BR112012008418B1 - method and apparatus for increasing the thickness of embossed decorations - Google Patents

Abstract

method and apparatus for increasing the thickness of embossed decorations a method for increasing the thickness of embossed decorations comprises the steps of: providing a decorated object (3) having at least one embossed part made of a thermoplastic or thermosetting decorative material (4 ) arranged on a decorated surface (2) of said object (3); heat the part of the thermoplastic or thermoset decorative material (4) applied to the decorated surface (2) until it becomes sticky; spreading a powder material (22) on the decorated surface (2), said powder material (22) adhering to the part of the thermoplastic or thermoset decorative material (4); wherein the third step is performed by immersing the object (3) at least once in a fluidized bed made by introducing a fluid under pressure through the powder material (22).

Description

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METHOD AND APPARATUS TO INCREASE THE THICKNESS OF EMBROIDERED DECORATIONS

The present invention relates to a method and apparatus for increasing the thickness of the embossed decorations and, in addition, to a method and apparatus for decorating embossed surfaces.

Preferably, the present invention relates to the execution of three-dimensional decorations defined by raised parts relative to the base surface to be decorated, consisting of added decorative thermoplastic material.

In particular, but not necessarily, the present invention relates to the decoration of objects in the form of sheets, such as fabrics, leather, imitation leather, etc.

As is known, the embossed decoration of surfaces can be made with added materials, through the hot transfer of the decoration from transfer papers or transfer films to the object to be decorated. The decoration material is applied first to the transfer film using known methods. The decoration on the transfer film is embossed. The transfer film is subsequently applied to the surface to be decorated and pressed against it, providing heat through a heated calender, for example. Heat and pressure cause the decoration of the film to transfer to the object to be decorated. The film is then separated from the object and the decoration remains on the surface of the object itself.

The known method, of the type described above, however, has some disadvantages, mainly with regard to the weak three-dimensional effect obtained. In fact, the compression of the film against the surface to be decorated, which is necessary for the transfer, causes the uniform leveling of the decoration. As a result, the thickness of the decoration is minimal and, above all, that thickness cannot be defined “a priori” with sufficient precision. Additionally, it is not possible to obtain regions with different thicknesses in the same decoration.

In this context, the technical task underlying the present invention is to propose a method and an apparatus for increasing the thickness of the embossed decorations and a process and apparatus for decorating embossed surfaces that overcome the above mentioned disadvantages of the known technique.

Petition 870190033660, of 4/8/2019, p. 8/15

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In particular, the present invention aims to provide a method and an apparatus to increase the thickness of embossed decorations, firstly allowing the three-dimensional effect of the decoration to be more apparent and, in addition, the thickness to be controlled and the regions to be created having more or less relief areas marked in the same decoration.

The mentioned technical task and the specified objectives are substantially achieved by a method and an apparatus, as well as by a process and an apparatus comprising technical characteristics established in the appended claims.

More specifically, in a first aspect, the present invention relates to a method for increasing the thickness of embossed decorations, comprising:

i) providing a decorated object having at least a part of the relief made of a thermoplastic or thermoadhesive decorative material arranged on a decorated surface of said object;

ii) heat the part of the thermoplastic or thermoset decorative material applied to the decorated surface until it becomes sticky;

iii) spreading a powder material on the decorated surface, said powder material adhering to the thermoplastic or thermosetting decorative material; wherein step iii) is performed by immersing the object at least once in a fluidized bed made of said powder material.

Preferably, the fluidized bed is created by introducing a fluid under pressure through the powder material.

Preferably, step ii) is performed before and after step iii).

In a preferred embodiment, the method comprises a plurality of steps ii) alternating with steps iii).

Preferably, after step iii), the excess powder material is removed from the decorated surface.

Preferably, the introduction of the fluid occurs with a pressure between about 1 bar and about 5 bars.

Preferably, in step ii) the part of the thermoplastic or thermoset decorative material is brought to a temperature "T" between about 120 ° C and about 170 ° C.

Preferably, the powder material has a particle size between about 100pm and about 500pm.

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Preferably, the powder material is a thermoplastic or thermoset decorative material preferably selected from the group comprising: polyamide, polyethylene, acrylic polyurethane, glass, ceramic.

Preferably, the powder material is selected from the group comprising: glass, ceramic, wood, plastic material, steel. For example, it is defined by colored or transparent ceramic glass spheres.

Preferably, the powder material has a neutral color.

Preferably, the thermoplastic or thermoset decorative material is selected from the group comprising: polyamide, polyethylene.

In a second aspect, the present invention relates to an apparatus for increasing the thickness of the embossed decorations, comprising: at least one support for a decorated object, said decorated object having at least a raised part of thermoplastic or thermoset decorative material arranged on a decorated surface of said object; at least one heating device acting on said support; at least one fluidized bed container (16) having a wall provided with holes and delimiting a retention volume of the powdered material; means for admitting the fluid under pressure into the holding volume, through said wall provided with holes; means for transferring the decorated object from said support to said container and / or vice versa.

Preferably, the apparatus comprises a first support and a first heating device arranged upstream of the fluidized bed container and a second support and a second heating device disposed downstream of said fluidized bed container in relation to a feed direction (X ) of the decorated objects.

Preferably, said at least one support comprises a conveyor belt.

Preferably, said at least one heating device comprises at least one lamp facing the said support.

In a third aspect, the present invention relates to a process for embossing surfaces, comprising: applying at least a part of the thermoplastic or thermosetting decorative material to a surface of an object to be decorated; characterized by the fact that it still comprises a method as described above.

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Preferably, during the application, some regions of the surface to be decorated are left without the thermoplastic or thermosetting decorative material.

Preferably, the application comprises: providing a transfer film carrying the part of the thermoplastic or thermosetting decorative material, applying and pressing the transfer film against the surface of the object, heating at least part of the thermoplastic or thermosetting decorative material to cause the transfer of the even for said surface, separate the transfer film from the decorated object.

In a fourth aspect, the present invention relates to an apparatus for embossing surfaces, comprising: means for applying at least a raised part of the thermoplastic or thermosetting decorative material to a surface of an object to be decorated; characterized by the fact that it still comprises an apparatus as described above, in which said at least one support is disposed operationally downstream of the application medium.

Preferably, the application means comprises a heated calender.

Additional features and advantages of the present invention will become more apparent from the description, given as a non-limiting example, of a preferred embodiment of a process for decorating embossed surfaces and a preferred embodiment of an apparatus for decorating surfaces. embossed surfaces, as illustrated in the attached figures, where:

- Fig. 1 is a diagrammatic view of an apparatus made in accordance with the present invention;

- Fig. 2 is a plan view of a decorated object according to the invention;

- Fig. 3 is a cross-sectional view of the object seen in fig. 2 after a first step in the process;

- Fig. 4 is a cross-sectional view of the object seen in fig. 2 after a second step in the process.

In relation to the accompanying figures, an apparatus for decorating embossed surfaces 2 of objects 3 according to the present invention has been identified with reference numeral 1.

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The apparatus 1 is designed for decoration of surfaces 2, preferably, although not exclusively, of objects in the form of a blade, such as leather, imitation leather or fabrics.

As shown in figs. 2, 3 and 4, the decorations preferably consist of parts 4 of thermoplastic or thermoset material transferred to the surface 2 to be decorated, delimited by the regions 5 of said surface 2 that are without said material, thus giving the decoration the said three-dimensional effect .

In the present specification and the appended claims, the term "thermoplastic or heat-bonding material" generally means a material that, at room temperature, is substantially hard and acquires malleability ie becomes soft - and sticky properties under the action of heat . Therefore, the term "thermoplastic or thermoset material" refers not only to real plastic materials (polymers, such as polyethylene, polyamide, polyurethane acrylic), but also to other products such as ceramic glass.

The thermoplastic or heat-stick decorative material can be colored (in a single color or different colors), transparent, opaque etc.

The apparatus 1, therefore, comprises the means 6 suitable for applying the thermoplastic or thermoset decorative material to the surface 2 of object 3.

In the embodiment shown in fig. 1, object 3 is a continuous sheet of fabric, leather or imitation leather, unwound from a coil, not shown, and transported through a calender 7 made of a pair of heated cylinders 8. The apparatus 1 shown here, thus, works continuously.

In a not shown variant of the present invention, the device works on smaller objects (such as pieces of leather, fabric or imitation leather, tiles, individual pieces etc.) with different working cycles. A press is shown as an example instead of a calender 7.

In addition, a transfer film 9 is transported between cylinders 8, and in the film the parts 4 of the thermoplastic or thermo-adhesive decorative material, to be transferred to object 3, are attached. This transfer film 9, also known as transfer paper, is produced following techniques known to you and therefore not described here. Upstream of the cylinders 8, said parts 4 of the thermoplastic or thermoset decorative material face the surface 2 of the blade 3. During the passage between the cylinders 8, the transfer film 9 is coupled to the surface 2 and pressed against it. Simultaneously, the transfer film 9 with the decorative material

6/9 thermoplastic or thermoset and blade 3 is heated. Pressure and heat cause the decoration to stick to the surface 2.

Downstream of the cylinders 8 in relation to the feed direction “X” of the blade 3, the film 9 is separated, by a hot or cold treatment, from the film 3 to which the parts 4 of the thermoplastic or thermoset decorative material are now attached. defining the embossed decorations (shown in fig. 3).

The apparatus 1 also comprises an apparatus 10 (fig.1) suitable for increasing the thickness of the embossed decorations, preferably, but not exclusively, obtained following the work previously described.

In the non-limiting embodiment shown, the apparatus 10 comprises a first support 11 in turn comprising a conveyor belt 12 passing through a pair of conductive rollers 13. The conveyor belt 12 preferably comprises non-adhesive material, Teflon® for example. The blade 3 falls on an upper surface of the conveyor belt 12 and its decorated surface faces upwards. Blade 3 is fed along the “X” feed direction. A heating device 14, defined by a series of infrared lamps 15 sending radiation to the blade as it passes, is installed above the conveyor belt 12.

Downstream of the first support 11 is a fluidized bed container 16 into which the blade 3 is passed. The fluidized bed container 16 comprises a bowl 17 within which a wall 18 is provided which is provided with a plurality of holes (having a diameter on the order of microns). The wall 18 divides the internal space confined by the bowl 17 into an upper retaining volume 19 that is opened upwards and a lower hollow space 20. The wall 18 delimits the upper retaining volume 19 at the bottom of the same. The lower hollow space 20 is in fluid communication with a fluid source (preferably air) under pressure, such as a compressor, through a duct 21.

The upper retention volume 19 is filled with powder material 22 which is the same as, or different from, the material that constitutes the decoration already disposed on the blade 3.

Preferably, the powder material 22 consists of plastic granules (polyethylene or polyamide, polyurethane acrylic, for example) or powder products in general, such as colored or transparent ceramic glass spheres, or steel, wood. The powder material 22, therefore, can be either of the thermoplastic type

7/9 or hot-stick (plastic, glass, ceramic) according to the definition above, or not (steel, wood).

The powdered material 22 preferably has a particle size (expressed as the average diameter of the granules) between about 100pm and about 500pm. The powdered material 22 can be colored, transparent or neutral.

Preferably, the fluidized bed container 16 further comprises a guide cylinder 23 disposed close to the first support 11 and parallel to the conductive cylinders 13, whose function is to guide and drag the blade 3 from said first support 11 into the bowl 17.

Positioned downstream of the fluidized bed container 16 is a second support 24 which can have the same structure as the first support 11 (conveyor belt 12, conductive cylinders 13, heating device 14 and infrared lamps 15).

An additional guide cylinder not shown can also be provided; it is arranged in the fluidized bed container 16 and close to the second support 24, its function being that of guiding and dredging the blade 3 coming from the bowl 17 along the second support 24.

In use, the fluid source is activated and admits air in the hollow space 20 at a pressure between about 1 bar and about 5 bars. The air is filtered through the holes in the wall 18 and the powder material 22 contained in the upper holding volume 19 of the bowl 17. When the air flow passes through the powder material 22, it fills the space between the particles and a condition is achieved in which the aerodynamic force acting on the particles is able to counteract the forces of gravity, the granular solid begins to expand and the upper surface of the bed takes on a mobile profile similar to the free surface of a liquid.

The decorated blade 3 from the calender 7 (shown in fig. 3) passes under the infrared lamps 15 arranged above the first support 11 and is heated to a temperature "T" (preferably between about 120 ° C and about 170 ° C) sufficient to cause the parts 4 of the thermoplastic material to become sticky.

Subsequently, the blade 3 falls or is dredged along the bowl 17, so as to immerse into the fluidized powder material 22. During the displacement of the blade 3 in the fluidized bed, the particles of the powdered material 22 adhere to and / or complete or partially penetrate parts 4 of the heated thermoplastic or heat-stick decorative material. A stirring device, not

8/9 shown, it can transversely (in relation to the “X” feed direction) move the blade in transit to further make the distribution of the powder particles on the surface 2 even.

Subsequently, the slide 3 is removed from the fluidized bed and dredged along the second support 24, where it passes under infrared lamps 15 arranged above the second support 24 and is heated to a temperature (preferably between about 120 ° C and about 170 ° C) sufficient to cause partial melting of parts 4 of the thermoplastic or thermosetting decorative material and of the powder material 22 (if it is thermoplastic or thermosetting) that adhered to parts 4 of the thermoplastic or thermosetting decorative material, and mixing occurs. The powdered material 22 becomes part of the parts 4 of the thermoplastic or thermoset decorative material and increases its thickness (as shown in fig. 4).

Preferably, the powdered material 22 is of a neutral color, so that once incorporated into the parts 4 of the thermoplastic or thermoset decorative material it does not change the original colors. The powder material 22 can also be colored in order to provide specific chromatic effects to the final decoration.

The powdered material which, during immersion in the fluidized bed 19, is deposited in the free regions 5 of the surface 2 (which are devoid of parts 4 of thermoplastic decorative material) does not adhere to these regions 5 and can be easily eliminated before or after the second step of heating.

The method of the invention can also contemplate several immersion operations in the fluidized bed and several heating steps, each performed between one immersion operation and the next.

The present invention achieves the intended purposes and achieves important advantages.

First, the method, according to the present invention, allows the thickness of the decoration to be increased in a simple, fast and efficient way.

Additionally, it is possible to obtain different degrees of thickness in the same decoration. In fact, parts with a larger surface area tend to accumulate more powder material, which will involve a greater increase in thickness than where there are smaller parts.

The method of the invention, due to the use of the fluidized bed, allows the powder material to be evenly distributed over the parts of the thermoplastic or thermoset decorative material of the decorated surface without formation

9/9 uncontrolled material accumulated at specific points. As a result, the variables of the method and consequently the characteristics of the final product can be controlled in a safer way. In particular, as already mentioned above, due to the control of the distribution of the powdered material, it is prevented from adhering to the regions of the surface where the parts of the thermoplastic or thermosetting decorative material are not present.

Additionally, through the appropriate establishment of method parameters, such as characteristics of the powder material, temperatures, immersion and heating steps, it is possible to fix the quantity and distribution of the increase in thickness “a priori”.

The apparatus of the invention is simple in structure and allows the method to be put into practice easily. Additionally, if provided with conveyor belts, the apparatus can work continuously, which will save time and reduce production costs.

Claims (3)

1. Method for increasing the thickness of embossed decorations, comprising: i) providing a decorated object (3) having at least an embossed part made of a thermoplastic or thermosetting decorative material (4) disposed on a decorated surface (2) of said object (3); ii) heat the part of the thermoplastic or heat-stick decorative material (4) applied to the decorated surface (2) until it becomes sticky; iii) spreading a powder material (22) on the decorated surface (2), said powder material (22) adhering to the part of the thermoplastic or thermoset decorative material (4); characterized by the fact that step iii) is performed by immersing the object (3) at least once in a fluidized bed made of said powdered material (22). 1/3 2/3 9. Method, according to claim 1, characterized by the fact that the thermoplastic or thermoadhesive decorative material (4) is selected from the group comprising: polyamide, polyethylene. 10. Method according to any one of claims 1 to 9, characterized by the fact that it comprises: - apply at least an embossed part of decorative thermoplastic or heat-stick material (4) to a surface (2) of an object (3) to be decorated. 11. Method, according to claim 10, characterized by the fact that, during the application, some regions (5) of the surface to be decorated (2) are left without the thermoplastic or thermosetting decorative material (4). 12. Device for increasing the thickness of embossed decorations, comprising: - means (6) for the application of at least an embossed part of the thermoplastic or thermosetting decorative material on a surface (2) of an object to be decorated (3); - at least one support (11, 24) for a decorated object (3), said decorated object (3) having said at least an embossed part of thermoplastic or heat-stick decorative material (4) arranged on the decorated surface (2) said object (3); wherein said at least one support (11, 24) is operatively disposed downstream of the application medium (6); - at least one heating device (14) acting on said support (11, 24); characterized by the fact that it comprises: - at least one fluidized bed container (16) having a wall (18) provided with holes and delimiting a holding volume (19) for the powder material (22); - means for admitting fluid under pressure to the holding volume (19) through said wall (18) provided with holes; - means for transferring the decorated object (3) from said support (11, 24) to said container (16) and / or vice versa. Apparatus according to claim 12, characterized in that it comprises a first support (11) and a first heating device (14) arranged upstream of the fluidized bed container (16) and a second support (24) and a second heating device (14) arranged to Petition 870190033660, of 4/8/2019, p. 10/15 2. Method, according to claim 1, characterized by the fact that the fluidized bed is created by introducing a fluid under pressure through the powder material (22); 3. Method according to claim 1, characterized by the fact that step ii) is performed before and after step iii). 4. Method according to claim 1, characterized in that after step iii) the excess powder material (22) is removed from the decorated surface (2). 5. Method according to claim 1, characterized in that the powder material (22) has a particle size between about 100pm and about 500pm. 6. Method, according to claim 1, characterized by the fact that the powder material (22) is a thermoplastic or thermoset material, preferably selected from the group comprising: polyamide, polyethylene, acrylic polyurethane, glass, ceramic. 7. Method, according to claim 1, characterized by the fact that the powder material (22) is selected from the group comprising: glass, ceramic, wood, plastic material, steel. 8. Method according to claim 1, characterized by the fact that the powder material (22) has a neutral color. Petition 870190033660, of 4/8/2019, p. 9/15 3/3 downstream of said fluidized bed container (16) in relation to a feeding direction (X) of the decorated objects (3).