Digital full-color 3-dimensional stamped metal

Abstract

Sublimation (transfer of color via existing heat activated process) of computer generated process color/full color images into polyester coating that has been applied to the flat surface of malleable metal. A dimensional metal stamping die is then created with relief and/or texture to correspond in location to or otherwise enhance the color image that has been previously sublimated on the flat metal. Metal is then locked into position and stamped with the impression that has been cut into the hardened die. The result is a new, efficient method to achieve life-like color on 3-dimensional sculpted metal. Virtual patinas and tinting can also be achieved without additional chemicals or plating. Digitally generated variable printed data, variable sublimated color images and variable color schemes can be sublimated before minting or added as a third step with good definition on raised flat areas post stamping.

Claims

1. A method of enhancing 3d stamped metal surface with color, tint or shading by using the following steps in the following order: sublimation of color into full-face polyester coating on flat faced metal prior to minting/debossing/embossing/stamping versus using other colorizing methods or in spot locations prior to stamping or versus colorizing after forming the metal.

2. This method of claim 1 allows 3 dimensional surfaces the appearance/illusion of plating or tinting without requiring plating processes or mixing tints into lacquers. This includes altering the hue of the metal in selective areas only. Also, the metal finish (polished, brushed, etc.) remains visible.

3. The method of claim 1 makes it possible for stamped, 3 dimensional metal surfaces to have any or all of the following visual features simultaneously within a single layer of coating and with no additional production steps regardless of how many of the visual features below are present: Metal protection The look/illusion of plating (full surface or selective areas) The look/illusion of antiquing or shading to accentuate stamped relief Spot color or full photographic process color colorization

4. The method of claim 1 can visually represent the colors and surface shapes of non-metal surfaces on metal. (For example, a rough grey rock surface with many subtle shades of green moss growing in some areas can be represented both photographically and dimensionally. Note-this is one of innumerable examples)

5. The method of claim 1 allows colorization and/or the appearance/illusion of antiquing, plating, shading, etc. through the use of color, tinting or shading to be applied with aesthetically pleasing locational precision throughout what will become both raised and recessed areas with no diking, masking or physical (robotic or manual painting or dispensing) application of color. All color is output to flat paper and sublimated to the flat surface of polyester coated metal.)

6. The method of claim 1 means that color is deposited within a continuous full-surface layer of coating to eliminate the individual vulnerabilities of color and patina applied to spots on the surface.

7. The method of claim 1 for colorized, dimensionally stamped products, provides means by which variable color schemes, such as the various stock color choices of a vehicle model, shades of lipstick or clothing color in promotional product settings can be modified digitally, economically and as 1 offs or small batches prior to the sublimation step. (For example, if a new motorcycle model comes in 5 color choices, a dimensional/color metal rendition of each color can be produced simply by digitally printing photos of each color for the sublimation process prior to stamping. Please note that examples are to demonstrate, but not to limit the description of this process benefit.)

8. The method of claim 1 for colorized, dimensionally stamped products, provides means by which variable text (each product produced with its own unique printed text or numbers) can be produced digitally with no physical setups as variable colorized text is generated simply by digitally altering the print image prior to printing the paper used in the sublimation step.

9. The method of claim 1 provides means by which, after creating a product via this invention for colorized, dimensionally stamped products, variable data and images can be added to flat areas via an additional sublimation step with all the efficiency and lack of mess that the sublimation process offers.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The drawings and images included detail the process steps and examples of its results. The drawings are to describe but not show or limit the specific equipment used to execute the process and illustrate/ship examples of but not all actual product that can be produced via this process. Existing knowledge product-results-impactors including but not limited to metal finishing processes and equipment, alloys, hardness, sublimation and stamping equipment types and brands, polyester coating types and application techniques, and others are not addressed within these drawings.

[0022] The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee 37 CFR 1.117(h). As a utility patent (not a design patent), these images demonstrate process results and products can be produced in many variations not limited to the color image included.

[0023] FIGS. 1(A, B & C) flow charts the process

[0024] FIG. 2 demonstrates the variable versions of product that can be produced with excellent efficiency as one offs, in small color-scheme based batches, or in large quantities with one color-scheme by simply changing metals, and/or changing metal finish and/or changing coating color from white to clear (or vice-versa) and/or altering the print image using computer generated color graphic design.

[0025] FIG. 3 is a generic representation of the basic equipment and materials used in the process.

[0026] FIG. 4 shows visual alteration of stamped metal images using this process that can be realistic in full color and/or accentuate, capitalize on, or alter the unique visual characteristics of metal in ways that are both variable and (cost) efficiently achieved.

DETAILED DESCRIPTION

[0027] All terminology, phrasing and word choices in these description details are to be considered in conjunction with the drawings and images, and in the context of the following categories of existing knowledge: Metal die-stamping. Sublimation/heat transfer colorization on Metal. Metal coatings.

[0028] Beyond those categories of existing knowledge, all information is meant to be understood by the general public and should be interpreted with this in mind so that the most obvious layman's understanding is applied. To avoid confusion between Sublimating (colorizing) and Metal Stamping, which both use machines called a press, the mechanism that creates the heat and pressure needed to transfer color from printed paper into polyester coating on metal will be referred to as Sublimator in this documentation because it does not create a dimensional change in the part being created. Therefore all references to a press refer to a metal die stamping press, which uses weight/pressure to stamp the dies image into the part.

[0029] FIG. 1A, 1B, 1C and FIG. 3 show materials used: malleable metal alloys 1, to be coated with malleable, sublimation-accepting polyester 3 24 coating that is clear or white 6 24 , or pre-coated with malleable, sublimation-accepting polyester 4 24 coating that is clear or white 4 24 for the same result of malleable sublimation accepting coating on malleable metal 3 4 6 24.

[0030] FIG. 1A, 1B, 1C shows the order of steps. Appropriate alloy of flat-faced stamping-friendly metal is chosen 1. Decide 2 to apply full-face polyester coating on flat-faced metal 3 or select existing polyester coated metal 4 that has been proven to work. Choose 5 white polyester coating for opaque, vivid color and shading or clear polyester coating for metallized translucent color, effects, tinting, shading and patinas. Creation of digital color art file 6 and cutting the stamping die 7 must be sequential, and either can come first but the second in the sequence must be created to correspond in location/position with the first so that it is positioned as intended to colorize/add shape or texture to, or otherwise enhance the first. The digital art file is then printed 8 on paper using a typical printer that is loaded with sublimation toner. The printed image on the paper is then precisely aligned with the flat metal part so that the printed side of the paper and the polyester coated face of the metal part are face to face so the color image can be sublimated 9 (heat and pressure transferred) from the paper into the polyester coating. The (now colorized) flat part is then removed from the sublimator and allowed to cool. The hardened metal stamping die is then loaded into the press and the colorized part is positioned under it and locked into position 10. The dimensional image is then stamped into the part 11.

[0031] FIG. 2 demonstrates some of the many versions of colorization, tints, effects and patinas that can be achieved without adding production steps. The items stamped with the same dimensional die 12 13 14 15 16 17 18 19 20 can result in many different appearances via choices in metal and/or coating color, and on-computer alterations to digital art color scheme for output on flat paper. These different appearances include, but are not limited to: endless but not metallic vivid colors, hues and shading on material coated with white polyester 12, reflective metallic color and exposed plain metal on polished aluminum 13, monochromatic reflective tone on tone with exposed metal areas on polished aluminum 14, Vivid colors with less reflective metal influence on clear coated satin finish silver aluminum 15, translucent grey to create the impression of antique/oxidation on brushed aluminum 16, rich vivid reflective metallic colors that allow the influence of polished brass shine thru the colors 17, translucent hues on brushed gold-tone aluminum that create the faux effects of both selective copper plating and antiquing 18, vivid opaque (non-metallic) colors on formed metal with white coating 19, and solid black plus translucent greys and hues on polished brass to create the impression of selective copper plating and antique 20.

[0032] FIG. 3 is a simple generic representation of tools/equipment/machines. Color is generated via simple desktop publishing/office equipment 21 22. Color art of photos, tint, patinas, shading, etc. is designed on a computer with graphics software 21 and printed from a computer printer 22 loaded with sublimation ink cartridges (Previously Sawgrass brand but their patent has expired). The flat (metal) product face must be coated full-face with polyester coating before the color image is transferred. Polyester coating can be sprayed on 24, or applied via other existing processes can be purchasedwhile intended to be used flatcan be die stamped. Metal stamping dies 23 can be cut and hardened or can be purchased. A Sublimator 25 applies heat to both release color from printed paper and allow color penetration of color in its gaseous state to penetrate the polyester coating. It also applies pressure to aid in the color transfer and to hold the paper and coated metal tightly together, but it does not change the shape of the face of part. Metal stamping presses 26 come in many forms and is represented via conceptual illustration rather than a drawing of an actual press. A metal stamping press 26 applies many lbs of pressure from the hardened metal stamping die to the softer metal part being stamped.

[0033] FIG. 4 demonstrates digitally generated colorization features of stamped metal via this process that can be achieved simultaneously with no extra process steps. Finely detailed textures can be selectively stamped into, seen through and enhanced with color 27. Photographic subtlety in color variation, brightness and shading is stretches to conform to shape 28. Depth of stamped relief is visually enhanced by strategically colorizing to allow the metal to reflect more light in high areas and absorb more light in lower areas 29. Metal of one color/alloyin this case aluminumcan be made to look like multiple other metalsin this case bronze to various degrees throughout the piece without adding layers and without additional setups 30. Colorization details, including but not limited to potential variables such as dates 31, names, years, hair color, paint and clothing color, product color choices, etc. can be changed, added or left out on a piece by piece basis with no mechanical setups. Only alteration/edit of the digital print file is required. Dimensionally stamped features do require a die to be changed.