Encapsulated Signage Edge Bare Border Delamination
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Solution Overview
Problem
Signs and labels face premature illegibility and damage due to environmental exposure and vandalism, with existing coatings failing to adequately protect the indicia from delamination, especially at edges and mounting holes, leading to reduced lifespan and increased maintenance costs.
Innovation Solution
A method involving the application of a UV curable liquid monomer to create a clear polymer protective coating that fully encapsulates the indicia between the substrate and the protective layer, with bare substrate regions around edges and openings to enhance bonding strength and resistance to delamination, pressure washing, and mechanical forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protective coating is applied over the entire surface including edges and mounting holes, then the coating provides continuous protection, but the coating is prone to delamination at edges and openings due to environmental exposure and mechanical forces
Solution Approach 1:
The patent extracts the problematic areas (edges and mounting holes) from the coated region by intentionally leaving these areas uncoated. This creates a bare substrate border around the perimeter and around mounting holes, eliminating the delamination-prone interfaces while maintaining protective coating coverage over the central indicia areas.
Solution Approach 2:
The patent applies different surface treatments to different regions: the central area receives protective coating for ink protection, while the peripheral edges and mounting hole areas remain as bare substrate to provide superior adhesion anchors and resist delamination from environmental exposure and mechanical forces.
2Area of stationary object
If ink is printed to the edges of the substrate, then the indicia coverage is maximized, but the exposed ink edges become susceptible to delamination and environmental damage
Solution Approach 1:
The patent performs preliminary design planning to position indicia within the substrate area, deliberately maintaining a margin or border between the ink edges and the substrate perimeter. This preliminary layout decision ensures that when coating is applied, there will be a bare substrate buffer zone protecting the ink edges from direct environmental exposure and delamination forces.
3Strength
If mounting holes are positioned within the indicia area, then the structural integrity is improved, but the ink around the holes becomes exposed and prone to delamination
Solution Approach 1:
The patent applies different treatments around mounting holes: the holes are positioned within the indicia area for structural benefits, but a circular or annular bare substrate region is maintained around each mounting hole, preventing ink exposure at these critical stress points while preserving the overall indicia design integrity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution significantly extends the lifespan of signs and labels by preventing delamination and maintaining legibility, even under harsh environmental conditions, while allowing for easy cleaning and restoration, thereby reducing maintenance costs.
Implementation Method 1
The liquid monomer is then cured, creating a clear polymer by UV radiation
Data Source
AI summary
An article of manufacture (160) in the form of a sign or label comprises a disclosed embodiment, produced in accordance with an example method. A substrate (170) is provided which forms a flat planar surface area having a desired shape, thickness and size. A design layer is formed through the use of inks and/or paints (172) applied to the substrate (170) in a predetermined pattern. When the inks and/or paints (172) are applied to the substrate (170), no ink or paint (172) is applied on one or more edges formed around the periphery of the sign (160) for an edge bare border (164). Also, a mounting hole (168) is provided, and an opening bare border (166) is formed around the mounting hole (168). A protective coating (176) is then applied over the inks and/or paints (172) so as to provide a protective cover. Also, the protective coating (176) is applied to the edge bare border (164) and the openings bare border (166) so that the protective coating (176) fully covers not only the inks and/or paints (172), but also all borders, thereby fully encapsulating edge bare borders (164) and an openings bare border (166) between the protective coating and the substrate.