System and method for applying an image to a substrate to form a display article

1. A method for forming a product for displaying an image comprising the steps of:

forming or applying an image on a rear surface of a first sheet;

providing a jig for affixing the first sheet to an adhesive coated substrate to form the product, the jig including a base having a top edge, a first side and a second side, the base having a recessed portion formed along a front face thereof for receiving the adhesive coated substrate;

a retaining member configured to hold the first sheet, the retaining member being located outside the recessed portion, the jig further including a first guide member formed outside the recessed portion and configured to locate and hold a first portion of the first sheet;

and a second guide member formed outside the recessed portion and configured to locate a second portion of the first sheet such that in combination with the first guide member the first sheet can be placed in a target registration relative to the adhesive coated substrate;

inserting the adhesive coated substrate within the recessed portion with a top adhesive layer of the adhesive coated substrate facing upward;

using the first guide member to hold the first portion of the first sheet such that the first and second guide members position the first sheet above the adhesive coated substrate with the rear surface of the first sheet facing the top adhesive layer of the adhesive coated substrate; and

affixing the rear surface of the first sheet to the top adhesive layer of the adhesive coated substrate by applying pressure to the first sheet in a direction toward the adhesive coated substrate to adhesively mount the first sheet to the adhesive coated substrate with the image facing the adhesive coated substrate.

2. The method of claim 1 , wherein the step of forming an image comprises the step of printing the image on the rear surface of the first sheet.

3. The method of claim 1 , wherein the adhesive coated substrate comprises a ferrous metal substrate and the image comprises a printed image formed on an aqueous ink receptive coating.

4. The method of claim 1 , wherein the first sheet is formed of an optically clear material and the image is formed of inks deposited on the rear surface of the first sheet.

5. The method of claim 1 , wherein the adhesive coated substrate comprises a pre-laminated structure including a base metal substrate along with an adhesive component formed along a top surface of the base metal substrate, the adhesive component including the top adhesive layer.

6. The method of claim 5 , wherein the adhesive component comprises a carrier having a first face and an opposing second face; a bottom adhesive layer formed along the second face and in contact with the top surface of the base metal substrate and the top adhesive layer is formed along the first face of the carrier for bonding the first sheet to the base metal substrate.

7. The method of claim 6 , wherein the bottom adhesive layer comprises a pressure sensitive permanent acrylic adhesive and the top adhesive layer comprises a pressure sensitive removable acrylic adhesive.

8. The method of claim 1 , wherein the first guide member comprises a pin for reception in a hole formed in the first sheet to restrict lateral movement of the first sheet but permit rotation of the first sheet and the second guide member comprises a rib for placement against one edge of the first sheet.

9. The method of claim 8 , wherein the first guide member and the second guide member are formed along the first side of the base.

10. The method of claim 8 , wherein the first guide member and the second guide member are formed along the top edge.

11. The method of claim 1 , wherein the retaining member comprises a clip for holding a top edge of the first sheet.

12. The method of claim 1 , further including at least one notch formed along one of the first side and second side of the base, an inner end of the notch being in communication with the recessed portion to permit removal of the adhesive coated substrate.

13. The method of claim 1 , wherein the first sheet comprises a transparent sheet with a printed image formed along a rear face thereof and the substrate comprises an adhesive coated metal substrate to which the sheet is affixed.

14. The method of claim 1 , further comprising the step of:

using a squeegee to apply the pressure to the first sheet to affix the rear surface of the rear sheet to the top adhesive layer of the adhesive coated substrate by removing a protective layer from the top adhesive layer in a direction from a first end to a second end of the adhesive coated substrate and placing the squeegee at the first end and applying a force to a first end of the first sheet to contact and affix the first end of the first sheet to the first end of the adhesive coated substrate.

15. The method of claim 14 , wherein the squeegee has a longitudinal slot formed therein and the step of using the squeegee comprises the step of inserting and passing the first sheet through the longitudinal slot.