture or a household item, such as a chair, table, furniture, for example a sofa, wherein the method comprises the following steps: providing (100) the surface (21), wherein the surface (21) comprises or is formed from a polymer material (22), in particular a mineral casting, the polymer material (22) comprising at least one polymer (23) and a filler (24), and the filler (24) comprising silicon dioxide; providing (200) a dye for the image (10) to be produced; combining (300) the surface (21) and the dye; and heating (400) the dye (30), wherein 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 on the surface of an everyday object.

[0002] The consumer item, in particular a sanitary item, may be a shower tray, a bathtub, a washbasin, a toilet seat, a seat ring, a floor or wall panel, an apron for bathtubs, a bathroom piece of furniture or a household item, such as a chair, a table, a piece of furniture, for example a sofa, in particular made of or with an at least partially polymerized plastic material or polymer material.

[0003] Sanitary ware is often designed with visual appeal, for example, for visibility in the peripheral field of vision and / or to blend in with its surroundings. It is known to apply and / or print designs to sanitary ware, particularly images, lettering, decorations, and / or imprints. Typically, sanitary ware is printed on near-surface layers or on and / or within the surface.

[0004] Typically, the visual design on the surface, such as an image, lettering, decoration, and / or print, fades over time on an everyday object. This can be caused by cleaning, UV radiation, foot traffic, handling, especially chemical aging effects, or other environmental influences.

[0005] According to current technology, an image on the surface of a sanitary fixture can be protected against fading and its colorfastness by a transparent coat of lacquer. However, applying a coat of lacquer is complex and can also lead to poor colorfastness if the lacquer is damaged.

[0006] US 2004 / 151899 A1 discloses a clear coat coating containing 1 to 10 wt% powdered silicon dioxide as a filler. US 4,406,662 A, on the other hand, proposes aluminum oxide trihydrate as a filler.

[0007] Therefore, the object of the invention is to provide a method for producing an image in or on the surface of a sanitary fixture, wherein the image is colorfast and protected against fading for as long as possible after production. Furthermore, the method should be economically viable. According to the invention, this object is achieved by the method with the features of claim 1. Advantageous embodiments are the subject of the dependent claims.

[0008] According to the invention, a method for producing a color-stable or color-resistant image on the surface of a consumer product, in particular a sanitary object, such as a shower tray, bathtub, washbasin, toilet seat, seat ring, floor or wall panel, apron for bathtubs, bathroom furniture or household item, such as a chair, table, furniture, for example a sofa, wherein the method according to the proposal comprises the following steps, in particular wherein an order of the steps is given below by way of example. Providing a surface, wherein the surface comprises or is formed from a polymer material, in particular mineral casting, wherein the polymer material comprises at least one polymer and a filler, and the filler is silicon dioxide-based, wherein the filler constitutes at least 20% by weight or volume of the polymer material. Providing a dye for the image to be produced; combining the surface and the dye; and heating the dye, wherein the dye diffuses into the surface by sublimation and the image is formed.

[0009] The invention is based on the concept of printing a surface of a polymer material, comprising at least the filler silicon dioxide and an initially arbitrary polymer, using a technique in which the dye is sublimated by elevated temperature and introduced into the surface, particularly 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 that, thanks to the polymer material, a sublimation print adheres particularly well to the surface, especially because the porosity typically inherent in the polymer material with the silicon dioxide filler ensures good diffusion of the dye into the pores of the surface, particularly at elevated temperatures.The proposed fillers increase the porosity of the polymer material, particularly at elevated temperatures or during heating, thus improving the diffusion and absorption capacity of dyes and colors. The image can extend to a certain depth of the surface, making it resistant to fading. Furthermore, and surprisingly, the silicon dioxide in the polymer material provides greater wear resistance, which in turn makes the image more resistant to fading and more colorfast, as the surface with the image experiences less wear and tear, and the dye lasts longer.

[0010] The surface comprises the polymer material and / or is formed from it. The surface or the polymer material can be arranged on a material component of the sanitary ware that differs from the polymer material. Preferably, the polymer material is a cast material and / or a mineral casting, that is, a cast material containing minerals. A cast material, unlike a formed material or formed material, can advantageously be shaped very flexibly. The polymer material has two essential components: a polymer or plastic and a filler made of or based on silicon dioxide (SiO₂). Of course, two, three, or more different polymers and / or fillers can also be used. A casting process can be used to create the surface, preferably one suitable for manufacturing mineral castings and / or sanitary ware.

[0011] When the dye for the image to be produced is provided, it can be loose and / or arranged on a dye carrier. For example, the dye carrier, which is at least substantially flat, can carry the dye in an arrangement corresponding to a negative of the image to be produced. The dye carrier can therefore carry the dye on a side that can be oriented towards the surface or that can be oriented towards it during the process. The dye can adhere to the dye carrier, at least on one side, particularly lightly (in particular, "lightly" means with less adhesion than to the finished product after production or printing of an image), preferably so that the dye remains on the dye carrier in its arrangement until subsequent heating, in particular sublimation, and / or during handling.The dye can have monochrome or multicolored dye particles, e.g. to create cost-effective monochrome or attractive colorful images.

[0012] When the surface and the dye are brought together, they can come into contact. In particular, the dye and / or the dye carrier can lie flat against the surface. This results in a homogeneous image.

[0013] When the dye is heated, the image can be formed, particularly on or within the surface. During heating, the dye can be introduced into the surface through sublimation. This means, for example, that the initially solid dye transitions directly into a gas phase, especially if the dye is near the surface and / or penetrates the surface. The dye can also diffuse or penetrate the surface, particularly through sublimation. In this process, the image can be formed, especially by printing and / or being applied to, on, or within the surface.

[0014] Heating is understood to mean raising the temperature to a level above the ambient temperature, preferably above 140, 150, 160 or 165 °C.

[0015] A higher temperature can increase the colorfastness of the image by penetrating the image deeper into the surface and / or by allowing the dye to form a better bond with the polymer material.

[0016] The image can extend to a depth of more than 1, 50, 150, or 200 micrometers in the uppermost layer of the surface. The dye can be provided in a dye layer, preferably before heating and / or on a dye carrier, of at least 1, 50, 150, or 200 micrometers thickness.

[0017] The polymer material contains at least one polymer, specifically a plastic. Thermoplastics and / or thermosets are suitable examples. A synthetic resin is a preferred polymer. Acrylic or acrylic resin, when used as the polymer, results in particularly good colorfastness of the image, along with equally good or even improved strength of the polymer material.

[0018] 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 contains no metallic components; alternatively, it may contain metallic components.

[0019] The invention is generally applicable to objects that are essentially planar or have large surfaces, or surfaces suitable for images. The objects or surfaces can be flat, but need not be. Contoured objects or surfaces of objects are also suitable.

[0020] The type of images is not restricted. For example, abstract monochrome or grayscale images, colored or single- or multi-colored geometries, or pictorially represented textures can be used as images, or representational images; any combination thereof is also conceivable. One or more images can be applied, especially side by side and / or on top of each other. The term "image" can also be understood as "print," "representation," or "optical design."

[0021] 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 a filler. This further enhances the inventive effect of the dye penetrating the surface or the material of the sanitary fixture itself. It has been found that cristobalite and quartz, in particular, exhibit excellent properties for the inventive process. This allows for the creation of a particularly color-stable or color-resistant image.

[0022] Preferably, a cristobalite used preferably has or consists of a tetragonal α-cristobalite and / or a cubic β-cristobalite.

[0023] Increased surface wear resistance results when the filler has a hardness of at least 5, and especially at least 6 or 7, on the Mohs hardness scale. The higher the Mohs hardness, or at least when it is at least 5, 6, 7 or more, the more wear-resistant not only the surface is, but also the more resistant the image is to fading and the more color-stable it is.

[0024] In another 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.

[0025] In particular, the diffusion capacity is increased by a higher porosity of a filler, especially a porosity higher than that of aluminium trihydroxide, which can result in a faster process and / or a dye penetrating deeper into the surface and an image with improved color fastness.

[0026] Additionally, the polymer material can contain aluminum trihydroxide. This allows the dye to penetrate primarily into the filler, for example, without affecting the properties of the aluminum trihydroxide. Furthermore, the wear resistance and / or strength of the polymer material or its surface can be improved.

[0027] According to the invention, the filler constitutes at least 20% by weight or volume of the polymer material. It is further preferred if the polymer material contains at least 60% by weight, volume, or mass of filler. The filler can constitute 60% 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 allows not only the surface to exhibit further increased wear resistance, but also the image to exhibit good colorfastness, because the diffusion rate is increased by higher porosity, enabling the dye to penetrate deeper, and the process can be carried out comparatively quickly.

[0028] The polymer material preferably also comprises, for example, at least and / or within a 5% range, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70 or more wt., volume., or mass percent 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% range, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30 or less wt., volume., or mass percent polymer, in particular with acrylic and / or acrylic resin.

[0029] In a simple and preferred case, the polymer material comprises at least, exactly or approximately (i.e., + / - 1) 30 wt., volume, or mass percent cristobalite and / or quartz, at most, exactly or approximately (i.e., + / - 1) 70 wt., volume, or mass percent polymer, in particular with or made of acrylic and / or acrylic resin, and, if in doubt, one or more further proportions of up to 100 wt., volume, or mass percent of another filler, another polymer, and / or another dye, or another substance that favorably influences the strength or hardness of the polymer material.

[0030] In a further embodiment, the polymer material is acrylic, preferably acrylic resin. The polymer can be acrylic or acrylic resin, or it can contain acrylic or acrylic resin. It has been found that acrylic or acrylic resin is not only cost-effective and easy to process, but also exceptionally resistant to fading when printed, preferably using sublimation printing.

[0031] 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 printable, preferably by sublimation printing.

[0032] In a preferred embodiment of the method, 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.

[0033] In this process, a chamber can be used at least at one point during the process in which a colorfast image is at least partially produced or the surface to be printed is arranged, wherein the chamber is pressurized to a lower pressure than ambient pressure or vacuum. Preferably, the dye is heated under vacuum. Alternatively or additionally, the dye is diffused into the surface and / or sublimation takes place under vacuum.

[0034] To increase colorfastness, it has proven particularly advantageous to incorporate the dye at a greater depth into the surface, so that the dye remains visible even when the surface wears down. It can therefore be designed so that the dye is at least partially worn away along with the surface, or so that the dye is positioned sufficiently deep within the surface that wear above the dye does not impair the dye or the image. Combinations of the above are also conceivable.

[0035] A filler is a substance that can be finely dispersed within a polymer material. The filler is preferably finely dispersed on the surface of the polymer material, and in particular, not clumped or agglomerated. The filler provides hardness and color stability and should therefore not be agglomerated.

[0036] In a further embodiment of the process, it can be provided that during diffusion and / or heating, the dye and / or a dye carrier is at least partially, preferably over a surface or across its entire surface, preferably under force and / or pressure, in contact with the surface. The dye carrier(s) can carry the dye and serve to transfer the dye onto or into the surface. The dye carrier can have a shape that allows it to conform to the surface over a surface or across its entire area, preferably in a printing area. It is particularly advantageous if the dye or the dye carrier is arranged very close to the surface, at least temporarily, or in contact with the surface, in order to produce a homogeneous, i.e., clean, or, according to a template, uniform image in the vertical (i.e., normal to the surface) and horizontal (i.e., along and parallel to the surface) direction of the surface.

[0037] It is advantageous if one or more process steps are carried out under pressure, preferably by means of a press and / or a weight. Alternatively or additionally, the dye can be diffused under pressure. Preferably, "pressure" refers to atmospheric pressure in a chamber and / or pressure on, for example, the surface, the polymer material, the dye, and / or a dye carrier. This ensures a homogeneous and color-stable image.

[0038] Preferably, a vacuum is used, while the support weight or pressing device ensures surface pressure on the surface or of the polymer material. Advantageously, the vacuum causes gas or air to be expelled from the pores, which is beneficial for the process, and / or the pressure or compression improves diffusion into the surface.

[0039] 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 to provide further protection.

[0040] Preferably, at least one or more process steps or process features can be repeated and / or performed multiple times, for example, two, three, or more times, during the production of an image. The sequence of the steps or features of the process can also be arranged arbitrarily. For example, the surface can be prepared only once, while the dye is prepared twice, and the dye and the surface are brought together twice, preferably in the same arrangement relative to each other, and / or heated twice. A very color-stable or color-resistant image can also be produced in this way, also because more dye can penetrate the surface.

[0041] In the context of the aforementioned and subsequent disclosure, the abbreviation "bzw." is used as a short form for "beziehungsweise" (respectively / in relation to) and is intended to indicate alternative, essentially equivalent and / or synonymous characteristics or terms in order to clarify the idea or meaning of a particular use of a characteristic or term. "Beziehungsweise" can always be replaced with "und / oder" (and / or).

[0042] The invention is explained in more detail below with reference to exemplary embodiments and the accompanying schematic drawings. These show: Fig. 1 is a top view of an image in a surface according to the prior art, and Fig. 2 is a top view of an image in a surface in which the method according to the invention has been used, and Fig. 3 is a schematic representation of a method according to the invention.

[0043] Fig. 1shows a consumer object 20, the surface 21 of which has been printed with an image 10 using a prior art method. Fig. 1 The colorfastness or color stability of image 10 on the surface 21 of the object 20 is demonstrated by the fact that a circular, point-like, and continuous rubbing motion was performed on the surface 21 with respect to time and force. A so-called rub test was thus carried out. This resulted in circular wear on the surface 21, forming a circular area 25 or a groove 25. Image 10 faded in a circular pattern. The object 20 is a polymer material 22 comprising aluminum trihydroxide as filler 24 and acrylic resin as polymer 23.

[0044] Fig. 2Figure 1 shows a consumer item 20 which is provided with a color-stable or color-resistant image 10 on its surface 21. The image 10 was produced using the method according to the invention. This consumer item 20 also underwent an abrasion test as described for the consumer item 20 of the Fig. 1 The procedure was carried out, resulting in a circular area 25 and a furrow 25 within it. In comparison of Fig. 1 and Fig. 2 It can be seen that the image 10 on the consumer item 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 in Fig. 1 to Fig. 2 has faded more.

[0045] The consumer item 20 of the Fig. 2 The material comprises a polymer 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.

[0046] 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 image 10, was provided. The dye carrier 40 with the dye 30 was laid flat onto the surface 21, so that the dye 30 came into contact with the surface 21. After heating and under pressure and with the dye 30 being pressed against the surface 21, the dye 30 sublimated and diffused into the surface.

[0047] In particular, image 10 of the consumer item 20 is the 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 consumer product 20 Fig. 1 with less abrasion or less fading of image 10. Likewise, the item 20 exhibits the Fig. 2In the circular area 25, a lesser amount of material is removed due to abrasion or fading compared to the Fig. 1 on; in other words, furrow 25 is in Fig. 2 less deep than in Fig. 1 .

[0048] The Fig. 3 Figure 1 shows a method according to the invention. In the first step, a surface 21 is provided on a body that is merely exemplary, block-shaped or essentially cube-shaped, and which represents the consumer product or a section thereof. The surface 21 is arranged on a polymer material 22 made of mineral casting, or the body consists of this material.

[0049] In the second step 200, which can run parallel to the first step 100, a dye 30 for an image 10 to be produced is prepared on a dye carrier 40 or applied to the dye carrier 40, essentially creating a negative of the image 10 on the dye carrier 40. For clarity, a bottle of dye 30 is shown, representing, for example, a printing process during preparation 100. For further clarity, the negative of the image 10 to be produced is illustrated as two rectangles and a circle on a rollable paper 40.

[0050] In the third step 300, the dye 30 is brought into contact with the paper 40 or dye carrier 40 and the surface 21, particularly over as full a surface as possible. In this case, the paper 40 is unwound and arranged in full contact with the surface 21.

[0051] Finally, in the fourth step 400, at least the dye 30, in particular the surface 21, is heated, preferably without the dye carrier 40. During this process, the dye 30 sublimates. The dye 30 penetrates at least partially into the surface 21. In particular, this is followed by diffusion of the dye 30 into the surface 21. In other words, in step 400, a sublimation print is applied to or on the surface 21. In particular, the ten curved, upward-pointing arrows and the sketched thermometer are representative of the increased temperature and the sublimation process, respectively.

[0052] Independently of or in conjunction with this, in a further step 500 the surface 21 with the image 10 or the dye 30 can be cooled. This allows the product 20 to be obtained and / or used with the color-stable or color-resistant image 10. Reference symbol list

[0053] 10 Image, image to be produced 20 Object of use 21 Surface 22 Polymer material 23 Polymer 24 Filler 25 Circular area, groove 30 Dye 40 Dye carrier, paper 100 Prepare, first step 200 Prepare, second step 300 Merge, third step 400 Heat, fourth step 500 Cool, next step

Claims

1. Method for producing a colour-stable or colourfast image (10) in a surface (21) of an everyday article (20), in particular sanitary article, for example shower tray, bathtub, washbasin, toilet lid, seat ring, floor or wall panel, skirt for bathtubs, bathroom furniture or household items, for example chair, table, furniture, for example a sofa, the method comprising the following steps: - providing (100) the surface (21), where the surface (21) comprises or is formed from a polymer material (22), in particular mineral granite, the polymer material (22) comprises at least a polymer (23) and a filler (24), and the filler (24) is based on silicon dioxide, where the filler (24) forms at least 20 per cent by weight or volume of the polymer material (22); - providing (200) a dye (30) for the image (10) to be produced; - bringing (300) surface (21) and dye (30) together; and - heating (400) the dye (30), with diffusion of the dye (30) into the surface (21) by a sublimation and formation of the image (10).

2. Method according to Claim 1, characterized in that the filler (24) is based on and / or includes cristobalite, quartz and / or any other modification of silicon dioxide.

3. Method according to Claim 1 or 2, characterized in 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 any of the preceding claims, characterized in that the filler (24) has a higher porosity than aluminium trihydroxide.

5. Method according to any of the preceding claims, characterized in that the filler (24) forms at least 60 per cent, in particular per cent by weight or volume, of the polymer material (22).

6. Method according to any of the preceding claims, characterized in that the polymer material (22) includes acrylic, in particular acrylic resin.

7. Method according to any of the preceding claims, characterized in that at least one method step is effected under reduced pressure, in particular at a pressure below an ambient pressure, for example at 0.1 bar or 0.01 bar or less.

8. Method according to any of the preceding claims, characterized in that during the diffusion, the dye (30) and / or a dye carrier (40) at least partly abuts the surface (21), in particular two-dimensionally or over the whole area.

9. Method according to any of the preceding claims, characterized in that at least one method step is effected under pressure, in particular by means of a pressing device and / or a weight on top.

10. Method according to any of the preceding claims, characterized in that the dye (30) diffuses into the surface (21) under reduced pressure.

11. Method according to any of the preceding claims, characterized in that during the heating, the dye (30) and / or a dye carrier (40) at least partly abuts the surface (21), in particular two-dimensionally or over the whole area.

12. Method according to any of the preceding claims, characterized in that the dye diffuses under pressure.

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