WO1990015724A1

WO1990015724A1 - Metallic leaf laminate and method for the automated production of metallic leaf signage

Info

Publication number: WO1990015724A1
Application number: PCT/US1990/003437
Authority: WO
Inventors: David G. Pierson
Original assignee: Pierson David G
Priority date: 1989-06-15
Filing date: 1990-06-14
Publication date: 1990-12-27
Also published as: AU5856690A; CA2018888A1

Abstract

An integrated, releasably backed laminate (10) of metallic leaf material (12) sandwiched between a top layer of transparent protective material (20) and a bottom layer of transparent protective material (14) coated with a pressure sensitive adhesive (16) attached to releasable backing (18) for use in the automated production of reproducible metallic leaf signage elements is disclosed and claimed. Methods for the production of integrated metallic leaf laminate (10) as well as methods for its use in the production of one-step metallic leaf laminate signage are also disclosed and claimed.

Description

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METALLIC LEAF LAMINATE AND METHOD FOR THE AUTOMATED PRODUCTION OF METALLIC LEAF SIGNAGE

Field of the Invention The present invention relates to metallic leaf signage and methods for producing same. More particularly, the present invention is directed to an integrated laminate of metallic leaf and at least one transparent protective coating layer, which laminate is particularly well suited for die cutting and numerically controlled machine cutting to repeatedly produce metal leaf signage elements which may be applied to a surface in a single step. Additionally, methods for producing this metallic leaf laminate and for producing the associated metal leaf signage are also disclosed and claimed.

Background of the Invention

The reduction of fine mint gold to thin leaf by beating is one of the most ancient arts. When alloyed with small amounts of silver or copper, gold becomes readily workable. This enabled ancient craftsmen to hand produce microfine gold leaf which was applied to surfaces for decorative purposes. Homer noted the production of thin sheets of gold in the Odyssey, and Ancient Rome reportedly gleamed with decorations in gold leaf.

To produce metallic-leaf, ancient craftsmen worked ribbons of mint gold enclosed in sheets of vellum or leather by repeatedly beating and dividing the flattened metal until the thickness was reduced to approximately 1/280,000th of an inch. The translucent thinness of the gold leaf so produced resulted in a metal foil that was so delicate it could be moved and straightened with a light breath. Additionally, this repeated working produced a random, flattened grain structure in the metal leaf which was particularly pleasing to the eye. Typically, the metal leaf sheets were cut to a standard size of approximately 3-7/8 inches square and placed in books between sheets of tissue paper. These standardized metal leaf sheets could be conveniently manipulated by artisans for use in gilding surfaces and applying ornamental designs and lettering.

This ancient technology has carried over to the present day virtually unchanged. Though machine production may replace the hand beating of old, modern gold leaf continues to be produced in foils as thin as 1/280,000th inch and cut to the standard 3-7/8 inch square for use by metal leaf artisans. Additionally, over the years, pure metals and alloys of palladium, aluminum, and platinum have been added to the gold, copper, and silver- palate of the craftsmen. Nonetheless, the basic technology of "gilding*' or metal leaf decorating remains unchanged, with the following basic procedures pertinent to all types of gilding. First, if necessary, the area to be gilded is primed with flat paint, lacquers or sealing glues to provide a surface suitable for the attachment of the metallic leaf. Those skilled in the art will appreciate that smooth surfaces such as glass need not be primed in this manner. Additionally, modern adhesives may eliminate this step as well. Next, the artisan lays out the desired design on the surface in pencil or chalk. The design area to be gilded is then sized utilizing oils, glues, or varnishes. It should be noted that water sizing consisting of isinglass or gelatin in an aqueous solution is particularly well suited for gilding glass surfaces and remains so today. After sizing, the size is allowed to dry or set to the point that it slightly adheres to the artisan's fingertips. At this point it is ready to receive the gold or metallic leaf. The artisan then removes a metallic leaf from the leaf book, trims it to the appropriate size for the sized area and transfers it to the sized surface using a camel hair brush known as a "gilder's tip." The metallic leaf is so light and delicate, it is held to the gilder's tip through static electricity alone, making it easily releasable to the sized surface.

In some cases, it is necessary for the artisan to protect the delicate leaf from damage by moving air currents. In such instances, the artisan will cushion the delicate leaf with a padded material until it is firmly set in the sizing.

The sized leaf is then hand burnished with surgical grade cotton to a high luster, highlighting the aesthetically pleasing internal grain structure of the leaf. The artisan then removes unsized bits of metal leaf with a camel hair brush through a simple flaking action as the metallic leaf is extremely delicate and brittle and thus fractures easily at the edge of the unsized surface. The gilding is then finished with a coating of clear lacquer to add gloss and preserve the luster of the metal leaf, as well as to protect the adhered leaf from damage or peeling. Pigmented paint can also be used to highlight or trim the metal leaf design elements. In contrast to the individual works of guilder's art typified by the beautiful illuminated manuscripts and Egyptian relics of old, the dominant form of metal leaf artistry present in today's world is commercial signage. The particular aesthetic beauty of the metallic leaf grain structure and the easy readability of the highly lustrous surfaces makes metal leaf signage particularly desirable. However, the considerable amounts of highly skilled hand labor necessary to produce such metal leaf signage results in it being some of the most expensive commercial signage available. To date, it has been impossible to automate the production of metal leaf signage elements because of the extremely delicate nature of the metal foils involved. Simply folding the extremely thin leafs of beaten metal can produce embrittling work hardening at the fold causing the leaf to fracture. Additionally, the extreme light weight and susceptibility to drafts or electrical charges further complicates the automation of such processes using metal leaf elements. Accordingly, because of the hand labor intensive application techniques necessary to produce metal leaf signage elements, it is not uncommon for such metal leaf signage to cost on the order of $10 per square inch of overall sign dimension.

Further contributing to this expense is the fact that metal leaf signage elements can wear out. Though impervious to ultraviolet or environmental damage, metal leaf signage elements are susceptible to mechanical wear such as that associated with window washing. Additionally, in some circumstances, the underlying surface itself may corrode and damage the extremely delicate metal foil. Accordingly, it is a common practice to replace individual metal leaf signage elements over time. Such replacement is as expensive as producing the original metal leaf signage elements and may have the undesirable effect of producing new metal leaf signage elements which differ slightly from the replaced original and possibly detract from the overall appearance of the sign.

Nonetheless, to those who can afford such expense or who desire the exceptional aesthetic beauty of metal leaf signage, this expense is a cost that is acceptable and worthwhile. Moreover, traditional metal leaf signage is the only way to achieve these desireable aesthetics as attempts to reduce the cost of such signage or to substitute alternative and less acceptable materials have been less than satisfactory. As noted above, metal leaf foil is particularly unsuited to automated or machine cutting because of its extreme light weight and fragility. Conversely, plastic materials which can be readily cut by machine can not duplicate the exceptionally pleasing aesthetics of properly applied metal leaf signage. Similarly, efforts at developing metallic looking paints have also proved unsatisfactory as they cannot duplicate the unique granular structure of metal leaf foils. What is more, plastic or painted design elements are susceptible to photo aging and environmental damage and thus do not have the extended lifetime of metal leaf signage.

Summary of the Invention Accordingly, it is a principal object of the present invention to provide a metal foil or leaf product which is particularly well-suited for use in the automated production of metal leaf signage elements having all of the desirable characteristics of hand- gilded metal leaf signage.

It is an additional object of the present invention to provide a method for utilizing such metal leaf products to simply and easily produce metal leaf signage with a minimum of hand labor. Moreover, it is an additional object of the present invention to provide a metal leaf product and method for its use which can produce substantially identical individual signage elements for replacing damaged signage or producing duplicate signage at various locations.

These and other objects are achieved by providing an integrated laminate formed of an adhesive coated layer of metallic leaf to which is bonded a layer of transparent protective material which in turn is coated with a layer of pressure sensitive adhesive and releasably bonded to a supporting layer of backing material. The laminate is preferably formed of generally planar sheet elements having correspondingly dimensioned perimeters. From the bottom up, the first layer of the integrated laminate is a releasable backing material such as kraft paper, preferably having a smooth, flat or planar top surface that will releasably bond to a second layer of pressure sensitive adhesive. The pressure sensitive adhesive uniformly coats and securely adheres to a third layer of transparent protective material such as polyester sheet. The third layer is permanently bonded to a fourth layer of metallic leaf. An alternative embodiment of the present invention includes a fifth layer of transparent protective material permanently bonded to the layer of metallic leaf.

The resulting integrated laminate can be cut by hand, by machine, or by numerically controlled programmable machine cutters to produce individual signage elements without damaging the extremely fragile metal leaf layer encased therein. Those skilled in the art will appreciate that because the integrated metal leaf laminate of the present invention is particularly well suited to machine cutting, it enables the signage artisan to readily reproduce identical, individual signage elements in unlimited numbers.

To produce metal leaf signage in accordance with the teachings of the present invention, the artisan need only remove the releasable backing from the pre-cut individual signage elements and then apply the pressure sensitive adhesive coating of each element to the surface of the area to be gilded. Because the metal leaf laminate includes the pressure sensitive adhesive as well as the permanently bonded protective transparent top coat, the finished metal leaf signage is applied in a single step, dramatically reducing the amount of hand labor and associated expense involved. The integrated metal foil laminate of the present invention can be produced by machine or through hand lay-up procedures and may include a burnishing step prior to the bonding of the transparent protective top layer if desired. Additionally, the integrated laminate can be formed in individual sheets or rolls which may be provided with machine readable indexing features such as sprocket holes for use in automated XY plotters or numerically controlled cutting machines. Additionally, computer aided design (CAD) techniques can be utilized by such machine cutters to enable the metal leaf signage artisan to repeatedly produce exotic or complicated design elements which could not be duplicated utilizing traditional metal leaf gilding techniques. Further objects and advantages of the integrated, releasably backed metal leaf laminate of the present invention, as well as a better understanding thereof, will be afforded to those skilled in the art from a consideration of the following detailed description of exemplary embodiments thereof. Reference will be made to the appended drawings which will now be first described briefly.

Brief Description of the Drawings Fig. 1 is a perspective view of an exemplary embodiment of the integrated, releasably backed metal foil laminate of the present invention.

Fig. 2 is a partial sectional view of the integrated, releasably backed metal foil laminate of the present invention taken through the plane II-II of Fig.

1 illustrating the individual layers of the integrated laminate; and

Fig. 3 is a fragmentary sectional view illustrating the method for applying the integrated, releasably backed metal leaf laminate signage elements of the present invention to a surface. Detailed Description of Exemplary Embodiment

Referring more particularly to the drawings. Figs.

1 and 2 illustrate an exemplary embodiment of the integrated, releasably backed metallic leaf and transparent protective top layer laminate of the present invention generally indicated by reference numeral 10. As shown more clearly in the partial cross-section of Fig. 2, integrated metallic leaf laminate 10 is preferably formed of a layer of metallic leaf or foil 12 which is permanently bonded to the surface of an underlying layer of transparent, protective material 14. The surface of protective material layer 14 opposing that surface permanently bonded to metallic leaf layer 12 is uniformly coated with a thin layer of substantially transparent, pressure sensitive adhesive 16 which, in turn, is releasably bonded to a layer of backing material 18. Also shown in the exemplary embodiment of the present invention illustrated in Fig.

2 is a second layer of transparent protective material 20 permanently bonded to the top surface of metallic leaf layer 12; however, it is contemplated as being within the scope of the present invention to produce an integrated metallic leaf laminate 10 which does not include the second layer of transparent protective material 20.

Those skilled in the art will appreciate that the relative dimensions of the cross-sectional areas of the respective layers 12 through 20 of integrated metallic leaf laminate 10 as shown in Fig. 2 are greatly exaggerated for purposes of explanation and clarity. Accordingly, as noted above, it is anticipated that in practice the actual thickness of metallic leaf layer 12 will be on the order of 1/280,000 of an inch. Similarly, the respective layers of substantially transparent protective materials 14 and 20 are preferably as thin as possible, being on the order of 1/1000 of an inch thick. Those skilled in the art will appreciate that the preferred dimensions of the respective layers provided are exemplary only and that other thicknesses may be utilized to produced the integrated metallic leaf laminate of the present invention. However, to enhance the flexibility and appearance of the metallic leaf laminate, it is preferred that the various layers be made as thin as practicably possible. Conversely, the thickness of backing material 18 has little impact on the final appearance of the metallic leaf signage produced in accordance with the teachings of the present invention because the layer of backing material 18 will be removed prior to affixing the laminate to a signage surface as will be discussed in more detail herein.

It will appreciated that integrated metallic leaf laminate 10 can be formed of a variety of different materials. For example, metallic leaf layer 12 can be formed of a wide variety of metals or metallic alloys such as copper, silver, gold, platinum, palladium, or aluminum. Additionally, it is contemplated as being in the scope of the present invention to utilized any other suitably malleable metallic material to form laminate 10. The principal criteria for selecting such materials would include the color and grain structure of the metallic leaf material as well as the ability to form a suitably thin layer for incorporation into laminate 10.

Similarly, a wide variety of substantially transparent protective materials may be utilized to form layers 14 or 20 within the scope and teachings of the present invention. Exemplary materials include polyester or vinyl sheet materials which are readily available in thicknesses of 1 and 2/1000 of an inch. Additionally, polyvinylfluoride sheet materials may also be utilized where it is anticipated that the metallic leaf signage may be exposed to more hostile environmental factors such as solvents or abrasive chemicals. For example, where it is anticipated that the integrated metallic leaf laminate of the present invention would be applied to the exterior surfaces of cars, trucks, or motor racing vehicles it is preferable that the second layer of transparent protective material 20 be formed of polyvinylfluoride to impart an additional degree of resistance to fuels, solvents, and road hazards. An exemplary backing material layer 18 can be formed of bleached kraft paper or equivalent materials. Because backing layer 18 will not form a permanent part of the integrated metallic leaf laminate it is not necessary that backing material 18 incorporate the same aesthetic and environmental resistance characteristics of the remaining layers of laminate 10. Similarly, backing material 18 need not be transparent. Rather, backing material 18 should preferably be relatively flexible, yet substantially non-elastic. Though not essential to practice the present invention, flexibility of backing material 18 is preferred in that it allows the final integrated metallic leaf laminate 10 to be rolled into convenient shapes for utilization on automated cutting machines. Similarly, though non- elasticity is not an essential feature of backing material 18, it is preferred for forming integrated metallic leaf laminate 10 in that it prevents shifting or buckling of the laminate and also facilitates removal of the backing material itself. Those skilled in the art will appreciate that backing material 10 should also be capable of releasably bonding to the layer of pressure sensitive adhesive 16 distributed over the exposed surface of protective material layer 14. Coating a sheet of bleached kraft paper with a thin film of polyethylene will provide a backing material 18 with this preferred releasable -j -J

bonding feature. However, it is contemplated as being within the scope of the present invention to use other releasably bonding backing materials such as polyethylene sheets, coated plastic sheets, or equivalent materials.

Similarly, a wide variety of pressure sensitive adhesives may be utilized to form the metallic leaf laminate of the present invention. An exemplary pressure sensitive adhesive is high gloss clear enamel sizing, though other equivalent adhesives may be utilized within the scope and teachings of the present invention. Though not essential, it is preferred that the pressure sensitive adhesive utilized be generally transparent and colorless so as not to impact the appearance of the metallic leaf laminate. Colorless pressure sensitive adhesive also enables the laminate of the present invention to be affixed to the interior surface of transparent signage such as glass doors or windows without affecting the final appearance of the signage so produced. However, utilizing colored adhesives or colored transparent protective materials for layers 14 and 20 are also contemplated as being within the scope of the present invention and may be particularly desireable for unique applications such as automotive exterior signage.

The preferred method for forming integrated metallic leaf laminate 10 utilizes a first step of permanently bonding the layer of metallic leaf material 12 to one surface of a correspondingly dimensioned layer of substantially transparent protective material 14. Permanently bonding layers 12 and 14 together can be accomplished through the use of a permanent adhesive such as clear acrylic high tack adhesive or through thermalbonding or other equivalent, nondestructive, permanent bonding techniques. The next step in the manufacturing process of integrated metallic leaf laminate 10 involves applying a generally uniform thin coating of substantially transparent pressure sensitive adhesive to the surface of substantially transparent protective material 14 which opposes the surface bonded to metallic leaf layer 12. The adhesive utilized for layer 16 should be suitably strong to enable laminate 12 to be securely bonded to a signage surface yet sufficiently releasably or pressure sensitive to be releasably bonded to backing layer 18. Once the adhesive layer 16 has been applied to the bonded laminate layers 12 and 14, the correspondingly dimensioned layer of backing material 18 may be releasably bonded to adhesive layer 16 to form metallic leaf laminate 10.

An alternative embodiment of integrated metallic leaf laminate 10 as shown in Fig. 2 may be formed through the additional step of permanently bonding a second correspondingly dimensioned layer of transparent protective material 20 to the exposed surface of metallic leaf layer 12. Though a second layer of transparent protective material 20 may be applied to the metallic leaf laminate following the application of pressure sensitive adhesive layer 16 and backing material 18, it is preferred that a second layer of protective material 20 be applied at some point prior to the application of adhesive layer 16 and backing material 18. However, those skilled in the art will appreciate that in the mechanized production of integrated metallic leaf laminate 10 in accordance with the teachings of the present invention, all steps may be performed virtually simultaneously or in any logical sequence.

The method of the present invention may also include the additional step of burnishing the exposed surface of bonded metallic leaf layer 12 as a final step or prior to permanently adhering the second layer of transparent protective material 20 thereto. The additional burnishing step is desireable in that it produces a high lustre to the surface of metallic leaf layer 12.

All of the steps of the method of the present invention can be performed either by hand or through mechanized processes. When performed by hand or by machine, it is preferred that metallic leaf layer 12 be permanently bonded to one surface of substantially transparent protective material 14 through the steps of coating the surface of protective material layer 14 with a substantially uniform thin layer of substantially transparent adhesive and then allowing that adhesive to set to a slightly tacky state. At that point, the layer of metallic leaf material 12 can be applied to the layer of set adhesive either by machine or by hand. If applied by hand, metallic leaf layer can be formed by abutting individual sheets of metallic leaf material to form a substantially non-interrupted uniform layer of metallic leaf material.

Similarly, burnishing the bonded layer of metallic leaf material 12 may be performed either by machine or by hand. Hand burnishing can be accomplished through vigorous rubbing with surgical grade cotton to polish the exposed metallic surface of metal leaf layer 12 to a high lustre. Similar results can be achieved by machine burnishing.

Though a variety of techniques may be utilized to permanently bond second layer of protective material 20 to the exposed surface of metallic leaf layer 12 within the scope of the present invention, an exemplary method for achieving this step in the production of metallic leaf laminate 10 involves coating the exposed surface of the bonded layer of metallic leaf material 12 with a generally uniform thin layer of substantially transparent permanent adhesive and then applying the second corresponding dimensioned layer of transparent protective material 20 to the transparent permanent adhesive. Where the additional step of burnishing the exposed surface of metallic leaf material 12 is desired, it should be accomplished prior to coating this surface with permanent adhesive or bonding layer 20 thereto.

The integrated, releasably backed metallic leaf laminate produced in accordance with the method of the present invention is uniquely suited for use in the automated produced of metal leaf signage elements and in the subsequent one-step application of such signage elements to produced metal leaf signage. Though not essential to practice the present invention, the integrated metal laminate 10 may be provided with means for indexing laminate 10 into an automated cutting machine. In the exemplary embodiment of the present invention, the means for indexing comprise a plurality of sprocket holes 22 disposed along at least one peripheral edge of integrated metallic leaf laminate 10. Holes 22 are particularly well suited for machine cutting applications wherein laminate 10 is manipulated in roll form. Conversely, in those circumstances where laminate 10 is utilized in the form of individual sheets of laminate, notch 24, as shown in Fig. 1, may be provided as a means for indexing laminate 10 into an automated cutting machine. However, it should be appreciated that means for indexing 22 and 24 are equally well suited for facilitating the hand production of individual signage elements such as those indicated by reference 26 in Fig. 1.

In the hand production of individual signage elements 26 from integrated metallic leaf laminate 10, the signage artisan can sketch signage elements 26 directly onto the top or bottom surface of laminate 10. Elements 26 can then be cut from laminate 10 by hand. - ^

The individual signage elements 26 so produced may then be applied to a sign surface as will be discussed below.

For the automated or machine production of individual signage elements 26, the following steps are utilized in accordance with the teachings of the present invention. First, a sheet or roll of integrated metallic leaf laminate 10 produced as discussed above is provided. Next, the signage artisan produces a machine readable program die for cutting individual signage elements 26 from integrated laminate 10. This machine readable program die can be a numerical control program or a mechanical template or stamping and cutting die.

Preferably, a numerical control program will be utilized as this enables the signage artisan to utilize the benefits of computer aided design in the production of individual signage elements 26.

Following the production of the machine readable program die, individual signage elements 26 are machine cut from laminate 10 utilizing the machine readable program. Those skilled in the art will appreciate that a significant benefit of machine production of individual signage elements 26 is that the signage elements are readily reproducible with previously uncharacterized exactness. Thus, in contrast to the variability of hand produced metal leaf signage, the method of the present invention provides readily reproducible metallic leaf signage.

As shown in Fig. 3, once the individual signage elements 26 have been cut from laminate 10, the individual signage elements are respectively applied to a sign surface 28 to form reproducible metallic leaf signage by simply removing the releasably bonded backing material layer 18 to expose the pressure sensitive adhesive coating 16 on the surfaces of the signage elements which can then be applied directly to the sign surface 28. Those skilled in the art will appreciate that replacing individual signage elements that may be damaged in an existing metallic leaf sign produced in accordance with the teachings of the present invention involves the same simplified steps. The signage artisan either produces a duplicate signage element or maintains an inventory of the respective individual signage elements and, when necessary, simply peels an sticks a replacement element to repair an existing metal leaf sing. Moreover, complex or detailed signage elements may be readily reproduced by a machine in accordance with the teachings of the present invention greatly simplifying the process of producing individual or multiple metal leaf signs. As a result, significant amounts of highly skilled hand labor are eliminated from the process, substantially reducing the cost of the associated signage by a factor on the order of 10.

In the foregoing description of the present invention, preferred embodiments of the invention have been disclosed. It is to be understood by those skilled in the art that other mechanical and design variations are within the scope of the present invention. Accordingly, the invention is not limited to the particular methods and embodiments which have been illustrated and described in detail herein.

DOCS 73270PAT.01D

Claims

-WHAT IS CLAIMED IS:

1. A method for forming an integrated, releasably backed laminate of a layer of metallic leaf material and a layer of pressure sensitive adhesive coated transparent protective material for use in the automated production of metal leaf signage elements, said method comprising the steps of: permanently bonding a layer of metallic leaf material to one surface of a layer of substantially transparent, protective material; coating the opposed surface of said layer of substantially transparent protective material with a uniform, thin coating of substantially transparent pressure sensitive adhesive; and releasably bonding a correspondingly dimensioned layer of backing material to said pressure sensitive adhesive coated surface of said layer of substantially transparent protective material.

2. The method of claim 1 further comprising the additional step of: permanently bonding a second correspondingly dimensioned layer of substantially transparent protective material to the exposed surface of said bonded layer of metallic leaf material.

3. The method of claim 2 further comprising the additional step of: burnishing the exposed surface of said bonded layer of metallic leaf material prior to permanently bonding said second correspondingly dimensioned layer of substantially transparent, protective material to said exposed surface.

I

4. The method of claim 1 wherein said layer of metallic leaf material is permanently bonded to one surface of said layer of substantially transparent protective material through the additional steps of: coating said one surface of said layer of substantially transparent, protective material with a substantially uniform thin layer of substantially transparent adhesive; allowing said adhesive to set to a slightly tacky state; and applying said layer of metallic leaf material to said set adhesive.

5. The method of claim 4 further comprising the additional step of: burnishing the exposed surface of said bonded layer of metallic leaf material.

6. The method of claim 5 further comprising the additional step of: permanently bonding a second correspondingly dimensioned layer of substantially transparent protective material to the exposed surface of said bonded layer of metallic leaf material.

7. An integrated, releasably backed laminate of a layer of metallic leaf material and a layer of pressure sensitive adhesive coated, transparent protective material produced in accordance with the method of claim 1.

8. An integrated, releasably backed laminate of a layer of metallic leaf material and a layer of pressure sensitive adhesive coated, transparent protective material produced in accordance with the method of claim 6.

9. A method for forming an integrated, releasably backed laminate of a layer of metallic leaf material and a layer of pressure sensitive adhesive coated, transparent protective material for use in the automated production of metal leaf signage elements, said method comprising the steps of: providing a layer of generally flexible, substantially transparent, protective material; coating one surface of said layer of generally flexible, substantially transparent, protective material with a substantially uniform thin layer of substantially transparent adhesive; allowing said adhesive to set to a slightly tacky state; applying a layer of metallic leaf material to said layer of set adhesive; coating the opposed surface of said layer of generally flexible, substantially transparent, protective material with a uniform thin coating of pressure sensitive adhesive; and releasably bonding a correspondingly dimensioned layer of generally flexible, substantially non-elastic backing material to said thin coating of substantially transparent pressure sensitive adhesive.

10. The method of claim 9 further comprising the additional step of: -^, burnishing the exposed surface of said layer of said metallic leaf material.

11. The method of claim 9 further comprising the additional step of: permanently bonding a second correspondingly dimensioned layer of substantially transparent protective material to the exposed surface of said bonded layer of metallic leaf material.

12. The method of claim 9 furtner comprising the additional steps of: coating the exposed surface of said bonded layer of metallic leaf material with a generally uniform thin layer of substantially transparent permanent adhesive; and applying a second correspondingly dimensioned layer of substantially transparent protective material to said layer of substantially transparent permanent adhesive.

13. The method of claim 10 further comprising the additional step of: permanently bonding a second correspondingly dimensioned layer of substantially transparent protective material to said burnished surface of said bonded layer of metallic leaf material.

14. The method of claim 10 further comprising the additional steps of: coating said burnished surface of said bonded layer of metallic leaf material with a generally uniform thin layer of substantially transparent permanent adhesive; and applying a second correspondingly dimensioned layer of substantially transparent protective material to πaid layer of substantially transparent permanent adhesive.

15. An integrated, releasably backed laminate of a layer of pressure sensitive adhesive coated, transparent protective material, a layer of metallic leaf material bonded thereto, and a second layer of pressure sensitive adhesive coated, transparent protective material bonded to said layer of metallic leaf material produced in accordance with the method of claim 14.

TE SHEET

16. The integrated, releasably backed metallic leaf material and transparent protective material laminate of claim 14 further comprising means for indexing said laminate into an automated cutting machine.

17. The method of claim 9 wherein said layer of metallic leaf material is applied to said layer of set adhesive by hand abutting individual sheets of metallic leaf material to form a substantially uninterrupted layer.

18. A method for applying machine produced, integrated, releasably backed, metallic leaf material and pressure sensitive adhesive coated, transparent protective material laminate signage elements to a sign surface to form reproducible metallic leaf signage, said method comprising the steps of: providing an integrated laminate of a layer of metallic leaf material bonded to a layer of pressure sensitive adhesive coated, transparent protective material which in turn is releasably bonded to a correspondingly dimensioned layer of backing material; producing a machine readable program die for cutting individual metallic leaf signage elements from said integrated laminate; machine cutting respective ones of said individual signage elements from said integrated laminate utilizing said machine readable program; removing said releasably bonded backing material from said machine cut individual signage elements to expose said pressure sensitive adhesive coated surfaces of each of said machine cut individual metallic leaf signage elements; and applying said pressure sensitive adhesive coated surfaces of each of said individual machine cut metallic leaf signage elements to said sign surface.

ET