JP5841166B2 - Foil stamping parts with asymmetric edges - Google Patents

Description

  The present invention is directed to parts having asymmetric edges and coated asymmetric surfaces with decorative foil protection or protective foil pressing.

  Foil stamping on parts for decorative or protective purposes is known. Foil for decorating and protecting parts is also known. The foil is usually a thin multilayer sheet or ribbon. These layers typically comprise a thin film support, a volatile separating material, a colorant or protective coating, a metal layer, and an adhesive. However, conventional machines and methods of using these machines are usually used with flat symmetrical surfaces. For example, it is known how to coat mandrels meshed on cylindrical and frustoconical parts by simply rotating them. The foil is fed between the part and the mandrel and adheres uniformly to the part. However, these systems do not work with parts that have asymmetric shapes because the mandrels cannot maintain constant contact with the asymmetric parts.

  In addition, the complicated shape can be stamped with foil by producing a stamping die that is a negative image of the pressed part. Although this method can press virtually any shape, this process has one inherent disadvantage. The foil is flat and, when pressed on a complex shape, inevitably stretches and folds on itself, resulting in a non-uniform coating. There is therefore a geometric limitation for this type of foil stamping.

  A highly flexible, deformable stamping die is also used for pressing the foil or label against the asymmetric surface. Containers for carbonated beverages are often labeled in this manner. However, these highly flexible, deformable push pads also suffer from the same drawbacks described above. When a flat foil is pressed against a curved surface, it needs to conform to the surface by folding and stretching. This always results in a non-uniform coating.

  There is a need for an apparatus and method that overcomes these problems and other problems associated with conventional methods and apparatus. More specifically, there is a need for an apparatus that can apply a thin decorative film or a thin protective film to the surface of a part having an asymmetric portion.

  The present invention is directed to a part having an asymmetric edge, which is coated with a thin film applied by a device having a part holder and a mandrel, the part being held by the part holder, and then the part Rotate on a mandrel with a thin film sandwiched between the mandrel and the mandrel, and either or both of the mandrel and part holder operate in an angular relationship with each other. The apparatus used for coating the parts of the present invention further comprises a film unwinder and a film winder. Furthermore, the film unwinder and the film winder operate in cooperation in at least two dimensions with respect to the part holder. The apparatus can further include a film having a first edge and a second edge, the film being a decorative coating, a protective coating, or a combination thereof. The film is preferably a multilayer film comprising a support, a release compound, a metal foil, and an adhesive.

  The present invention provides parts having asymmetric edges that are coated with a decorative or protective foil in a quick and economical manner that results in a uniform coating. This part does not suffer from the disadvantages of previous methods and devices that when the foil is stretched or spread over an irregularly shaped part, visible streaks appear in the foil. The ability to coat irregularly shaped parts gives designers considerable new design freedom. Adding different surfaces not only allows new part shapes to be manufacturable and decorative or protectable, but allows multiple decorations on a single part. These and other advantages of the present invention will be apparent to those skilled in the art.

While the specification concludes with claims that particularly point out and distinctly claim the invention, it is believed the present invention will be better understood from the following description taken in conjunction with the accompanying drawings.
Sectional drawing of parts having asymmetric edges. Sectional drawing of parts having asymmetric edges. Prior art mandrels, parts, and parts holders. Mandrels, parts and parts holders according to the invention. Device according to the invention. A jar having a lid with an asymmetric edge according to the invention. A lid having an asymmetrical edge that is decorated in a different manner than the remaining surface of the lid according to the present invention. A transparent top with an asymmetric edge according to the invention. A jar with a pump with asymmetric edges and a transparent top lid according to the present invention. A jar with a pump having an asymmetric edge according to the invention.

  The present invention can be understood more readily by reference to the following detailed description of exemplary and preferred embodiments. The claims are not limited to the specific components, methods, conditions, apparatus, or parameters described herein, and the terminology used herein limits the claimed invention. It should be understood that it is not intended to. Also, as used herein, including the appended claims, the singular forms “a”, “an”, and “the” include plurals, and references to specific numerical values are in the context. Unless specifically stated otherwise, at least that particular value is included. Where a range of values is stated, another embodiment includes from the one particular value and / or to the other particular value. Similarly, when a value is stated as an approximation by use of the preceding “about”, that particular value is understood to form another embodiment. All ranges are inclusive and combinable.

  As used herein, “parts” includes containers (eg, bottles, jars, overpacks, etc.), lids (eg, container lids, top lids, etc.), consumer products (eg, razors, toothbrushes, electric motors). Brushes, skin care devices, pumps, electric razors, appliances, etc.). The parts can be made of any known plastic and other polymer compositions, naturally derived compounds such as rubber, metals, and other manufacturing materials known to those skilled in the art. Similarly, the parts can be manufactured by methods known to those skilled in the art. Molding and high gloss molding are preferred examples of parts production. On the other hand, forging, thermoforming and the like are also preferable methods for forming the parts of the present invention.

  As used herein, “parts having asymmetric edges” are optimally defined with reference to FIGS. FIG. 1 is a cross-sectional view of a generally circular lid 22 such as a jar or bottle according to the present invention. More specifically, in FIG. 1, the lid 22 has an upper edge portion 12, a first inclined edge portion 14, and a second inclined edge portion 16. The lid 22 further includes a side wall 18, a thread 20, and a bottom 24. A line 19 drawn parallel to the bottom 24 intersects a line 21 drawn parallel to the first inclined edge 14 to form an angle β. Similarly, a line 23 drawn parallel to the second inclined edge 16 intersects the line 19 to form an angle α. Therefore, to determine if a part has an asymmetric edge, cut a vertical section through the center point of the part and calculate α and β. A part has an asymmetric edge if at least one vertical section through the center point of the part results in α not equal to β. Preferably, α is not equal to β by a difference of at least 3 °, more preferably at least about 5 °, and even more preferably at least about 10 °. It is understood that either α or β can be equal to 90 °. This occurs when there is no beveled edge (ie, the top edge 12 meets the side wall 18 directly), but only a small part of the part if the other angle is greater than 90 ° or less than 90 °. However, there are asymmetric edges.

  Reference is now made to FIG. 2, which is a cross-sectional view of a generally circular lid 32, such as a jar, bottle, etc. according to the present invention. More specifically, in FIG. 2, the lid 32 has an upper edge portion 42, a first inclined edge portion 34, and a second inclined edge portion 36. The lid 32 further includes a side wall 38, a thread 40, and a bottom 44. The first inclined edge 34 is concave, and the second inclined edge 36 is convex. FIG. 2 illustrates that none of the edges of the present invention need be flat. Nevertheless, the angles α 'and β' can be calculated as described above. The angle β ′ can be measured using the outer intersection 31 between the first inclined edge 34 and the side wall 38 and the outer intersection 33 between the first inclined edge 34 and the upper edge 42. A line 49 drawn parallel to the bottom 44 intersects with a line 51 drawn through the outer intersections 31 and 33 to form an angle β ′. Similarly, line 53 drawn through outer intersections 35 and 37 intersects line 49 to form angle α ′.

  As used herein, the term “film” is generally used to describe any thin sheet-like material having multiple layers with at least one layer attached to the part. The adhesion layer can be a protective coating, a decorative coating, or the like. Metals, colors, labels, transfer seals, printing, plastics, and many more materials can be affixed to the parts of the present invention by film. Exemplary films that may be suitable for use in the present invention are described, for example, in US Patent Application Publication No. 2009/0286054 (Meiki et al.) Published on November 19, 2009, 2008 published on March 13, 2008. / 0063863 (Colella et al.) And U.S. Pat. No. 7,410,551 (Bethune) issued Aug. 12, 2008.

  Although different films can be used to obtain different end results, a typical film includes a support, a release compound, an adhesion layer, and an adhesive. The support retains the layer to be deposited, and after deposition, the support can be recovered (eg, taken in by a film winder). The support is often a thin sheet made of plastic or other inexpensive material that can withstand heat, pressure, or both of these deposition processes. The release compound is a normally liquid, gel, or semi-solid material that allows the support to be easily pulled away from the adhesion layer without taking away any of the adhesion layer with the support. Preferably, the release compound is volatile so that it simply evaporates when the support is pulled away. Alternatively, the non-volatile release compound can be washed away or wiped off in a post-attachment process.

  The adhesion layer can be any number of materials and can itself include multiple layers. A thin layer of vacuum metallized metal is a common choice for both decoration and protection. A color layer is often added to the metal layer. The metal film can be manufactured by other methods, and can be thick or thin depending on the desired result. Thinner deposited layers are clearly economical and flexible, while thicker layers are more durable and have less color deviation when deposited. Ultimately, the adhesive simply functions to adhere the adhesion layer to the part. Adhesives are known to those skilled in the art and can be activated by temperature, pressure, activating compound, or all of these. In the case of a fast-curing epoxy, the part may be coated with a chemical with an epoxy and with other chemicals on the film. When the film contacts the part, a reaction occurs and an adhesive layer is formed. In many cases, the adhesive is simply activated by pressure and / or heat between the mandrel and the part. Naturally, the support side of the film is in contact with the mandrel, while the adhesive and adhesion layer side of the film is in contact with the part.

  Reference is now made to FIG. 3, which is the state prior to the foil pressing operation. This figure is presented to highlight the differences and advantages of the present invention. In FIG. 3, there is a rotating mandrel 60 attached to a mandrel holder 61. The part 63 is shown in a state where it is held in place by a parts holder 66. The part 63 has a planar side wall 65 that rotates in the opposite direction to the mandrel 60. The film 62 is fed between the mandrel 60 and the planar side wall 65 of the part 63 and contacts both. As shown in the figure, the angle between the mandrel 60 and the part 63 is unchanged. For this reason, the film 62 can move only along the side surfaces and is never twisted or moved out of the operating plane. This configuration generally results in a good coating with minimal or no pressure on the film. This system is known to work with symmetrical frustum parts. However, this simplified system does not work with parts that have asymmetric edges.

  FIG. 4 shows a schematic diagram of an apparatus for coating parts comprising asymmetric edges according to the present invention. The device 69 has a mandrel 70 that rotates and is attached to a mandrel holder 71. The part holder 76 holds a part 73 having an asymmetric edge 80. The film 72 is disposed between the mandrel 70 and the part 73. The part 73 rotates in the opposite direction to the mandrel 70. As described in detail below, either or both of the mandrel 70 and the parts holder 76 move relative to one another. In FIG. 4, the parts holder 76 is placed on a plate 81 attached to a mandrel holder 71 via a hinge 82. This is just one way of achieving the required angular motion of the present invention. To understand that the angular motion can be remotely controlled in a pre-programmed manner, for example using a servo motor, pneumatic motor, etc., by a computer controlling the part holder, mandrel, or both, the mandrel and part holder Need not be connected.

  Suitable mandrels for use with the present invention are frustoconical (eg, see mandrel 69 of FIG. 4), cylindrical (eg, see mandrel 102 of FIG. 5), or other generally symmetric shapes. Good. Similarly, the mandrel may be solid or deformable. “Deformable” means that the mandrel can conform to an irregular shape (eg, concave or convex). The deformable mandrel is used, for example, to coat the first inclined edge 34 and the second inclined edge 36 of the part 32 of FIG. Deformable mandrels are useful when coating parts with raised or depressed indicia, for example, product names, trademarks, or logos are molded directly into the part to be decorated.

  FIG. 5 is a somewhat detailed schematic diagram of the apparatus 90 of the present invention. A part 92 having an asymmetric edge 94, a side wall 96, and an upper edge 98 is shown, and the part 92 is attached to the part holder 100. A mandrel 102 attached to a mandrel holder 104 is shown and a mandrel heater 106 is also shown. The mandrel heater 106 is used when the adhesive layer of the film is activated by heating, and is not necessary for a pressure sensitive adhesive, epoxy, or the like. Film 108 attached to film unwinder 110 and film winder 112 is shown. Although the film 108 is illustrated as a roll, the simplest form of film 108 is a first edge 114 attached to the film unwinder 110 and a second edge attached to the film winder 112. 116. As shown, the mandrel 102 and mandrel holder 104 rotate. On the other hand, the part 92 and the part holder 100 rotate in opposite directions. The film unwinder 110 and the film winder 112 can also rotate to feed the film 108 between the mandrel 102 and the part 92. Film unwinder 110 and film unwinder 112 can be rotated continuously or only during the processing of each part, i.e. during indexing. Further, a new film sheet can be inserted between the film unwinder 110 and the film winder 112 for each part to be processed. In this case, the film unwinder 110 and the film winder 112 do not require rotation.

  As shown in FIG. 5, the film unwinder 110 and the film winder 112 need to be able to freely rotate around the shafts 111 and 113. If these can only move left and right or only up and down around the axes 111 and 113, they are considered as two-dimensional motion. If these can move both up and down and left and right around the axes 111 and 113, it is a three-dimensional movement. Without being bound by any theory, as the angle of the asymmetrical edge changes around the part and the part holder (or mandrel, or both) moves to compensate for this angle change, the film It is known that stress is applied to the. This stress is not experienced when coating flat parts or even frustoconical parts. This is because the angle between the film, mandrel and part is unchanged.

  As used herein, “operating in cooperation” means that at least one of the film unwinder or film winder operates in two dimensions and changes in parts having mandrels and asymmetric edges. Meaning to deal with the angle to do. Preferably, both the film unwinder and the film winder operate in two dimensions, more preferably at least one of the film unwinder or film winder operates in three dimensions, and even more preferably Both the film unwinder and the film winder operate in three dimensions. The method of operation of the film unwinder and film winder that relieves stress on the film during the film application process depends on the shape of the individual parts. While the intent and purpose of the present invention is to address parts with edges that change angle at least once during the film application process, it should be understood that the degree and number of changes will vary from part to part. However, as a general principle, the device keeps the mandrel surface area generally parallel to the edge of the part to be coated, and the film enters the gap between the mandrel and the part to some extent (ie, without kinking). As such, it is best to feed the film. Similarly, if the film is indexed (not continuously fed), the film can still be manipulated to maintain a parallel relationship with the mandrel / part edge interface in a generally flat state. . One skilled in the art can use this general principle to program the operation of the film unwinder, film winder, or both for individual asymmetric part configurations. Methods of operating mechanical devices such as film unwinders and film winders of the present invention are known to those skilled in the art. Air motors, servo motors, etc. can be used to operate the film unwinder and film winder, while the controller using the computer can adjust the operation to the changing angle of the mandrel and parts holder. it can.

System The device of the present invention can be in stand-alone operation or can be used in a system with known components, i.e. as one module in a system comprising at least two modules. Other modules for use with the module device of the present invention include devices for coating parts with symmetrical edges, devices for applying labels or transfer seals, devices with deformable mandrels for coating non-planar surfaces, etc. However, it is not limited to these. In the system of the present invention, the parts move in a predetermined order from one module to the next until the desired decoration or protection level of the part is achieved.

  The advantages of the modular system are that many different decorative or protective coatings can be applied to a single part without having to change the film between each process, the individual coating process is staged to achieve an optimal appearance, And the ability to provide the most efficient overlap between coatings in each step, and the ability to form layers of films, transfer seals, labels, etc. in a continuous flow from the beginning to the end of the operation. . FIG. 6 shows a part 120 that is a jar or bottle cap for purposes of illustrating the advantages of the system claimed herein. The part 120 has an inclined edge 122, a planar side wall 124, and an upper edge 126 that is concave. As shown, all three edges have different decorative coatings and a label 128 is present on the decorative surface of the concave upper edge 126. By changing the decoration material four times, the part 120 can be decorated and pasted in four steps at one station including one device. This inefficient process can be eliminated by using a four module system according to the present invention.

How to use The method of coating a part that contains an asymmetrical edge consists of placing the film on the asymmetrical edge of the part and then on the mandrel with the film sandwiched between the part and the mandrel. Rotating the part. In this method, either or both of the mandrel and part holder operate in an angular relationship with each other. The asymmetric edge changes angle, but the film preferably changes direction as well. To accomplish this, the film edges are held together by a film unwinder and film winder that work in concert to match the changing angle of the asymmetric edges of the parts coating the film. It is preferable. Methods of operation to achieve proper film alignment have been described above.

Parts The parts of the present invention may be selected, for example, from the group consisting of bottles, jars, top lids, pumps, lids, consumer products, and combinations thereof. Examples of consumer products include, but are not limited to, razors, toothbrushes, electric brushes, skin care devices, electric razors, appliances, and the like. The parts can be made of any known plastic and other polymer compositions, naturally derived compounds such as rubber, metals, and other manufacturing materials known to those skilled in the art. Similarly, the parts can be manufactured by methods known to those skilled in the art. Molding and high gloss molding are preferred examples of parts production. On the other hand, forging, thermoforming and the like are also preferable methods for forming the parts of the present invention. The asymmetrical edge can be molded into a part and can be physically pressed, chemically etched, cut or inset, or made by any other method known to those skilled in the art.

  In addition, the parts of the present invention have asymmetric edges that are coated with a thin film as described herein. FIGS. 7-10 illustrate exemplary and non-limiting parts of the present invention. FIG. 7 shows a jar 130 having a lid 132 with an asymmetric edge 133 decorated with a thin film 134. In this example, the part according to the invention is a lid 132. If the lid 130 has a decorated asymmetrical edge, this can also be a part according to the invention. FIG. 8 illustrates a transparent plastic top lid 140 having an asymmetric edge 143 with a thin film decorative coating 144. As will be apparent to those skilled in the art, the top lid is typically used to protect or conceal a pump or the like. FIG. 9 shows a jar 150 with a transparent top lid 152 having an asymmetric edge 154 with a thin film decoration 153. In addition, a pump 156 is shown below the top lid 152. Pump 156 has an asymmetric edge 158 with a film protective coating 157. FIG. 10 illustrates a jar 160 and a pump 162, which has an asymmetric edge 162 with a protective film coating 163. The parts illustrated in FIGS. 7-10 are merely exemplary and those skilled in the art will appreciate the myriad parts and consumer products that can implement this unique technology.

  All references cited herein, including any cross-references or related patents or patent applications, are hereby incorporated by reference in their entirety, except where expressly excluded or limited. Citation of any document is not an admission that such document is prior art to all inventions disclosed or claimed in this application, and such document alone or in all other references. And no reference to, teaching, suggestion or disclosure of any such invention in any combination thereof. Further, in this document, the meaning assigned to a term in this document if the scope of any meaning or definition of the term contradicts any meaning or definition of a similar term in a document incorporated by reference. Or it shall conform to the definition.

  While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. Accordingly, it is intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

Claims (12)

A method of coating a part having an asymmetric edge with an apparatus having a parts holder and a mandrel ,
a. The step of holding the parts by the parts holder;
b. Sandwiching a thin film between the part and the mandrel;
c. Rotating the part in the opposite direction with respect to the mandrel so that the film contacts the non-target edge of the part;
d. As the angle of the asymmetrical edge of the part changes, either or both of the mandrel and the part holder operate in angular relation to each other . The device is
e. A film unwinder,
f. The method according to claim 1, further comprising a film winder. The method of claim 2, wherein the film unwinder and the film winder operate in two or three dimensions in cooperation with the parts holder. The method of claim 3, wherein the film has a first edge and a second edge, and the film is a decorative coating, a protective coating, or a combination thereof. The method of claim 1, wherein the film is a multilayer film comprising a support, a release compound, a metal foil, and an adhesive. The film unwinder holds the first edge of the film, the film is disposed between the mandrel and the parts holder, and the film winder holds the second edge of the film. 5. The method of claim 4, wherein holding and both the film unwinder and the film winder are rotated. The method of claim 6, wherein both the film unwinder and the film winder rotate such that the film moves along the side between the mandrel and the parts holder. The film unwinder and the film winder are tertiary with respect to the part holder when the part rotates to relieve stress on the film while the angle of the asymmetric edge of the part changes. 8. A method according to any one of claims 2 to 7, wherein the methods operate in concert. The film unwinder and the film winder are continuously rotated while the parts are rotated, and the film is continuously fed between the parts and the mandrel. The method according to one item. 10. The film unwinder and the film winder are stationary while the part rotates, and rotate after the part is coated to provide a new film surface. The method according to one item. 11. A method according to any one of claims 2 to 10, wherein the mandrel is rotated, heated and deformable. 12. The method according to any one of claims 2 to 11, wherein the part is selected from the group consisting of a bottle, a jar, a top lid, a pump, a lid, a consumer product, and mixtures thereof.

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