Method for making decorative emblems

Abstract

A method of casting decorative emblems from a polyurethane-type compound. A series of decorvative discs are held flat and horizontal while the polyurethane composition is cast thereon to form a meniscus. The polyurethane composition comprises a polyether polyol component and a diisocyanate component. The cast polyurethane, when cured, gives a lens effect to the decorative discs.

What is claimed is: 
     
       1. A method of forming .Iadd.a plurality of .Iaddend.foil-backed inserts in the form of cast decorative emblems, comprising: a. .[.providing a series.]. .Iadd.releasably maintaining an arrangement of a plurality .Iaddend.of flat decorative foil shapes .Iadd.on a support sheet such that the plurality of shapes is on the sheet at the same time, .Iaddend.onto which .Iadd.shapes .Iaddend.a clear, hard plastic composition suitable as a substitute for vitreous enamel is to be cast, .Iadd.each of .Iaddend.said foil shapes .[.each.]. having a top and bottom surface,   .Iadd.each of .Iaddend.said foil shapes also having sharply defined peripheral sides which intersect with said top surface, and   .Iadd.each of said foil shapes .Iaddend.having an adhesive coated on said bottom surface,     b. holding said .[.series.]. .Iadd.arrangement .Iaddend.of foil shapes .Iadd.in a manner in which each shape is maintained .Iaddend.flat and horizontal on a .[.supported.]. .Iadd.supporting .Iaddend.surface free from surrounding side walls .Iadd.by temporarily securing said support sheet to the supporting surface,   c. casting a measured amount of said plastic composition in liquid form, which liquid is poorly wetting with respect to the top surface of said foil shapes, directly onto the top surface of each of said foil shapes .Iadd.in a casting sequence with respect to the arrangement in which each foil shape receives a measured amount of said plastic .Iaddend.so that it flows to said sharply defined peripheral sides .Iadd.of the shapes .Iaddend.and forms a positive meniscus without flowing over said sharply defined peripheral sides,   d. allowing said cast plastic composition to cure while maintaining .Iadd.said support sheet for the arrangement of .Iaddend.said foil shapes flat and horizontal, whereby said cured plastic composition gives a lens effect to the top surface .Iadd.of each .Iaddend.of said foil shapes onto which it has been cast, .[.and.].   e. removing said support sheet from the supporting surface and said shapes from said sheet,   .Iadd.f. .Iaddend.utilizing said adhesive coated bottom surface of said foil shapes to adhere said inserts .[.onto.]. .Iadd.at .Iaddend.their intended .[.base.]. .Iadd.decorative location. .Iaddend.   
     
     
       2. The method of claim 1 wherein said decorative foil shapes are discs formed of a metal foil having an ornamental design embossed thereon. 
     
     
       3. The method of claim 2 wherein said discs have a diameter of from 0.25-1.50 inches and said plastic composition is cast to a height of from 0.03 to 0.125 inches on each of said discs. 
     
     
       4. The method of claim 3 wherein said discs are approximately one inch in diameter and said plastic composition is cast to a height of no more than 0.125 inches. 
     
     
       5. The method of claim 1 wherein said plastic composition is a polyurethane having a polyether polyol component and a diisocyanate component. 
     
     
       6. The method of claim 5 wherein said polyether polyol component of said polyurethane composition comprises a polyether diol, a polyether triol, a catalyst, an antioxidant, and ultra-violet absorber, and a small amout of surface active agent. 
     
     
       7. The method of claim 6 wherein said diisocyanate component of said polyurethane composition comprises an aliphatic diisocyanate and a polyether triol. 
     
     
       8. The method of claim 7 wherein said polyether polyol component consists of approximately 19% polypropylene diol, 78% polypropylene triol, 1% catalyst, 1% antioxidant, 1% ultra-violet absorber and 0.04% surface active agent. 
     
     
       9. The method of claim 8 wherein said diisocyanate component consists of approximately 85% aliphatic diisocyanate and 15% polypropylene triol. 
     
     
       10. The method of claim 9 wherein said polyurethane composition comprises 40-50 percent of said polyether polyol component and 60-50 percent of said diisocyanate component. .Iadd. 
     
     
       11.  The method of claim 1: (i) wherein in the step of releaseably maintaining, said arrangement of foil shapes with the adhesive on the bottoms of the foil shapes, is placed on a release liner sheet and (ii) wherein in the step of holding, said liner sheet is held flat and horizontal by holding said release liner sheet on a support surface through creating a vacuum underneath said release liner sheet. .Iaddend. .Iadd. 
     
     
       12.  The method of claim 1 wherein said foil shapes are spaced such as to avoid any static charge attraction between the foil shapes as the material is cast thereupon. .Iaddend. .Iadd. 
     
     
       13.  A casting operation for producing a plurality of foil backed inserts having an enhanced ornamental design on the top of a surface thereof, comprising: a. providing each of a plurality of individual, flat decorative foil shapes with:   (i) a top and bottom surface,   (ii) an ornamental design on the top surface,   (iii) a sharply defined peripheral side having intersections with the top surface free from side walls, and   (iv) an adhesive on the bottom surface; onto which shapes a polyurethane casting composition suitable as a substitute for a vitreous enamel decoration is to be cast;   b. arranging the plurality of individual shapes on a releasable support surface for presention of the support surface with the arranged shapes thereon to a casting station;   c. and in the step of arranging said shapes:   (i) maintaining each shape flat and horizontal on the support surface free from said side walls, and   (ii) spacing the shapes apart from each other such as to avoid substantial static charge between said shapes during the step of casting;   d. presenting the support surface having the plurality of arranged shapes thereon to a casting station;   e. casting a polyurethane composition in a liquid form which is poorly wetting with respect to the top surface of said shapes directly onto the top surface of each of said shapes in a manner with respect to the plurality of arranged shapes in which   (i) a regulated amount of said polyurethane sufficient to form a positive meniscus is dispensed onto the top of each shape, and   (ii) said polyurethane flows to said sharply defined peripheral sides and forms a positive meniscus on the top of said shape without flowing over said sides; and   f. maintaining the shapes flat and horizontal during the dispensing of the polyurethane and during the curing of the polyurethane, whereby, upon curing, the cast polyurethane composition enhances the ornamental design on the top of the shapes by providing a lens effect with respect to the design thereon. .Iaddend. .Iadd.   
     
     
       14.  The method of claim 13 in which the decorative foil shape is a metallic film shape and in which (a) in the step of providing an ornamental design the top surface thereof, the design is provided by at least one of embossing and silk screening or lithographing; and   (b) in the step of arranging, said shapes are arranged on a sheet of release paper such that the plurality of shapes is present on the paper at the same time and said release paper having the arranged shapes thereon is held by a vacuum chuck which comprises the support surface. .Iaddend.