Decorative composite body

专利摘要:
A decorative element (1) comprising a decorative body (2) having at least one faceted surface (2a), and a support (3) is provided, wherein the support (3) and the decorative body (2) are bonded by an elastomeric material (4). Methods of making decorative elements comprising transparent bodies of e.g. glass are also provided, wherein the decorative elements have improved resistance to environmental conditions common in outdoors use.
公开号:EP3704990A1
申请号:EP19179825.5
申请日:2019-06-12
公开日:2020-09-09
发明作者:Florian LECHTHALER
申请人:Swarovski KG；D Swarovski KG；
IPC主号:A44C17-00

专利说明:
[0001] The invention relates to a decorative element comprising a decorative body having at least one faceted surface, such as a crystal, and a support, wherein the support and the decorative body are bonded by an elastomeric material. A method of making a decorative element is also provided. Background
[0002] Faceted transparent decorative components such as crystals have been used to embellish products for a long time. Such components can be combined with a mirrored surface in order to create a "sparkling effect", where light incident on the mirror surface is reflected in all directions due to the interaction with the facets of the component. Multiple approaches exist to attach such components to objects. For example, such components can be glued directly to surfaces of objects to be embellished. Alternatively, such components can be provided with holes and combined with structures threaded through the hole to attach the component to an object or structure, as described in WO 2016/054664 . As a further alternative, such components can be glued to supports, such as e.g. pins, that can themselves be connected to a structure or object.
[0003] All of the above means of connecting decorative components to structures can have drawbacks in some situations. For example, holes disrupt the appearance of the component, limit the freedom of design in using the components, and potentially generate a weakness point in the structure of the decorative element. Adhesives on the other hand are prone to failure and may suffer from problems of resistance to some environmental conditions. In the context of the use of decorative elements comprising crystals in circumstances where the decorative elements can be exposed to the elements, such as in public installations, these drawbacks can become significant. For example, such circumstances pose particular challenges associated with risks of breakage or detachment (i.e. durability) of the crystal component, which challenges may increase with the size of the component.
[0004] It is against this background that the invention has been devised. Summary of the Invention
[0005] In a first aspect, the invention resides in a decorative element comprising a decorative body having at least one faceted surface, and a support, wherein the support and the decorative body are bonded by an elastomeric material.
[0006] The present inventor has surprisingly discovered that a decorative element with superior properties could be obtained by binding a faceted decorative body to a support using an elastomeric material. In particular, the inventor has discovered that the use of the elastomeric material resulted in a decorative element that has superior resistance to environmental stresses, tensile stresses, etc., compared to decorative elements constructed with standard adhesives. For example, the use of the elastomeric material may enable the decorative element to withstand conditions that may otherwise lead to breaking of the faceted decorative body due to e.g. differential thermal expansion between the decorative body and the support (due to exposure to different temperatures and/or due to different thermal expansion coefficients), and/or to conditions that may otherwise lead to the breaking of the bond between the faceted decorative body and its support. Further, in the event of breakage of the decorative body, the elastomeric material is able to maintain the fragments of decorative body in place on the support, thereby decreasing a potential risk of injury posed by these fragments.
[0007] The decorative body is preferably made of a transparent material. In embodiments, the decorative body is made of a brittle material. In particular embodiments, the decorative body is made of glass, plastic or cubic zirconium. In some embodiments, the decorative body is made of crystal glass.
[0008] In embodiments, the support is made of metal (including e.g. aluminium, stainless steel, etc.), a polymer (including any commonly used plastic), glass, including crystal glass, a gemstone (including e.g. cubic zirconium, natural stones such as opals, sapphires, diamonds, etc.), composite mineral materials such as e.g. concrete, ceramics etc., or combinations thereof. Without wishing to be bound by theory, it is believed that any material that can be bonded with an elastomeric material can be used according to the invention. As the person skilled in the art would understand, suitability for use with an elastomeric material may include resistance to the conditions necessary to process the elastomeric material to form a bond. In embodiments, the support may be made of one or more materials that are resistant to temperatures up to 150 °C, up to 200 °C, or up to 250 °C, where "resistant" means that the molecular structure of the material is not significantly altered as a result of the exposure to such heat, and major changes to the macroscopic structure of the material (including its shape) do not occur. As the skilled person would understand, some level of minor macroscopic change of shape may nonetheless occur due to e.g. thermal expansion.
[0009] In embodiments, the support is made of metal. Metals are commonly used to support decorative elements in architecture, art, jewellery making, etc. Advantageously, metals can be chosen to be resistant to many expected conditions of use as described further below, to be resistant to conditions that may be used to process an elastomeric material according to the invention, as well as to be possible to manufacture in a variety of shapes and configurations to suit the intended use of the decorative element.
[0010] In other embodiments, the support is made of glass, and may for example be a glass plate. Such embodiments may be particularly advantageous for architectural applications.
[0011] In embodiments, the decorative element further comprises a reflective layer between the faceted decorative body and the elastomeric material and/or between the elastomeric material and the support. In embodiments, the reflective layer comprises a metal, such as silver and/or aluminium. In embodiments, the reflective layer comprises aluminium. In embodiments, the reflective layer comprises a single layer of a metal or metal alloy. In embodiments, the reflective layer comprises a plurality of layers, at least two of these layers comprising a metal or metal alloy that is different from each other.
[0012] The reflective layer may have a thickness of between approximately 10 nm and approximately 2 microns. The reflective layer may be applied for example by Physical Vapour Deposition (PVD) or Chemical Vapour Deposition (CVD).
[0013] Reflective layers are commonly used in combination with faceted decorative elements to enhance their appearance. However, many reflective layers are susceptible to damage such as e.g. by corrosion. The present inventor has discovered that the use of an elastomeric material in a decorative element comprising a reflective layer may efficiently protect the reflective layer from damage, for example by corrosion.
[0014] In embodiments, the reflective layer may be present over a region that covers substantially the whole area of the bond between the decorative body and the support. In embodiments, the reflective layer may be present over a region that covers most (such as e.g. 90%, 95%, 98%, or 99%) of the area of the bond between the decorative body and the support. In other words, the elastomeric material may be provided over a bond area that covers all of the reflective layer and an additional area of overlap between the support and the decorative body. In some such embodiments, the reflective layer may be present over a region that covers most of the area of the bond between the decorative body and the support except for a small perimeter region outside of the reflective layer (where the area of the perimeter region represents e.g. approx. 10%, 5%, 2% or 1% of the area of the bond). In some embodiments, the reflective layer may be present over a region that covers most of the area of the bond between the decorative body and the support except for a perimeter region outside of the reflective layer, wherein the perimeter region is at least 0.5 mm wide, at least 0.8 mm wide, at least 1 mm wide, at least 1.5 mm wide, or at least 2 mm wide. In other words, the elastomeric material may be provided over a bond area that covers all of the reflective layer and an additional area of overlap between the support and the decorative body, the additional area forming a perimeter around the area provided with a reflective layer.
[0015] The use of an elastomeric material that extends over at least the whole surface of the reflective layer may enable the elastomeric material to form a seal that protects the reflective layer from damage by e.g. corrosion. Further, the use of a perimeter around the area of the reflective layer where the elastomeric material bonds the decorative body and the support may increase the protective properties of the seal formed by the elastomeric material and hence further decrease the risk of damage to the reflective layer. In particular, the use of such a perimeter may increase the tolerance of the manufacturing process to e.g. alignment and correspondence of the reflective layer and the elastomeric material, presence of bubbles or imperfections at the edges of the bond area, etc., while maintaining the quality of the finished product. Without wishing to be bound by theory, it is believed that the use of the elastomeric material to bond the support and decorative body while protecting the reflective layer removes the need for additional protective layers such as layers of lacquer that are commonly used to protect reflective layers on faceted transparent bodies such as crystals.
[0016] In embodiments, the decorative body comprises a front surface and a back surface, and the elastomeric material is provided over at least some of the back surface of the decorative body. In other words, the front surface of the decorative body may comprise any surface of the decorative body that is not at least partially bonded to the support.
[0017] In embodiments, the elastomeric material may be present over a region that covers substantially the whole area of the back surface of the decorative body. In embodiments, the elastomeric material may be present over a region that covers most (such as at least e.g. 90%, 95%, 98%, or 99%) of the back surface of the decorative body.
[0018] In embodiments, the elastomeric material may be present over a region that does not overhang the area of overlap between the support and the decorative body. In other words, the elastomeric material may be present over a region that covers at most the smaller of the surface of the decorative body that overlaps with the support and the surface of the support that overlaps with the decorative body.
[0019] The absence of overhang may contribute to the stability of the product as overhangs may be caught or damaged, which damage may spread through the elastomeric material. Further, overhangs may be aesthetically problematic.
[0020] In embodiments, the back surface of the decorative body may be substantially flat. In embodiments, the back surface of the decorative body may be curved and/or faceted. As the skilled person would understand, any shape of the back surface of the decorative body may be suitable for the present invention. In particular, any shape of the back surface of the decorative body may be combined with a support having a surface with a corresponding shape.
[0021] In embodiments, the decorative body is coloured. In some such embodiments, the colouring is provided as a colouring agent throughout the body of the decorative body. Alternatively or in addition to colouring the body of the material, a colouring may be provided as a coating or surface treatment on a surface of the decorative body.
[0022] In embodiments, a decorative coating is provided on at least a region of the front surface of the decorative body. In other embodiments, a decorative coating is provided on at least a region of the back surface of the decorative body.
[0023] Colouring and decorative coatings may enable the decorative element to be provided with a variety of decorative effects, improving their flexibility of use. Colourings and decorative coatings are preferably configured such that the decorative body remains transparent to light entering through the front surface and reflecting on the retroreflective film provided on the back surface of the decorative body.
[0024] In embodiments, the decorative body may have a diameter of between 1 mm and 100 cm, where the diameter refers to the diameter of the smallest circle in which the transparent element would fit when viewed from any angle. In embodiments, the decorative body may have a diameter of between 1 cm and 80 cm, between 1 cm and 60 cm, between 1 cm and 40 cm, or between 2 cm and 40 cm.
[0025] Larger transparent bodies may be particularly challenging to attach to supports using conventional means, as they may be more prone to breaking, may require stronger bonds, and may generate more dangerous fragments when broken. Advantageously, the solution of the invention may be suitable for attaching a transparent element to a support in a manner that results in a safe and robust decorative element even when using large transparent bodies.
[0026] In embodiments, the elastomeric material may be transparent when the decorative element is assembled. In embodiments, the elastomeric material is chosen such that, when applied at a thickness sufficient to bond the support and the decorative body, the elastomeric material forms a transparent bonding layer. Preferably, the elastomeric material is such that visible light can pass through the material when the decorative element is assembled with no loss of visible light and no appearance of coloring visible to the naked eye due to the presence of the elastomeric material.
[0027] In embodiments, the decorative element comprises a reflective layer between the faceted decorative body and the elastomeric material. In such embodiments, transparency of the elastomeric material may not be particularly desirable and instead the elastomeric material may be chosen for different reasons. For example, the elastomeric material may be chosen for its stability, adhesive properties, material compatibility or even availability.
[0028] In embodiments, the elastomeric material forms a layer between the support and the decorative body. The layer may have a variable thickness. For example, the support and the decorative body may have surface geometries that are such that a constant distance between the bonded surfaces cannot be guaranteed.
[0029] Advantageously, the use of an elastomeric material to bond the support and the decorative body may enable a larger level of tolerance in relation to the distance between the support and the decorative body than would be possible or convenient using conventional adhesives. In particular, the variability in thickness of the elastomeric material may have no noticeable impact on the strength and stability of the bond above a minimum thickness. Further, the inventor has discovered that an elastomeric material could be processed to create a stable bond between a decorative body and a support even when the support and the decorative body are such that physical contact between the support, the elastomeric material and the decorative body cannot be obtained throughout the whole bond area prior to processing of the assembly to form the bond.
[0030] In embodiments, the elastomeric material forms a layer between the support and the decorative body that has a thickness of at least about 0.3 mm, or between 0.3 and 0.4 mm such, such as about 0.38 mm. Advantageously, elastomeric materials may be commercially available in films of about 0.38 mm thickness, as such films can be used to make laminated safety glass. Further, the inventor has discovered that the use of elastomeric material forming a layer between the support and the decorative body that has at least these thicknesses consistently resulted in satisfactory bond between even large (in the order of multiple 10's of cm) transparent bodies and their support. Where the thickness is variable, the specified thickness is the maximum thickness across the layer of elastomeric material.
[0031] In embodiments, the elastomeric material forms a layer between the support and the decorative body that has a thickness of at most about 4 mm, such as at most 3.8 mm. By contrast, conventional adhesives are typically applied in layers of 100 µm to 1 mm at the most. Advantageously, the inventor has discovered that multiple layers of films of elastomeric material could be "stacked" between a decorative body and a support and processed to generate a satisfactory bond. This is particularly advantageous when, as explained above, the size of the "spacing" between a support and a decorative body can only be specified up to a certain level due to the surface geometry and a high level of tolerance in this regard is necessary while maintaining a suitable bond.
[0032] In embodiments, the elastomeric material is a thermoplastic or thermoset polymer. Thermoplastic or thermoset polymers are particularly advantageous as they can be processed to obtain a strong bond by applying heat, and optionally pressure, to an assembled system such as the decorative element of the invention. Without wishing to be bound by theory, it is believed that thermoplastic polymers are particularly advantageous as they may be supplied in the forms of sheets or films that can be cut to shape and inserted (possibly in stacks) between a support and decorative body before processing to create a bond. In other words, the material can be easily manipulated and assembled with the other components of the decorative element prior to processing into an assembled decorative element. Further, thermoplastic materials may advantageously be able to flow to some extent during processing in order to "fill" the gap between a support and decorative body in the presence of irregularities in the thickness of this gap.
[0033] In embodiments, the elastomeric material comprises a polycarbonate (PC), a polyvinyl butyral (PVB), an ethylene vinyl acetate (EVA, also known as poly(ethylene vinyl actetate), PEVA), or a thermoplastic polyurethane. Advantageously, these materials can create strong bonds, including between surfaces including glass, are commonly available, and can even be chosen to be optically transparent if desired.
[0034] In embodiments, the decorative element may comprise additional layers between the support and the elastomeric material, and/or between the elastomeric material and the decorative body. For example, the decorative element may comprise a protective layer, such as a layer of lacquer. A protective layer may provide an additional level of protection for a reflective coating or other decorative coating that may be applied on the decorative body. For example, a protective layer may be useful to additionally protect a reflective layer or decorative coating prior to and during assembly with a support, where the elastomeric material may provide protection as explained above after assembly.
[0035] In embodiments, a layer of lacquer may comprise a lacquer selected from the group consisting of: epoxy lacquers, one component polyurethane lacquers, bi-component polyurethane lacquers, acrylic lacquers, UV-curable lacquers, and sol-gel coatings. The lacquer may optionally be pigmented. In embodiments, the lacquer is applied by spraying, digital printing, rolling, curtain coating or other two-dimensional application methods known in the art.
[0036] Suitably, the lacquer may be selected so as to be mechanically and chemically robust and bondable with a chosen elastomeric material.
[0037] In embodiments, the use of an elastomeric material may enable to obtain an assembled decorative element that is mechanically and chemically robust. A decorative element is mechanically and chemically robust if it would not substantially degrade or allow degradation of a coating (such as e.g. a reflective layer) in the conditions that would be expected in the intended use. For example, the decorative element may advantageously show high resistance to any of corrosion, exposure to high temperatures, temperature changes, sun exposure test, tensile stress, and suitable performance in anti-corrosion and salt spray tests, climate tests, shear tests, and temperature stress tests.
[0038] In embodiments, the decorative element of the invention may have an increased resistance to shear stress compared to commonly used adhesives. For example, the bond between a metallic support (e.g. stainless steel) and a glass decorative body (e.g. crystal glass) may be stronger using an elastomeric material (e.g. EVA) than using a two components epoxy adhesive commonly used to attach crystals to supports.
[0039] According to a second aspect of the invention, there is provided a method of making a decorative element, the method comprising: providing a decorative body; providing a support; bonding a surface of the decorative body and a surface of the support with an elastomeric material to form an assembly; processing the assembly such that a composite body is obtained comprising the decorative body and the support bonded by the elastomeric material.
[0040] Embodiments of the present aspect of the invention may comprise any of the features of the first aspect. In particular, any of the features of the decorative body, support, elastomeric material and decorative element described in relation to the first aspect apply equally to the decorative body, support, elastomeric material and composite body of the present aspect.
[0041] In embodiments, the elastomeric material is provided as a film or sheet. In embodiments, the elastomeric material is provided as a plurality of films or sheets that may be stacked over some or all of the area of overlap between the decorative body and the support prior to processing. Thus, the elastomeric material is advantageously applied as a sheet that can be stacked to accommodate for varying distances between the surface of the decorative body and the surface of the support to be bonded.
[0042] In embodiments, the elastomeric material is cut to a desired shape before or after processing to form a composite body. In particular, the film may be cut such that it forms a piece that can cover at least a region of the back surface of the decorative body. Preferably, the film is cut such that it forms a piece that can be applied between the decorative body and the support so as to overhang the smaller of the support surface and the decorative body surface to be bonded together. In such embodiments, the method may further comprise cutting the elastomeric material after processing to form a composite body, in such a way that the elastomeric material does not overhang the bonded surfaces.
[0043] In embodiments, the method further comprises applying a reflective layer on a surface of the support and/or on a surface of the decorative body, wherein the reflective layer is applied such that it is located between the elastomeric material and the support and/or the decorative body in the assembled composite body. In embodiments, a reflective layer comprising a metallisation layer may be applied to the back surface of the decorative body.
[0044] In embodiments, processing the assembly comprises applying pressure on the assembly. Pressure may advantageously contribute to ensuring the strength of the bond formed by the elastomeric material between the support and the decorative body. Advantageously, the use of pressure may also remove bubbles that may have been trapped between the support, the decorative body and the elastomeric material, as the case may be. Bubbles may be formed for example due to unevenness in the thickness of gap between the support and the decorative body. As such, if no measures are taken in order to reduce and/or prevent the creation of bubbles / remove any bubbles that may have been created, bubbles may remain trapped in the composite body, and the optical quality of the decorative element may be lower. Further, in embodiments where a reflective layer is present, the presence of bubbles may cause the appearance of corrosion damage that may, in addition to the disruptive optical effect of the bubbles themselves, cause further degradation of the optical quality of the decorative element. Additionally, the use of pressure nay advantageously encourage flowing of the elastomeric material during processing, in order to fill in the gap between the surfaces of the support and of the decorative body to be bonded.
[0045] Any suitable mechanism for applying the desired pressure to the composite elements can be used.
[0046] In embodiments, the pressure is applied by means of a vacuum. For example, the pressure may be applied by placing a flexible material over the assembled composite body(ies) and surrounding support surface, and pumping out air between the flexible material and the composite body. Alternatively, pressure may be applied by placing the assembled composite body(ies) within an enclosure formed from a flexible material (e.g. in a bag), and pumping out air within the enclosure. The use of a vacuum may ensure that a uniform pressure is applied on a composite body or each of a plurality of composite bodies even in the presence of complex and variable geometries of the composite body(ies). In embodiments, a negative pressure may be used. In embodiments, a negative pressure of -0.2 bar to -7 bar may be used. In embodiments, a pressure of between -0.2 bar and -3 bar, between -0.2 bar and -2 bar, between -0.2 bar and -1.5 bar, between -0.2 bar and 1 bar, between -0.5 bar and -3 bar, between -0.5 bar and -2 bar, between -0.5 bar and -1.5 bar, or between -0.5 bar and 1 bar may be used. In embodiments, a pressure of about -0.9 bar may be used.
[0047] In embodiments, processing the assembly comprises exposing the assembly to a temperature of at least 100 °C, at least 150 °C, or at least 200 °C. In embodiments, processing the assembly comprises exposing the assembly to a temperature of about 130 °C, between about 100 °C and about 150 °C, between about 120 °C and about 150 °C, or between about 130 °C and about 140 °C. Advantageously, exposure of the assembly to heat may enable the elastomeric material to form a bond between the support and the decorative body. As the skilled person would understand, the temperature used may vary depending at least on the elastomeric material used. For example, when the material is EVA, a temperature of about 130 °C may be sufficient.
[0048] In embodiments, processing the assembly may comprise applying pressure to the assembly at the same time as exposing the assembly to a temperature sufficient to form a bond between the support and the decorative body. Advantageously, the combination of pressure and heat may strengthen the bond and may enable some of the elastomeric material to move (such as e.g. flow) to regions where the width of the gap between the surfaces to be bonded is larger. As such, the elastomeric material may be made to substantially fill the gap between the surfaces of the decorative body and of the support to be bonded.
[0049] In embodiments, the pressure and/or the temperature is maintained for at least 1 minute, at least 5 minutes, at least 10 minutes, at least 15 minutes, at least 30 minutes, or at least one hour. In embodiments, the pressure and/or the temperature is maintained for between about 5 minutes and about two hours, between about 15 minutes and about 1.5 hours, or between about 20 minutes and about 1 hour. Advantageously, this period of time may be sufficient to form a suitable bond and remove any bubbles trapped between the elastomeric material and the surfaces to be bonded, and cause the elastomeric material to move to fill the gap between the support and the decorative body. In embodiments, the pressure and/or temperature is maintained for a minimum amount of time that is dependent on the dimensions of the decorative element. For example, the pressure and/or temperature may be maintained for about 15 minutes for a decorative element that has a diameter of about 5 to 7 cm, between about 15 and about 40 minutes for a decorative element that has a diameter of between about 7cm and about 15 cm, and for between about 40 minutes and about 80 minutes for a decorative element that has a diameter of between about 15 cm and about 30 cm. For example, a decorative element having a diameter of about 12.5 cm may be processed for about 30 minutes. A decorative element having a diameter of about 25 cm may be processed for about 60 minutes.
[0050] In embodiments, processing the assembly comprises exposing the assembly to a gradual increase of temperature up to a temperature sufficient for the elastomeric material to form a bond between the decorative body and the support. For example, when the temperature reached is 200 °C, processing the assembly may comprise exposing the assembly to a temperature increasing from room temperature to 200 °C in about one hour. In embodiments, processing the assembly comprises exposing the assembly to an increase of temperature that has an average gradient of between 1 and 5 °C per minute, such as about 3 °C/minute. As the skilled person would understand, the gradient may not necessarily be linear and may instead be implemented as temperature steps. When such steps are used, any single step is preferably not larger than 30 °C.
[0051] In embodiments, processing the assembly comprises exposing the assembly to a gradual decrease of temperature from the highest temperature used. For example, when the temperature reached is 200 °C, processing the assembly may comprise exposing the assembly to a temperature decreasing from 200 °C to 50 °C in at least 2 hours, such as between 2 and 4 hours. In embodiments, processing the assembly comprises exposing the assembly to a decrease of temperature that has an average gradient of between 1 and 5 °C per minute, such as about 2.5 °C/minute. As the skilled person would understand, the gradient may not necessarily be linear and may instead be implemented as temperature steps. When such steps are used, any single step is preferably not larger than 30 °C.
[0052] Gradual increases and decreases in temperature may advantageously reduce the risk of fracture of the decorative element. Without wishing to be bound by theory, it is believed that the cooling down process in particular may be very sensitive to abrupt changes in temperature, resulting in breakage of the decorative body, at least when the decorative body is made of glass, such as crystal glass.
[0053] According to a third aspect, the invention provides a structure comprising at least one decorative element according to the invention. Due to the advantageous properties of the decorative element of the invention as described above, the decorative element of the invention is particularly useful for outdoors use. Therefore, in embodiments, the structure is an outdoors installation. In embodiments, the installation may be a sculpture, a fountain, or an architectural work such as a building, bridge or other structure.
[0054] In embodiments, the installation comprises a plurality of decorative elements according to the invention, wherein the elements are connected to each other through their supports.
[0055] In embodiments, the plurality of decorative elements may together form a hollow cylindrical structure, where each decorative element forms part of the radius of the hollow cylindrical structure.
[0056] Embodiments of the third aspect of the invention may comprise any of the features of the first or second aspects.
[0057] For the avoidance of any doubt, embodiments of any of the aspects of the invention may comprise any of the features described in relation to any other aspect of the invention, unless such features are clearly not compatible. Brief Description of the Drawings
[0058] One or more embodiments of the invention will now be described, by way of example only, with reference to the appended drawings, in which:Figures 1A, 1B and 1C shows schematic views of decorative elements according to embodiments of the invention, comprising a decorative body having a faceted front surface and a back surface, a support and an elastomeric material forming a bond between the decorative body and the back surface of the decorative body, wherein the bond area covers the whole of the back surface of the decorative body, with no overhanging portion of the support beyond the bond area (A), part of the back surface of the decorative body (B), and the whole of the back surface of the decorative body, part of the support overhanging beyond the bond area (C); Figures 2A and 2B show schematic side (A) and top / front (B) views of a decorative element of the invention, comprising a reflective layer; Figure 3 is a flowchart illustrating a method of making a decorative element according to embodiments of the invention; Figures 4A and 4B-4C are graphs showing the results of tensile tests (shear tests) for decorative elements assembled according to embodiments of the invention (Figure 4A), and comparative examples (decorative elements assembled using a standard adhesive according to the prior art - Figures 4B and 4C, where Figure 4C focuses on the 0-2.5mm deformation range of the data shown on figure 4B); Figures 5A and 5B show the results of salt spray tests for decorative elements according to the invention comprising a reflective layer on all of the back surface of the decorative body (Figure 5A), or all of the back surface of the decorative body except for a perimeter around the back surface (Figure 5B), the elastomeric material covering the whole back surface of the decorative body. Detailed Description
[0059] The inventor has discovered that a decorative element with advantageous properties could be obtained by binding a faceted decorative body, such as a crystal, to a support, such as e.g. a metal structure of a connector, using an elastomeric material.
[0060] In particular, the inventor has discovered that the use of the elastomeric material resulted in a decorative element that has superior resistance to some environmental stresses (such as e.g. temperature changes, exposure to extreme temperatures, corrosive atmospheres, wind, rain, hail, etc.) and/or tensile stresses, compared to decorative elements constructed with standard adhesives. For example, the inventor has identified that the use of the elastomeric material may enable the decorative element to withstand conditions that may otherwise lead to breaking of the faceted decorative body resulting from e.g. differential degrees of thermal expansion between the decorative body and the support (which might occur due to exposure to different temperatures and/or due to different thermal expansion coefficients). Further, in the event of breakage of the decorative body, the elastomeric material may be able to maintain the fragments of decorative body in place on the support, thereby decreasing any potential risk of injury posed by these fragments.
[0061] Throughout this description, the term 'back' surface is used to refer to the surface of the decorative body that is at least partially bonded to the support, whereas the term 'front' surface is used to refer to the surfaces of the decorative body that are not bonded to the support. However, the skilled person will appreciate that the decorative element may have a complex geometry, as required by the circumstances, and as such a back or front surface may, in fact, comprise a collection of jointed or disjointed surfaces. In practice, a front surface is intended to be visible in use, whereas a back surface is intended to be at least partially bonded to a support and as such may be partially hidden in use.
[0062] Further, throughout this description, the decorative body is referred to as having at least one "faceted" surface. As used herein, the term "faceted" refers to any 3-dimensionally shaped surface. Such a surface may comprise facets (i.e. planar surfaces that intersect at sharp angles), continuous tridimensional shapes (e.g. curves) or combinations thereof. As such, the term "faceted" also encompasses curved geometries. Typically, at least the front surface of the decorative body may be faceted. Faceted front surfaces may advantageously produce an optically pleasing appearance. However, in embodiments, the back surface of the decorative body may instead or in addition be faceted. In particular, combinations of faceted front and back surfaces may produce desirable optical effects, particularly in combinations with a reflective layer as will be described further below.
[0063] Figure 1A shows a schematic view of a decorative element 1 according to the invention. The decorative element 1 comprises a decorative body 2 having a faceted front surface 2a and a back surface 2b. The decorative body 2 is bonded to a support 3 via a layer of elastomeric material 4. According to this embodiment, substantially the whole back surface 2b overlaps with the support 3, and the surface 3a of the support that overlaps with the decorative body is of substantially the same geometry as that of the back surface 2b of the decorative body 2. The surfaces of the support 3 and of the decorative body 2 that overlap with each other define an overlap area (also referred to as bond area) between the decorative body 2 and the support 3.
[0064] In the embodiment shown in Figure 1B , a region of the back surface 2b of the decorative body 2 overlaps with a surface 3a of the support 3, with the elastomeric material 4 between the surfaces 2b, 3a. In other words, in this embodiment, the surface 3a of the support that overlaps with the back surface 2b of the decorative body 2 is smaller than the back surface 2b of the decorative body 2.
[0065] In the embodiments shown on Figures 1A and 1B, the back surface 2b of the decorative body and the surfaces 3a of the support 3 are substantially flat.
[0066] In the embodiment shown on Figure 1C , the back surface 2b of the decorative body is curved, and substantially the whole back surface 2b overlaps with the support 3. Further, in this embodiment, the surface 3a of the support 3 comprises a region 3a' that forms an overlap area with a curved shape that corresponds to the shape of the back surface 2b of the decorative body 2. In this embodiment, the surface 3a comprises additional one or more regions 3a" that do not form part of the overlap area, and may for example overhang the overlap area.
[0067] In the embodiments shown on Figures 1A, 1B and 1C, the elastomeric material is present over a region that does not overhang the area of overlap between the support 3 and the decorative body 2. In other words, the elastomeric material is present over a region that covers at most the smaller of the surface of the decorative body that overlaps with the support and the surface of the support that overlaps with the decorative body.
[0068] In the embodiments shown on Figures 1A, 1B and 1C, the elastomeric material is present over substantially the whole area of overlap between the support 3 and the decorative body 2. In other embodiments, the elastomeric material may be present over a region that covers most (such as e.g. 90%, 95%, 98%, or 99%) of the overlap area between the support 3 and the decorative body 2.
[0069] In the embodiments shown on Figures 1A and 1B, the elastomeric material 4 forms a layer between the support 3 and the decorative body 2 that has substantially constant thickness. By contrast, in the embodiment shown on Figure 1C, the elastomeric material 4 forms a layer between the support and the decorative body 2 that has a variable thickness t. Further, in the embodiment shown on Figure 1C, the geometries of the support 3 and of the decorative body 2 are such that direct physical contact between the surface 2b of the decorative body and the surface 3a of the support 3 would not be possible over the whole surface 2b. In other words, in the embodiment of Figure 1C, a gap of variable thickness is present between the decorative body 2 and the support 3. In the embodiment shown on Figure 1C, this gap is substantially filled by the elastomeric material 4.
[0070] Figures 2A and 2B show schematic side and front views, respectively, of a decorative element 1 according to another embodiment of the invention. In the embodiment shown in Figures 2A and 2B, the decorative body 2 has a back surface 2b that is substantially flat, and a reflective layer 5 is provided over a region of the back surface 2b of the decorative body 2 (between the decorative body 2 and the elastomeric material 4). In this embodiment, the surface 3a of the support comprises an overlap area 3a' an additional region 3a" that does not form part of the overlap area.
[0071] In the embodiment shown, the region of the back surface 2b that is covered by the reflective layer 5 is smaller than the back surface 2b of the decorative body, and smaller than the overlap area between the decorative body 2 and the elastomeric material 4.
[0072] In the embodiment shown on Figures 2A and 2B, the the elastomeric material is present over substantially the whole area of overlap between the support 3 and the decorative body 2. As such, the elastomeric material is provided over an overlap / bond area that covers all of the reflective layer 5 and an additional area of overlap between the support and the decorative body. As best seen on Figure 2B, the reflective layer 5 is present over a region R that covers most of the area B of the bond between the decorative body 2 and the support 3 except for a small perimeter region p outside of the reflective layer 5. In other words, the elastomeric material may be provided over a bond area that covers all of the reflective layer and an additional area of overlap between the support and the decorative body, the additional area forming a perimeter p around the area provided with a reflective layer 5.
[0073] In some embodiments, the perimeter p may have an area that represents e.g. approx. 10%, 5%, 2% or 1% of the area B of the bond. In this case, the perimeter area may be at least 0.5mm wide, at least 0.8mm wide, at least 1mm wide, at least 1.5mm wide, or at least 2mm wide. The width of the perimeter region may be substantially constant over the whole perimeter region, or the width of the perimeter region is variable. In such embodiments, the minimum width of the perimeter region is advantageously at least 0.5mm, at least 0.8mm, at least 1mm, at least 1.5mm, or at least 2mm.
[0074] In other embodiments, shown in Figures 2A and 2B, a reflective layer may be present over a region that covers substantially the whole area of the bond between the decorative body and the support.
[0075] In the embodiment shown on Figures 2A and 2B, the reflective layer 5 is provided between the decorative body 2 and the elastomeric material 4. In other embodiments, a reflective layer may instead or in addition be provided between the elastomeric material 4 and the support 3. For example, the support may itself be reflective or may be coated with a reflective material. For example, the support may comprise a mirror onto which the decorative body 2 is bonded by the elastomeric material.
[0076] The reflective layer comprises a metal, such as silver and/or aluminium. For example, the reflective layer may comprises a single layer of a metal or metal alloy. In other embodiments, the reflective layer may comprise a plurality of layers, at least two of these layers comprising a metal or metal alloy that is different from each other. Methods of applying reflective coatings onto surfaces such as e.g. by physical vapour deposition are known in the art.
[0077] As the skilled person would understand, the geometric design of the decorative body 2 is not limited in principle, other than comprising at least one faceted (i.e. tridimensionally shaped) surface. The type of faceting is closely related to the geometry of the decorative body 2, and to the desired aesthetics of the decorative element 1. In particular, facets or any geometric shape may be used, in any number, and the number of different types of facets is also not limited. For example, rectangular, square or triangular facets may be used. As explained above, facets may not be completely flat and may instead form curves.
[0078] Further, the size of the decorative body 2 and the size of the decorative element are not limited in principle. In particular, the decorative body may have a diameter of between 1 mm and 100 cm, where the diameter refers to the diameter of the smallest circle in which the transparent element would fit when viewed from any angle. In embodiments, the decorative body may have a diameter of between 1 cm and 80 cm, between 1 cm and 60 cm, between 1 cm and 40 cm, between 2 cm and 40 cm.
[0079] The term 'transparent' is used throughout this disclosure to refer to a material that has a transparency higher than zero. In the context of the present invention, a material is called transparent if it allows the transport of light, preferably at least visible light. Preferably, the material is transparent in the conventional sense, i.e. allowing (at least visible) light to pass through the material without being scattered.
[0080] The decorative body 2 can be made of a wide variety of materials. In embodiments, the decorative body 2 is made of brittle material. Without wishing to be bound by theory, it is believed that the advantages associated with the user of an elastomeric material to bind the faceted decorative body to the support is particular advantageous when the decorative body comprises or is made of a brittle material. Indeed, in such context, the use of the elastomeric material may reduce the risk of breaking the decorative body when exposed with conditions such as temperature changes, extreme temperatures, etc., as well as reduce the risk of injury that may be associated with the user of brittle materials. In embodiments, the decorative body is made of glass, plastic or cubic zirconium. Transparent bodies made of glass or plastic are preferred, because they are low cost, non-conductive and are most readily provided with facets. Decorative transparent bodies 2 made of glass, and in particular crystal glass (e.g. as defined by the European Crystal Directive (69/493/EEC)), are particularly preferred, for their superior optical properties. Further, the advantages associated with the use of an elastomeric material as explained above are particularly salient when glass (such as crystal glass) is used.
[0081] The invention is not limited in principle with respect to the composition of the glass. 'Glass' in this context means any frozen supercooled liquid that forms an amorphous solid. Oxidic glasses, chalcogenide glasses, metallic glasses or non-metallic glasses can be employed. Oxynitride glasses may also be suitable. The glasses may be one-component (e.g. quartz glass) or two-component (e.g. alkali borate glass) or multicomponent (e.g. soda lime glass) glasses. The glass can be prepared by melting, by sol-gel processes, or by shock waves. Such methods are known to the skilled person. Inorganic glasses, especially oxidic glasses, are preferred. These include silicate glasses, soda lime glasses, borate glasses or phosphate glasses. Lead-free crystal glasses are particularly preferred.
[0082] For the preparation of the faceted transparent bodies for decorative purposes (e.g. gemstones), silicate glasses are preferred. Silicate glasses have in common that their network is mainly formed by silicon dioxide (SiO₂). By adding further oxides, such as alumina or various alkali oxides, alumosilicate or alkali silicate glasses are formed. If phosphorus pentoxide or boron trioxide is the main network former of a glass, it is referred to as a phosphate or borate glass, respectively, whose properties can also be adjusted by adding further oxides. The mentioned glasses mainly consist of oxides, which is why they are generically referred to as oxidic glasses.
[0083] The decorative body may for example be made of soda lime glass. Suitably, the faceted decorative body may alternatively be made of lead and barium-free crystal glass. Examples of suitable lead and barium-free crystal glass compositions for use in the present invention are disclosed in EP 1725502 and EP 2625149 , the contents of which are incorporated herein by reference.
[0084] As another raw material for the preparation of the decorative body 2, plastics can be employed. Transparent plastics are preferred. Among others, the following materials are suitable: acrylic glass (polymethyl methacrylates, PMMA); polycarbonate (PC); polyvinyl chloride (PVC); polystyrene (PS); polyphenylene ether (PPO); polyethylene (PE); poly-N-methylmethacrylimide (PMMI). A preferred plastic is poly-N-methylmethacrylimide, which is sold, for example, by Evonik under the name Pleximid® TT70. Pleximid® TT70 has a refractive index of 1.54, and a transmittance of 91% as measured according to ISO 13468-2 using D65 standard light.
[0085] An advantage of using a plastics material over glass in the manufacture of transparent bodies for use in the present invention resides, in particular, in the lower specific weight, which is only about half that of glass. In addition, other material properties may also be selectively adjusted. Further, plastics are often more readily processed as compared to glass. Some disadvantages of the use of plastics materials include the low modulus of elasticity and the low surface hardness as well as the massive drop in strength at temperatures from about 70 °C and above, as compared to glass. Further, plastics may have inferior optical properties compared to glass, especially crystal glass. Additionally, the low surface hardness may make plastics less suitable than glass for outdoors use where the decorative elements may be exposed to impacts (e.g. hail, objects, etc.).
[0086] The decorative body may in some examples be coloured. In some such embodiments, the colouring is provided as a colouring agent throughout the body of the decorative body. For example, when the decorative body is made of glass or crystal glass, a colouring can be achieved by introducing metal oxides in the glass. Alternatively or in addition to colouring the body of the material, a colouring may be provided as a coating or other surface treatment on at least a region of the front and/or back surface of the decorative body. For example, a coloured layer can be applied on the front surface of the decorative body.
[0087] A decorative coating may be provided on at least a region of the front surface of the decorative body. For example, special effect coatings may be used which provide colour or any other optical property that may have aesthetic value. Coatings may be provided on one or more regions of the front surface of the decorative body, e.g. to generate a pattern. In other embodiments, a decorative coating is provided on at least a region of the back surface of the decorative body.
[0088] Colouring and decorative coatings may enable the decorative element to be provided with a variety of decorative effects, improving its flexibility of use. Colourings and decorative coatings are preferably configured such that the decorative body remains transparent to light entering through the front surface and reflecting on the retroreflective film provided on the back surface of the decorative body.
[0089] The composition of the support is not limited in principle, other than to be suitable for bonding with an elastomeric material. In embodiments, the support is made of metal (including e.g. aluminium, stainless steel, etc.), a polymer (including any commonly used plastic), glass, including crystal glass, a gemstone (including e.g. cubic zirconium, natural stones such as opals, sapphires, diamonds, etc.), composite materials such as e.g. concrete, or combinations thereof. As the person skilled in the art would understand, suitability for use with an elastomeric material may include resistance to the conditions necessary to process the elastomeric material to form a bond. In embodiments, the support may be made of one or more materials that are resistant to temperatures up to 150 °C, up to 200 °C, or up to 250 °C, where "resistant" means that the molecular structure of the material is not significantly altered as a result of the exposure to such heat, and major changes to the macroscopic structure of the material (including its shape) do not occur. As the skilled person would understand, some level of minor macroscopic change of shape may nonetheless occur due to e.g. thermal expansion. Further, a support material is suitable for use with a chosen elastomeric material when the elastomeric material can form a bond with the surface of the support material. For example, many currently available elastomeric materials as described further below are capable of bonding metals and metal alloys such as aluminium, stainless steel, etc., as well as glass such as crystal glass as described above.
[0090] In particularly convenient embodiments, the support is made of metal. Metals are commonly used to support decorative elements in architecture, art, jewellery making, etc. Advantageously, metals can be chosen to be resistant to many expected conditions of use including outdoors use, to be resistant to conditions that may be used to process an elastomeric material according to the invention, as well as to be possible to manufacture in a variety of shapes and configurations to suit the intended use of the decorative element.
[0091] As the skilled person would understand, elastomeric materials are amorphous polymers with a glass transition temperature that is lower than the intended conditions of use of the decorative element (such as e.g. below -5 °C, below -10 °C, below -20 °C or below - 30 °C), and which are elastic in the sense that they can recover their shape after stretching (low Young's Modulus). In embodiments, the elastomeric material is a thermoplastic or thermoset polymer. Preferably, the elastomeric material is a thermoplastic polymer.
[0092] The elastomeric material may comprise a polycarbonate (PC), a polyvinyl butyral (PVB), an ethylene vinyl acetate (EVA, also known as poly(ethylene vinyl actetate), PEVA), or a thermoplastic polyurethane. For example, EVA in the form of sheets as used to produce laminated glass may be used as an elastomeric material according to the present invention.
[0093] The elastomeric material is preferably chosen such that, when applied at a thickness sufficient to bond the support and the decorative body, the elastomeric material forms a transparent bonding layer. In particular, the use of a transparent bonding layer may be particularly advantageous in embodiments where the decorative element comprises a reflective layer between the support and the elastomeric material. Preferably, the elastomeric material is such that visible light can pass through the material when the decorative element is assembled and be reflected on the reflective layer with no loss of visible light and no appearance of coloring visible to the naked eye due to the presence of the elastomeric material. Elastomeric materials that form transparent bonding layers may include polycarbonates, polyvinylbutyrate and ethylene vinyl acetate, for example as use in the production of laminated glass.
[0094] The elastomeric material may form a layer between the support and the decorative body that has a (possibly variable) thickness of at least about 0.3mm, or between 0.3 and 0.4 mm, such as about 0.38 mm. For example, the elastomeric material may form a layer between the support and the decorative body that has a thickness of at most about 4 mm, such as at most 3.8 mm.
[0095] The elastomeric material may be provided as a film. As further explained below, multiple layers of films of elastomeric material may be "stacked" between a decorative body and a support and processed to generate a satisfactory bond. In one example, films of elastomeric material having a thickness of between 0.3 to 0.4 mm (such as e.g. 0.38 mm) are used, in which case a stack of up to about 10 layers of film may be used in some regions of the bond area.
[0096] The use of an elastomeric material may provide an assembled decorative element that is mechanically and chemically robust. A decorative element is mechanically and chemically robust if it would not substantially degrade or allow degradation of a coating (such as e.g. a reflective layer applied on the back surface of the decorative body or the support) in the conditions that would be expected in the intended use. For example, the decorative element may advantageously show high resistance to any of corrosion, exposure to high temperatures, temperature changes, sun exposure test, tensile stress, and suitable performance in anti-corrosion and salt spray tests, climate tests, shear tests, and temperature stress tests. Some or all of these properties may be particularly important for decorative elements intended for outdoors use.
[0097] Resistance to high temperatures may be tested by storing the decorative element at a temperature of 100C for 12 hours and examining the decorative element for any visible damage, with the naked eye. Resistance to temperature changes may be tested by storing the decorative element at a temperature of -25 °C for 150 minutes, then exposing the decorative element to a temperature of +75°C for 150 minutes, and examining the decorative element for any visible damage, with the naked eye. Alternative setups for testing the resistance to temperature changes may be used, such as storing the decorative element at a temperature of 100°C, then cooling it down to between 10 and 25°C. Preferably, the decorative element is resistant to freezing temperatures, where resistance to freezing temperatures means that the decorative element does not fracture or sustain any other physical sign of damage when exposed to temperatures below 0 °C. Preferably, the decorative element is resistant to freezing temperatures of -5°C, -10°C, - 15°C, -20°C, and/or -25°C. Suitable performance in anti-corrosion salt spray may be tested according to DIN EN ISO 9227: 2006-10. In particular, suitable performance in anti-corrosion salt spray test may be assessed by exposing the decorative element to a salt spray of 5% by weight saline during 240 hours or 480 hours in a 35 °C atmosphere, and examining the decorative element for any visible damage, with the naked eye. Suitable performance in anti-corrosion tests may be assessed according to DIN EN ISO 6988. In particular, suitable performance in anti-corrosion tests may be assessed by placing the decorative element in a corrosion tester (e.g. WEISS-SC 1000): (a) at 40°C and with 100% relative humidity in an atmosphere charged with 0.067 vol.% SO₂ during 8 hours, then (b) in a standard atmosphere (room temperature) for 16 hours, repeating the process for 6 cycles (each cycle including a phase (a) and a phase (b)), and examining the decorative element for any visible damage, with the naked eye. Suitable performance in shear tests may be assessed by assessing the minimum shear force necessary to separate the decorative body and the support or break either of the decorative body and support.
[0098] The decorative element of the invention may have an increased resistance to shear stress compared to commonly used adhesives. For example, the bond between a metallic support (e.g. stainless steel) and a glass decorative body (e.g. crystal glass) may be stronger using an elastomeric material (e.g. EVA) than using a two components epoxy adhesive commonly used to attach crystals to supports (such as e.g. Swarovski's CG500 two components (epoxy resin and hardener) glue system.
[0099] In embodiments, the decorative element may comprise additional layers between the support and the elastomeric material, and/or between the elastomeric material and the decorative body. For example, the decorative element may comprise a protective layer, such as a layer of lacquer. A protective layer may provide an additional level of protection for a reflective coating or other decorative coating that may be applied on the decorative body. For example, a protective layer may be useful to additionally protect a reflective layer or decorative coating prior to and during assembly with a support, where the elastomeric material may provide protection as explained above after assembly. In embodiments, the layer of lacquer may be pigmented. The choice of a lacquer may depend on the aesthetic and functional properties that are desired for the object, as well as balancing considerations of costs and availability of the materials.
[0100] Preferably, the lacquer is selected so as to be chemically and mechanically robust. A lacquer is considered to be mechanically and chemically robust if it would not substantially degrade or allow degradation of an underlying reflective layer or decorative coating in the conditions that would be expected in the intended use (including the intended storage and/or assembly conditions). Thus, as the skilled person would appreciate, the choice of a particular lacquer may depend on the intended conditions of use of the decorative element. For example, depending on the intended use it may be advantageous for the multilayer coating to be highly resistant to shocks, sweat, corrosion and/or climate exposure. As the skilled person would appreciate, tests are available to ensure that a chosen lacquer results in a decorative body or decorative element (As the case may be) that satisfies the requirements of the product in which the decorative element is intended to be incorporated. For example, an anti-corrosion salt spray test may be used to test resistance to corrosion. In general, a composite body may be considered to be resistant to a particular condition when the decorative element comprising e.g. a reflective and/or decorative coating does not show significant visible degradation when repeatedly exposed to the said conditions in a laboratory setting. In particular, within the context of this disclosure, 'high resistance' may be interpreted to mean that the decorative element shows no significant alteration when exposed to one or more, and preferably all, of the following tests: temperature change test according to DIN 9022-2, sulfur dioxide (corrosion) test according to DIN 50018 - KFW 0,2 S; environmental test according to DIN ISO 9022-2 (cold, heat and humidity); and salt spray test according to DIN EN 60068-2-11 Ka.
[0101] The lacquer may additionally ensure that the decorative element according to the invention is bondable with a chosen elastomeric material. As the skilled person would understand, the choice of a suitable lacquer may depend on the material to which the decorative element is intended to be bonded, and/or on the adhesive that is intended to be used.
[0102] In convenient embodiments, the layer of lacquer comprises a lacquer selected from the group consisting of: epoxy lacquers, one component polyurethane lacquers, bi-component polyurethane lacquers, acrylic lacquers, UV-curable lacquers, and sol-gel coatings. Suitably, the lacquer is a polyurethane lacquer, such as a bi-component polyurethane lacquer.
[0103] The layer of lacquer may be applied using any two-dimensional application method known in the art. For example, the layer of lacquer may be applied by spraying, digital printing, rolling, or curtain coating.
[0104] In embodiments, the lacquer may be applied with a thickness of between about 4 and 14 µm (i.e. 9 ±5 µm); for example, the lacquer may be applied with a thickness of about 9 µm.
[0105] Figure 3 is a flowchart illustrating a method of making a decorative element according to embodiments of the invention. As the skilled person would understand, the method described below may be performed with a single decorative body or simultaneously for a plurality of transparent bodies, resulting in the making of a plurality of decorative elements. For example, tens, hundreds or thousands of decorative elements may be made simultaneously, or as part of a batch or continuous manufacturing process. As such, references to a 'decorative body' or 'decorative element' are to be understood as also optionally relating to single instances which are part of a plurality of instances processed simultaneously.
[0106] In step 300, a decorative body is provided. The decorative body may have a faceted front surface and a back surface, as described above. Methods of making transparent bodies, such as e.g. crystals, are known in the art and will not be detailed further herein.
[0107] In step 302, a reflective layer may be optionally provided on e.g. the back surface of the decorative body. Methods of applying a reflective layer on a surface are known in the art and will not be detailed further herein. In embodiments, the method may instead or in addition comprise applying a reflective layer on a surface of the support. In embodiments, a reflective layer comprising a metallisation layer may be applied to substantially the whole back surface of the decorative body.
[0108] In step 304, a support is provided for assembly with the decorative body. In embodiments, the support may be shaped to include a surface that has a geometry that substantially corresponds to the geometry of the back surface of the decorative body to be assembled with the support. For example, the decorative body may have a curved back surface and a support may be shaped to have a similar curve. Suitable shaping methods may depend on the material of the support, and may include casting, bending, etc., as known in the art.
[0109] In step 306, an elastomeric material is provided, preferably in the form of sheets or films. As explained above, an elastomeric material may be chosen to be solid at room temperature, such that it can be shaped and manipulated as a film.
[0110] In step 308, the support, decorative body and elastomeric material are assembled such that the elastomeric material is "sandwiched" between the decorative body and the support. In particular, films of elastomeric material may be cut to a desired shape and placed onto the support or the decorative body, then the decorative body or support (as the case may be) may be placed on the elastomeric material. In particular, one or more sheets of elastomeric material may cut such that they form a piece that can cover at least a region of the back surface of the decorative body corresponding to the bond area (or a plurality of pieces that each covers at least a region of the bond area). In embodiments, one or more sheets are cut such that they form a piece that is larger than the bond area. In other words, one or more sheets may be cut such that they form a piece that can be applied between the decorative body and the support so as to overhang the smaller of the support surface and the decorative body surface to be bonded together.
[0111] As mentioned above, the elastomeric material may be provided as a plurality of films or sheets that may be stacked over some or all of the area of overlap between the decorative body and the support prior to processing. In embodiments, multiple films or sheets may be stacked onto the support or decorative body (as the case may be), and the number of sheets stacked may vary across the surface of the bond area. For example, a larger stack may be provided in regions where the thickness of the gap between the support and the decorative body is expected to be larger.
[0112] At step 310, the assembly is then processed such that a composite body is obtained comprising the decorative body and the support bonded by the elastomeric material. According to the embodiment of the method depicted in Figure 3, pressure is applied 310a on the assembly (decorative body, elastomeric material and support) or assemblies, in order to remove bubbles that may have been trapped between the elastomeric material and the surfaces to be bonded (as well as optionally within a stack of elastomeric material sheets), increase the strength of the bond and cause the elastomeric material to move to fill the gap between the support and the decorative body.
[0113] At step 310a, pressure is applied, optionally by means of a vacuum. For example, the pressure may be applied by placing the assembled composite body(ies) on a support surface, placing a flexible material over the assembled composite body(ies) and surrounding support surface, and pumping out air between the flexible material and the composite body(ies). Alternatively, pressure may be applied by placing the assembled composite body(ies) within an enclosure formed from a flexible material (e.g. in a bag), and pumping out air within the enclosure. The use of a vacuum may ensure that a uniform pressure is applied on a composite body or each of a plurality of composite bodies even in the presence of complex and variable geometries of the composite body(ies). In embodiments, a negative pressure may be used (i.e. a pressure below atmospheric pressure). In embodiments, a pressure of between -0.2 bar and -3 bar, between -0.2 bar and -2 bar, between -0.2 bar and -1.5 bar, between -0.2 bar and 1 bar, between -0.5 bar and -3 bar, between -0.5 bar and -2 bar, between -0.5 bar and -1.5 bar, or between -0.5 bar and 1 bar may be used. In embodiments, a pressure of about -0.9 bar may be used.
[0114] According to the embodiment of the method depicted in Figure 3, processing the assembly further comprises heating 310b the assembly. For example, the assembly may be heated to a maximum temperature of at least 100 °C, at least 150 °C, or at least 200 °C. In embodiments, the assembly may be heated to a temperature of about 130 °C. Advantageously, exposure of the assembly to heat may enable the elastomeric material to form a bond between the support and the decorative body. As the skilled person would understand, the temperature used may vary depending at least on the elastomeric material used. For example, when the material is EVA, a temperature of about 130C may be sufficient.
[0115] As the skilled person would understand, processing the assembly preferably comprises applying pressure to the assembly at the same time as exposing the assembly to a temperature sufficient to form a bond between the support and the decorative body. Advantageously, the combination of pressure and heat may strengthen the bond and may enable some of the elastomeric material to move (such as e.g. flow) to regions where the width of the gap between the surfaces to be bonded is larger. As such, the elastomeric material may be made to substantially fill the gap between the surfaces of the decorative body and of the support to be bonded.
[0116] In embodiments, the pressure and/or the maximum temperature is maintained for at least 1 minute, at least 5 minutes, at least 10 minutes, at least 20 minutes, at least 30 minutes, or at least one hour. In embodiments, the pressure and/or the temperature is maintained for between about 5 minutes and about two hours, between about 15 minutes and about 1.5 hours, or between about 20 minutes and about 1 hour. Advantageously, this period of time may be sufficient to form a suitable bond, remove any bubbles trapped between the elastomeric material and the surfaces to be bonded, and cause the elastomeric material to move to fill the gap between the support and the decorative body. As the skilled person would understand, the pressure and/or the maximum temperature may be applied for longer minimum times for larger decorative elements that for smaller decorative elements. For example, the pressure and/or temperature may be maintained for about 15 minutes for a decorative element that has a diameter of about 5 to 7 cm, between about 15 and about 40 minutes for a decorative element that has a diameter of between about 7cm and about 15 cm, and for between about 40 minutes and about 80 minutes for a decorative element that has a diameter of between about 15 cm and about 30 cm. For example, a decorative element having a diameter of about 12.5 cm may be processed for about 30 minutes. A decorative element having a diameter of about 25 cm may be processed for about 60 minutes.
[0117] In embodiments, a negative pressure of between about -0.5 bar and about -1 bar may be applied in combination with a temperature of about 130 °C to about 140 °C. In embodiments, this pressure and temperature nay be applied for about 30 minutes for a decorative element having a diameter of about 12.5 cm, and for about 60 minutes for a decorative element having a diameter of about 25 cm.
[0118] The step of heating the assembly 310b comprises exposing the assembly to a gradual increase of temperature up to a maximum temperature, the maximum temperature being selected to be sufficient for the elastomeric material to form a bond between the decorative body and the support. For example, when the temperature reached is 200 °C, heating the assembly may comprise exposing the assembly to a temperature increasing from room temperature to 200 °C in at least 30 minutes, at least 45 minutes, at least one hour, or about one hour. In embodiments, processing the assembly comprises exposing the assembly to an increase of temperature that has an average gradient of between 1 and 5 °C per minute, between 2 and 4 °C/minute, such as about 3 °C/minute. In embodiments, the gradient is linear and with a substantially constant slope. In other embodiments, the gradient is implemented as temperature steps. When such steps are used, any single step is preferably not larger than 30 °C.
[0119] According to the embodiment of the method depicted in Figure 3, processing the assembly further comprises cooling down the assembly 310c. In embodiments, cooling down the assembly comprises exposing the assembly to a gradual decrease of temperature from the maximum temperature used. For example, when the temperature reached is 200C, processing the assembly may comprise exposing the assembly to a temperature decreasing from 200C to 50C in at least 1 hour, at least 2 hours, at least 3 hours, between 2 and 4 hours, or about 2 hours. In embodiments, cooling down the assembly comprises exposing the assembly to a decrease of temperature that has an average gradient of between 1 and 5C per minute, between 2 and 4C/minute, about 2.5C/minute, at most 4C/minute, or at most 3C/minute. In embodiments, the gradient is linear and with a substantially constant slope. In other embodiments, the gradient is implemented as temperature steps. When such steps are used, any single step is preferably not larger than 30C. In particular, cooling down the assembly may be performed in an environment where the assembly can be protected from drafts, such as e.g. a sealed enclosure. Without wishing to be bound by theory, it is believed that drafts may create temperature contrasts sufficient to cause a fracture of the decorative body in the composite body.
[0120] According to the embodiment of the method depicted in Figure 3, any overhangs of elastomeric material are cut at step 312, after processing of the assembly, where overhangs are pieces of elastomeric material that extend outside of the bond area. In other words, the elastomeric material may be cut such that it does not overhang the bonded surfaces.
[0121] The decorative elements according to the invention are particularly suitable for outdoors use.
[0122] As such, the invention also encompasses a structure comprising at least one decorative element according to the invention. In embodiments, the structure is an outdoors installation. In embodiments, the installation may be a sculpture, a fountain, or an architectural work such as a building, bridge or other structure.
[0123] Other variations of the invention will be apparent to the skilled person without departing from the scope of the appended claims. Examples Example 1
[0124] In this example, a panel of crystal glass of 40 mm by 40 mm with a reflective metallic coating was bonded to a stainless steel support (flat panel with a thickness of 5-6mm) using an elastomeric material (EVA) - this is used as a proxy for a decorative element according to the invention, as faceted transparent bodies may be practically more difficult to subject to e.g. tensile tests. This was compared to a similar panel of crystal glass bonded to a similar stainless steel support using an adhesive according to the prior art (Swarovski's CG500 two-components epoxy glue). The crystal used was a lead and barium-free crystal glass according to EP 1725502 . Similar results are obtained using different glass substrates, such as soda lime glass standard and crystal glass according to EP 2625149 .
[0125] Additionally, each of the composite bodies assembled according to the invention was produced with a reflective layer that covers the whole surface of the bond, or most of the surface of the bond with the exception of a perimeter of 1 or 2 mm around the reflective layer.
[0126] The resulting components were analysed for their resistance to tensile (shear) stress, high temperature, temperature changes, and corrosion.
[0127] The resulting components were additionally subjected to vibration tests followed by visual check for damage, followed by salt-spray corrosion test to assess any changes in corrosion resistance after exposure to vibrations.
[0128] Further, the resulting components were subject to facture test by applying a punctual load and assessing the fracture behavior of the components.
[0129] The components were additionally subject to transport simulation tests assessing any damage to the components due to exposure to packaging materials and transport vibrations.
[0130] The components were further subjected to UV exposure tests and checked visually for the presence of any discoloration, yellowing or material change.
[0131] All of the above tests indicated that a decorative element according to the invention would have suitable resistance to all of the conditions that can be expected in outdoors use.
[0132] In particular, Figures 4A and 4B-C show the results of tensile tests (shear tests) for decorative elements according to embodiments of the invention (Figure 4A), and the comparative example (Figures 4B and 4C).
[0133] Figure 4A is a graph showing the shear force applied to the component (in N) as a function of the deformation in mm, for each of 16 samples assembled according to the invention, as detailed in Table 1 below.
[0134] In particular, samples 1.1 to 1.4 and 4.1 to 4.4 were produced with a reflective layer extending over the whole bond surface (perimeter = 0mm), samples 2.1 to 2.4 were produced with a reflective layer extending over most of the bond surface except for a 1mm perimeter around the reflective layer (perimeter = 1mm), and samples 3.1 to 3.4 were produced with a reflective layer extending over most of the bond surface except for a 3 mm perimeter around the reflective layer (perimeter = 3 mm).
[0135] Samples 1.1 to 3.4 were subjected to a 480h salt-spray test prior to tensile test. In particular, suitable performance in anti-corrosion salt spray was tested according to DIN EN ISO 9227: 2006-10, by exposing the sample to a salt spray of 5% by weight saline during 480 hours in a 35 °C atmosphere, and examining the sample for any visible damage, with the naked eye.
[0136] Samples 4.1 to 4.4 were subjected to an anticorrosion test according to DIN EN ISO 6988, by placing the sample in a corrosion tester (e.g. WEISS-SC 1000): (a) at 40°C and with 100% relative humidity in an atmosphere charged with 0.067 vol.% SO₂ during 8 hours, then (b) in a standard atmosphere (room temperature) for 16 hours, repeating the process for 6 cycles (each cycle including a phase (a) and a phase (b)), and examining the sample for any visible damage, with the naked eye. Samples 4.1 to 4.4 were additionally subjected to a temperature shock test, by storing the sample at a temperature of 100 °C for 12 hours, then submerging the sample in cold tap water (temperatures between 10 and 25°C) within 2 seconds, and examining the sample for any visible damage, with the naked eye.
[0137] Each of the samples was then subject to a shear test, whereby a shear force parallel to plane of the assembly is applied on the assembly until the glass plate breaks or the bond fails. The maximum force at that point is recorded as Fmax in Table 1 below. The curves on Figure 4A show the movement (deformation) of the parts of the assembly relative to each other as the shear force is increased. Table 1 - test samples assembled according to the invention Sample Perimeter (mm) Fmax (N) Pre-treatment 1.1 0 4710 480h salt spray test 1.2 4950 1.3 7920 1.4 4630 2.1 1 7940 2.2 5650 2.3 6500 2.4 6910 3.1 2 8470 3.2 8150 3.3 3920 3.4 8430 4.1 0 6750 Anti-corrosion test + temperature shock test 4.2 8150 4.3 6570 4.4 6530
[0138] Figures 4B and 4C are graphs showing the shear force applied to the component (in N) as a function of the deformation in mm, for each of 14 comparative samples as detailed in Table 2 below, where the tests have the same meaning as explained above in relation to Table 1 except that the anti-corrosion test includes 5 cycles instead of 6. Figure 4C shows the same data as Figure 4B, focusing on the 0 to 2.5 mm deformation range. Table 2 - test samples - comparative examples Sample Pre-treatment Fmax (N) 1.1 Anti-corrosion test 882 1.2 2230 1.3 2290 1.4 1920 1.5 3230 2.1 Temperature shock test 2960 2.2 NA 2.3 NA 2.4 3750 3.1 Temperature cycle test - 20 cycles 2900 3.2 3430 3.3 3190 3.4 2650 3.5 1740
[0139] As can be seen by comparing the data on Figure 4A (Table 1) and the data on Figures 4B-4C (table 2), the samples assembled according to the invention show a significantly higher resistance to tensile stress (about twice as high) compared to samples assembled according to the invention, even after exposure to various corrosion and temperature tests. Therefore, this data shows that decorative elements according to the invention can be expected to have a significantly higher resistance to many environmental conditions that can be expected in outdoor use, including rapid changes in temperature, extreme temperatures, corrosion, and to result in less breakage and bond failure when exposed to tensile stresses that may be independent of or associated with such environmental stresses (e.g. different temperature related expansion rates between the support and the decorative body can be caused by environmental factors and directly result in tensile stresses).
[0140] Figures 5A and 5B show the results of salt spray tests for decorative elements assembled according to the invention comprising a reflective layer on all of the back surface of the decorative body (Figure 5A), or all of the back surface of the decorative body except for a perimeter around the back surface (Figure 5B), the elastomeric material covering the whole back surface of the decorative body. In particular, performance in anti-corrosion salt spray of the decorative elements were tested according to DIN EN ISO 9227: 2006-10 by exposing the decorative elements to a salt spray of 5% by weight saline during 240 hours (Figure 5A) or 480h (Figure 6B) in a 35 °C atmosphere, and examining the decorative element for any visible damage, with the naked eye. As can be seen on Figure 5A, samples with a reflective layer covering substantially the whole surface of the bond displayed traces of corrosion after 240h salt-spray test. By contrast, as can be seen on Figure 5B, samples with a reflective layer covering most of the surface of the bond except for a 1mm perimeter around the reflective layer displayed showed no traces of corrosion even after a 240h salt-spray test.
[0141] These data on figures 5A and 5B shows that decorative elements according to the invention may have particularly good resistance to corrosion of a reflective layer provided therein, especially when the bond area between the support and the decorative element covers the whole reflective coating and an additional at least 1 mm perimeter around the reflective layer.

权利要求:
Claims (15)
[0001] A decorative element comprising a decorative body having at least one faceted surface, and a support, wherein the support and the body are bonded by an elastomeric material.
[0002] The decorative element of Claim 1, wherein the decorative body is transparent and is preferably made of a brittle material, optionally wherein the decorative body is made of glass, preferably crystal glass.
[0003] The decorative element of Claim 1 or Claim 2, wherein the elastomeric material is a thermoplastic or thermoset polymer, preferably wherein the elastomeric material is a thermoplastic polymer and/or wherein the elastomeric material comprises a polycarbonate, a polyvinyl butyral, an ethylene vinyl acetate, or a thermoplastic polyurethane.
[0004] The decorative element of any preceding claim, wherein the support is made of metal or a metal alloy, glass, crystal glass, gemstone, composite mineral materials, or combinations thereof.
[0005] The decorative element of any preceding claim, further comprising a reflective layer between the decorative body and the elastomeric material and/or between the elastomeric material and the support, optionally wherein the reflective layer comprises a metallisation layer, such as a silver and/or aluminium layer.
[0006] The decorative element of Claim 5, wherein the elastomeric material is provided over a bond area that covers all of the reflective layer and an additional area of overlap between the support and the decorative body, the additional area of overlap forming a perimeter region around the area provided with a reflective layer, optionally wherein the perimeter region is at least 0.5 mm wide, at least 0.8 mm wide, at least 1 mm wide, at least 1.5 mm wide, or at least 2 mm wide.
[0007] The decorative element of any preceding claim, wherein the decorative body comprises a front surface and a back surface, and the elastomeric material is provided over at least some of the back surface of the body, optionally wherein the elastomeric material is present over a region that covers substantially the whole area of the back surface of the decorative body, such as at least 90%, 95%, 98%, or 99% of the back surface of the decorative body.
[0008] The decorative element of any preceding claim, wherein the elastomeric material is present over a region that covers, at most, the smaller of i) the surface of the decorative body that overlaps with the support and ii) the surface of the support that overlaps with the decorative body.
[0009] The decorative element of any preceding claim, wherein the elastomeric material forms a layer between the support and the decorative body that has a thickness of at least about 0.3 mm, optionally between about 0.3 and about 0.4 mm such, such as about 0.38 mm and/or wherein the elastomeric material forms a layer between the support and the decorative body that has a thickness of at most about 4 mm, such as at most 3.8 mm.
[0010] A method of making a decorative element, the method comprising: providing a decorative body having at least one faceted surface; providing a support; bonding a surface of the decorative body to a surface of the support with an elastomeric material to obtain an assembly; and processing the assembly such that a composite body is obtained comprising the decorative body and the support bonded by the elastomeric material.
[0011] The method of Claim 10, wherein the elastomeric material comprises a film or sheet, optionally wherein the elastomeric material is provided as a plurality of films or sheets that may be stacked over some or all of an area of overlap between the decorative body and the support prior to processing.
[0012] The method of Claim 10 or Claim 11, wherein the elastomeric material comprises a sheet that that overhangs the smaller of the support surface and the decorative body surface to be bonded together, when it is applied between the decorative body and the support, optionally wherein the method further comprises cutting the elastomeric material after processing to form a composite body, in such a way that the elastomeric material does not overhang the bonded surfaces.
[0013] The method of any of Claims 10 to 12, wherein the method further comprises applying a reflective layer on a surface of the support and/or on a surface of the decorative body, wherein the reflective layer is applied such that it is located between the elastomeric material and the support and/or the decorative body in the assembled composite body, optionally wherein the reflective layer is applied to cover most of the surface of the decorative body and/or the support to be bonded together, except for a perimeter around the reflective layer, wherein the perimeter is at least 1 mm wide.
[0014] The method of any of Claims 10 to 13, wherein processing the assembly comprises:
applying pressure on the assembly, optionally wherein the pressure is applied by means of a vacuum, such as by applying a pressure of between -0.5 bar and 1 bar; and/or
heating the assembly to a temperature of at least 100 °C, at least 150 °C, at least 200 °C, between 100 °C and 150 °C, or between 120 °C and 150°C and cooling down the assembly, optionally wherein heating the assembly comprises exposing the assembly to an increase of temperature that has an average gradient of between 1 and 5 °C per minute, such as about 3C/minute, and /or wherein cooling down the assembly comprises exposing the assembly to a decrease of temperature that has an average gradient of between 1 and 5 °C per minute, such as about 2.5 °C/minute.
[0015] A structure comprising at least one decorative element according to any of Claims 1 to 9, or a decorative element made according to the method of any of Claims 10 to 14, optionally wherein the structure is an outdoors installation.

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