JPS63170099A - Method of decorating three-dimensional molded product - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION Field of the Invention The present invention relates to in-mold decoration.
The present invention relates to a method for decoratively molding three-dimensional plastic products using a technique similar to that of Oration).

(Description of prior art) Decorative markings are added to the product during the molding process.
BACKGROUND OF THE INVENTION It is widely known to apply decorative marks, eg, to decorate various molded products using in-mold decoration techniques. This technique works by feeding a strip with at least one decorative mark into a mold for forming the product. The strip is indexed into position so that the decorative mark is aligned with the predetermined position on the product, and the product is then pressed against the decorative mark and shaped. The transferred decoration is then trimmed to form the final product by appropriately cutting out the remaining portions of the strip.

Standard in-mold decoration techniques have various drawbacks, especially when used in high speed continuous molding processes. For example, the thermal transfer material bearing the decorative marks had to be larger in size than the decorative marks, and the amount of plastic film needed for the decoration had to be greater than necessary. Furthermore, excess plastic film adhering to the final product would detract from its appearance.

Various attempts have been made to remove excess plastic film from decorations, but all are done after the molding process. This is because pre-cutting or drilling the strips results in breakage of the strips during the molding process and misalignment of the decorative mark with the molded product.

Similarly, excess film can be removed from a molded product, but this often results in the remaining decorative marks being torn off or broken, or even damaging the product itself, reducing the chance of rejects. is very high.

Prior art relating to in-mold decoration is disclosed in U.S. Pat.
, No. 663. These patents also describe the process of in-mold decoration, but their focus is on transferring the dye from the transfer sheet through the polyolefin film to the thermoplastic sheet. This is done using heat and pressure to sublime the dye from the film into the plastic sheet.

Similarly, U.S. Patent No. 3.2 issued to Mr. Wolfmann
No. 92.209 and U.S. Pat. No. 3,816.207 to Robertson et al. disclose various devices for use in transfer decoration. Mr. Wolfmann aimed to improve the apparatus for carrying out the method disclosed in U.S. Pat. The parison is inflated and welded. The apparatus shown by Mr. Wolfmann was complex and precise, and had to be used to ensure reliable positioning of the decorative marks on the product being molded.

The importance and complexity of in-mold decoration techniques work against their use in applying composite decorations, which are of current interest in the packaging field. For example, composite decoration is desirable for products containing three or four different printed marks, including reproductions of photographs suitably decorated with metallized layers and prone to a wide range of colors. The application of complex or composite decorations of this type requires the use of multi-step printing techniques, such as screen printing techniques, all of which require time to align the images of each decorative element. It costs a lot of money.

To date, the inventors have developed thermal transfer materials (boL tra
nsfer 5tock) was considered, but it was found that pre-cutting would be more cumbersome for use as a continuous in-mold decorative film. Specifically, if all or part of the material was pre-cut, the decorative portions of the stock could peel off or fail to maintain a predetermined alignment, especially when performing in-mold decoration at a profitable speed.

Cutting out the transcription, i.e. tycanto (di
Although e-cutting (e-cutting) is also known, this was applied only to pressure-sensitive labels. Representative prior patents related to die-cutting include U.S. Patent No. 2,391.539 to Mr. Avery, U.S. Patent No. 3.166.186 to Mr. Kahn, and U.S. Patent No. 3.166.186 to Mr. Pretty. U.S. Patent No. 4,236,955
The number is mentioned.

These three patents relate to crimp label stock applied onto a peel base, which is perforated or cut out completely by die-cutting, so that the labels adhere to each other before use. It can be easily removed from the base for attachment to a given substrate, without adhering to other objects.

Applications of die-cutting techniques to plastics have also generally been unsuccessful. Particularly when the plastic film is 3-10 mils thick, the precision of most die-cutting equipment does not allow the cutting edge to pass through the first film and into the second or carrier film. Similar difficulties have been experienced when die-cutting, perforating, etc. a single film. It has been found that die-cutting techniques, which are well known in the art of label manufacturing, are rarely able to meet the tight tolerances required in the thermal transfer field.

To solve the above problem, the applicant in US Patent Application No. 401,275 applied the desired decoration to the carrier film to form a thin layer (laminate), and then
He suggests a careful tie cut. after that,
The unnecessary parts of the transfer area are peeled off and the resulting carrier film is indexed into a mold in which the decoration is thermally transferred to form the final plastic product. This technology is an innovative starting point in decorative technology in that it is possible to continuously die-cut thermally transferable marks and continuously perform decoration by transfer inside a mold.

The present inventors considered applying the method described above to three-dimensional products manufactured by insert molding. Insert molding involves first creating a thermoformable base, layering a decorative surface, for example a metallized layer, onto said base, and then shaping the base with heat and pressure to form the shell of the final product. It is something to do. The shell is
It is typically indexed into either an injection molding chamber or a blow molding chamber, where the remainder of the final plastic product is pressed against the underside of the shell and molded.

In order to apply the above-mentioned in-mold transfer technology to insert molding, the transfer material and the insert must be precisely aligned in the mold, but it is difficult to implement this on a commercial basis.

In the case of insert-molded products, according to the prior art:
It is only possible to individually align the thermal transfer material and insert within the mold, which is time consuming and impractical from a financial standpoint.

Therefore, it is desired to develop a technique that can continuously decorate products by insert molding.

If it were possible, it would bring many advantages to the in-mold decoration technology already proposed by the applicant.

SUMMARY OF THE INVENTION The present invention discloses a method for making die-cut decorative films useful in continuous insert molding processes. The method of the present invention produces a composite, such as a laminate, of a thermoformable carrier film useful in a thermal transfer decoration process and a thermoplastic transfer film that serves as a decorative substrate. form,
The final insert is decorated, thermoformed, and then die cut from the transfer film on the carrier. The transfer film may be die cut before, during or after thermoforming, and may also be die cut within the molding chamber or after exiting the molding chamber.

The carrier and transfer film are first formed into layers by applying heat and pressure. Alternatively, the transfer film solution may be used to coat the carrier. A decorative mark is then printed on the composite, on at least a portion of the free surface of the transfer film. A decorative mark can be applied in one printing process, but in the case of a composite decorative mark, it may be applied in multiple processes. The decorative marks can be arranged regularly and at regular intervals.

It is also possible to place multiple identical decorative marks on the composite strip. The printing process may also include first properly superimposing the colored decorative marks, followed by brating or metallized decoration.

After applying the decorative marks, the decorated composite is die cut. Die-cutting is performed in a controlled manner so that the die does not penetrate into the surface of the carrier film, but completely penetrates the thickness of the transfer film.

However, if a perforated insert is desired, the two films can be die-cut and the die-cuts discarded.

Once die-cutting is complete, unnecessary portions of the transfer film are peeled off as necessary, leaving only the decorative portions of the transfer film on the continuous carrier film. When die cutting is performed prior to thermoforming, the transfer film is indexed into thermoforming equipment where heat and pressure are applied to form the transfer film into a three-dimensional shell or insert.

The shell or insert remaining on the carrier is then indexed into a molding chamber where the remainder of the final product is molded.

The final product is molded using molding techniques compatible with insert molding, such as injection molding and blow molding.

In another embodiment, the carrier with the decorative transfer film can be first thermoformed and then die cut to remove unnecessary material. In this embodiment, the die cutting can be done in the thermoforming chamber, or alternatively can be done in or after the final product forming chamber.

The thickness of the carrier film of the present invention is arbitrary and the material should be selected from thermoplastics useful in thermal transfer processes, non-elastic restoring materials, and vacuum formable. Examples of the material include polyester,
Examples include polycarbonate and cellulose derivatives. The film may be transparent or translucent and have a thickness of 0.5 mil or more, depending on the shell or insert from which it is made. Suitable thermoplastics include polyvinyl chloride and mod
if 1ed) polyurethane, acrylic polymer,
Cellulose esters such as cellulose acetate may be mentioned.

Laminated construction of the carrier film and transfer film is accomplished by passing the two films through a nip of heated rollers at speeds up to 200 feet per minute. The resulting layer is then printed by one or more printing steps. The latter is used when multiple colors or combinations of colors are desired. At the same time, by providing index marks on the transfer film, positioning in one step of subsequent thermoforming, die cutting, and insert molding 16 can be ensured.

When using many colors, if metallized decoration is applied later, apply a sizing coat (siziB) after the metal decoration.
It is desirable to apply a coat. Sizing coats can be selected from a variety of compositions, including IF polyurethanes, polyolefins, acrylic polymers, and vinyl polymers. In this case, it is desirable to apply a sizing coat to the entire surface of the transfer film.

Wherever die-cutting is performed, it is accomplished by indexing the decorated composite in the appropriate position with the aid of index marks applied during the printing process. When die-cutting only the transfer film, the cutting edge completely penetrates the transfer film, but the hardness of the die must be adjusted so that it does not penetrate into the surface of the carrier film.
Slope and temperature are carefully controlled. Within the above parameters, a heated mold with beveled cutting edges and a cold anvil are operated. Daikan 1
What is important in the embodiment in which - is carried out continuously is "Skel 1
There is a need to continuously remove unnecessary parts of the film, referred to as "-", from both the carrier film and the mold gap in which the skeleton parts fit. The "skeleton" can also be passed through an idler roll to remove the skeleton from the layer.

The final product emerges from the mold with a complete array of desired decorations. Post-processing of the product, such as trimming the decoration to remove excess heat transfer material, is not necessary unless it is desirable and practical to perform the die cut after molding. This is because the decoration is an integral part of the insert or shell. The resulting decorative pattern therefore has an improved appearance.

Since the invention combines the decoration and molding processes and can be operated continuously at economically desirable speeds, the technology of the invention is economically very attractive. . Applying decoration by thermal transfer according to the method of the present invention is equally economical in that relatively simple equipment can be used and the number of steps can be reduced. Furthermore, the technology of the present invention
- The molding can be replaced as a separate process.

It is therefore a primary object of the present invention to define a method by which a decorated thermal transfer material can be used in a continuous insert molding decoration process.

It is a further object of the present invention to demonstrate a method by which a decorated thermal transfer material can be made from relatively thin layers of plastic material and die cut prior to thermal transfer.

The invention further aims to define a method for continuous in-mold decoration of insert-molded products.

It is a further object of the invention to define a method that is simple and economical to operate.

Other objects and advantages of the invention will become apparent to those skilled in the art from the following description based on the illustrative drawings. DETAILED DESCRIPTION OF THE EMBODIMENTS In its broadest sense, the method of the present invention forms a composite comprising a thermoformable carrier film and a thermoplastic transfer film, the transfer film comprising: a thermoformable carrier film; is provided as at least a part of the outer surface and shell of the plastic product through the subsequent molding process. In one embodiment, the compound is a layer of two films stacked on top of each other, as described below in conjunction with the accompanying drawings.

The formed composite is printed with marks or patterns on the exposed surface of the transfer film and then thermoformed into the shape of a shell or insert. transfer film
r fil+n) is die-cut before, during or after thermoforming, or after molding, to separate the decorative portion of the transfer film from the unnecessary portion of the transfer film, referred to as the "skeleton". If desired, the skeleton can be removed leaving behind the decorative portion of the transfer film adhered to the carrier film. When die-cutting is performed prior to molding, the carrier film is indexed into and neatly aligned within the plastic product mold, allowing for a combination of continuous in-mold decoration and insert molding of the molded plastic product.

Carrier films useful in the method of the present invention are those types of films that are capable of being thermoformed and capable of maintaining their formed shape. The latter property is based on the fact that it does not have the property of elastic restoring force. A resin film having the property of elastic restoring force is one that can recover its original shape after a certain period of time. Therefore, the carrier films useful herein are not intended for reuse as in Applicants' prior applications.

Additionally, the carrier film may be vacuum deposited.
It should be able to be processed using a variety of printing techniques, including etal 1zation). Suitable materials include films made from materials selected from the group consisting of polyester resins, polycarbonate resins, and cellulose derivatives, including cellulose esters and ethers and copolymers thereof. Specifically, polyester includes polyethylene terephthalate, and polycarbonate includes acrylonitrile-butadiene-styrene resin. Cellulose derivatives include cellulose acetate, cellulose acetate butyrate, ethylcellulose and viscose, also known as "cellophane", with cellulose acetate being preferred.

The carrier film has a wall thickness of about 0.5 mil or greater, preferably about 3 mil or greater. Examples include a range of 0.5 mil to about 7 mil. The exact thickness of the carrier film is determined by the processing of the transfer film, the specific thermoforming and final forming methods, and the product being made.

The transfer film must likewise be thermoformable, and its materials include vinyl resins, modified polyurethane resins, and acrylic homopolymers (BO+NOPO
thermoplastic resins selected from the group consisting of polyolefin resins, including substituted resins and unsubstituted resins, and copolymers.

More specifically, vinyl resins include polyvinyl chloride, polyvinyl acetate, polyvinyl alcohol, and copolymers thereof.

Acrylic polymers include polyacrylic acids such as polymethyl methacrylate. Polyolefins include polyethylene, polypropylene, polystyrene, and the like. Polyurethanes include bisphenol A-epichlorohydrin derivatives and the like.

It is desirable that the transfer film be transparent, but it may also be semi-transparent with an appropriate coloring to provide a different visual effect. The transfer film, like the carrier film, has a thickness of 0.5 mil or more, but the thickness can vary depending on the plastic product to which the transfer film is attached. Thicknesses in the range of -3 mils are exemplified.

Layering the transfer film onto the carrier film may be accomplished simply by applying heat and pressure. Alternatively, it is within the scope of the present invention for the transfer film to be applied to the carrier film as a molten liquid or by applying the liquid to a roller and then dried and cured. 1st
The figure shows the state in which the carrier film and the transfer film are pressed together, and the carrier film (2) and the transfer film (4) are fed out from the respective reels (6) and (8), and the pressure rollers (10) and (12) Between the nips they are brought together to form a layer or laminate (14). A cross section of the laminate is shown in FIGS. 2 and 3.

As shown in FIG.
) is formed under heat and pressure in the nip between the carrier film (2) and the transfer film (4), creating a peelable surface bond between the carrier film (2) and the transfer film (4). For example, roller (10) (
12) is heated to a temperature range of about 180 DEG to about 350 DEG F. and adjusted such that a pressure in the range of 40 psi to 100 psi is applied to the carrier film (2) and the transfer film (4). Temperature is measured by pressure roller (10) (12
), and each film (2) (4
) is passed through the nip of rollers at commercial scale speeds up to about 200 feet per minute.

FIG. 3 shows another embodiment of lamination (14). In this case, the carrier film (2) is provided with a peelable adhesive coating (16) at a suitable room temperature, and the carrier film (2) and the transfer film (4) are held together during further processing. The contact state is maintained. However, this can be removed by the application of mechanical force, by peeling off the "skeleton" as described below, or by the application of heat from thermoforming of the insert or subsequent shaping of the final product. Suitable materials that serve as releasable adhesives include thermoplastic monomers and polymers, including cellulose ester ethers and vinyl compounds. For example, nitrocellulose can be used as an adhesive release coating. The coating thickness is less than 1 mil and is formed as shown in FIG.

In a preferred embodiment of the invention, a composite or laminate (
14) is a polyester carrier film approximately 2 mils thick with a transfer film approximately 1 mil thick (
pigI? y backed). It should be noted that the above-mentioned wall thickness dimensions are merely exemplary and do not limit the present invention, of course. After molding, the composite is suitably printed with the desired decorative marks. A typical printing station (18) is shown in FIG. 1 and includes a printing roller (20), an idler roll (22) and an ink supply roller (22).
It also rotates, transferring a thin film of ink from the ink reservoir (26).

A desired decorative mark or pattern is suitably formed on the printing roller (20), thereby causing the transfer film (
4) The desired decoration is applied on the free surface.

Figure 4 shows an embodiment in which it is preferable to die-cut and pre-trim the individually decorated portions of the transfer film (4), with suitable index marks (2).
8) is printed on the transfer film (4) during the printing process, and the index marks serve to help align the composite during die-cutting. In this way, as shown in Figure 4, the index mark (
28) are regularly arranged at regular intervals from the decorative marks (30).

In Figure 4, the decorative mark (30) is replaced by the index mark (
It shows a state in which they are placed regularly at a certain interval from each other in the same way as for laminate (1).
4) Indexing can be performed sequentially in the mold, thereby ensuring that the decorative marks (30) are aligned and accurately transferred during the molding process.

The dimensional accuracy and position of the decorated insert in the final product depends on its alignment within the vacuum forming chamber during the thermoforming process described below. The importance of index marks in this added capacity can be appreciated.

Another embodiment of the printing station is shown in FIG.
The stations sequentially apply different colors, patterns, etc. to form a complex decoration.

As shown, printing stations (32), (34), and (36) are provided at regular intervals for passing the composite or laminate 1-(14). The printing stations (32) (34) (36) carry patterns and/or colors individually, and mixtures of colors or patterns are superimposed, blended or combined with each other. If a printing roller is used, the printing ink etc. applied to the surface of the transfer film (4) should be of a type that dries on contact to prevent bleeding into the various colors of neighboring printing stations. For example, when printing by means other than pressure type, such as jet printing or screen printing, such "bleeding" does not pose a problem.

The present invention requires the use of a technique known as "reverse printing," which is one type of multicolor printing.

That is, when decorating a substrate with multicolor printing, the colors are applied in such an order that the last color added is the topmost part of the decorative material. However, if the decorative material is applied to the underside of the film, this order must be reversed, and therefore "reverse printing" must be used. Thus, the illustrated printing station (32) is the topmost color and pattern, and the printing stations (34) and (36) overlap each other to provide the middle and base colors and patterns, respectively. In this way, when a composite decoration is applied to the surface or substrate of a plastic product, the respective printed or colored layers are properly arranged.

As shown in FIG. 1, the printing process can also include a metallized coating as the "base" of the decoration.

At this time, the decoration may include borders and lettering.

Applying at least one color by the above-described technique, leaving certain areas unprinted and later applying a metallized layer to form decorative borders and/or lettering. There is also often Of course, it can also be printed in different colors to achieve the desired effect as a decorative material. Furthermore, the present invention is not limited to providing metalized layers at arbitrary locations. The foregoing description is exemplary only.

In Figure 1, when applying a metallized coating,
The printed composite (38) is attached to the idler roll (40)
(42) and is wound onto a pick-up roll (44). Next, it is fed out from the pick-up roll (44) and passes through the metallizing station (46),
A metallized coating is formed at appropriate locations on the surface of the already printed composite (38). Although idler rolls (48) and (50) are shown, these may be provided as needed. Metal coatings (metallization) can be performed using conventional techniques such as vapor deposition. The present invention is not limited to any particular metal coating method; other metal deposition techniques known in the art may be used. can be deposited to form a tightly adherent continuous coating. Such metals include noble metals and non-noble metals, and examples include gold, silver, tin, zinc, chromium, and aluminum. For example, when using aluminum, approximately 4
Coatings with thicknesses in the range of up to 0.000 angstroms can be formed. The exact thickness of the layers is arbitrary. Similarly, regarding the above explanation regarding printing,
The coating thickness for each color can generally vary in thickness on the order of 1 or 2 mils.

When forming a metal coating, a sizing coat is applied before die cutting of the composite (52) on which the metal coating is formed.
ng) is desirable. In FIG. 1, the sizing coat is applied at a coating roller station (54) and can vary in thickness up to several microns. Sizing compositions useful in the practice of this invention include vinyl polymers, acrylic polymers, polyolefins such as polyethylene, and polyurethanes. The sizing coat maintains the integrity of the metal coating during thermoforming and die cutting.
This can prevent damage to the edges.

Because sizing coats reduce the adhesion of the final decorative material, washcoats (U+
asl+ coat) or tie coat
t) may be applied. However, the application of a washcoat is entirely optional and depends on the extent to which the decorated composite is exposed during the insert molding process.

After being coated with the transfer film (4) in any of the embodiments described above, the decorative composite is then indexed into the appropriate position for die cutting. As will be explained later with reference to FIG. 8, die-cutting can be delayed and performed during thermoforming, or it can be performed during or after the final molding.

Figures 1-6 show an embodiment of a die-cutting station (56), which station includes a transfer film (56).
4), and an anvil (60) is provided in contact with the free surface of the carrier film (2). When the laminate is positioned in the station (56), the cutting blade (58) and the anvil (60) approach each other and the action of the cutting blade (58) creates a cut through the entire thickness of the transfer film (4). It is formed. At this time, care is taken not to invade the surface of the carrier film (2) that is in contact with the underside of the transfer film (4). This is important when it is desired to trim the outer margin of the insert.

As mentioned above, it is important to have a precise structure of the station (56) and to perform its functions accurately in carrying out the die cutting process. Specifically, FIG. 6 shows a die cutting station (56) which may include a cutting edge (58) and an anvil (60) as well as a support surface (62). The support surface (62) limits the movement of the cutting blade (58) and ensures that the cutting blade (58) is stopped without penetrating the carrier film (2). Carrier film (2
) to the aforementioned sizes, the support surface (62) must be made from a material with tight tolerances and good hardness to maintain dimensional stability.

Similarly, the cutting edge (58) must have good hardness to ensure cutting quality and dimensional stability during high speed operation. This causes the cutting edge (58) to move from the carrier film (
2) The effect of completely penetrating the transfer film (4) without penetrating is performed uniformly.

Therefore, for example, the cutting edge (58) is formed with an appropriate acute angle, the outer surface is hardened by chrome plating, etc.
This ensures dimensional stability and process uniformity.

Another embodiment of the die cut station 56) is shown in the sixth (6)
21. This is provided with an ejector means (67) in contact with the cutting blade (58), which appropriately removes any unnecessary parts of the transfer film (4) stuck to the cutting blade (58) after the cutting process. This prevents the cutting station (56) from becoming clogged or damaged. This ejector means is useful if the final transfer material is donut-shaped, since the central part of the transfer film (4) must be removed. Although not shown, evacuation can be accomplished by pneumatic, vacuum, or mechanical means. The choice of ejector means is not critical to the invention and can therefore be varied within the scope of the invention.

As previously mentioned, die cutting can also be performed to completely remove a portion of the composite, such as a finished product with holes. Examples of such products include automotive tri+n pieces that require other hardware to protrude from the molding. In this case, although not shown, the die cutting station may include a punch or stamp member that completely cuts through both the carrier and the transfer film to form the desired opening. Such drilling devices are known and can be fitted with vacuum or pneumatic means to remove the drilled portion of the composite from the remainder of the insert. "This device carries out the invention" is based on the obligation to disclose the best form ffJ, which a specialist in the field may be able to name, It does not constitute a part or part.

Once the tie-cutting process is complete, the decorated transfer material is transferred to a transfer film (4
> are separated from unnecessary parts. Carrier film
No. 7I21 shows a state in which the decorated transfer material 66) is left in 2) and the sugelton (64) is removed. Stell 1~n (64) is as shown in No. 1121,
The die-cut laminate is an idler roll (70
), it is pulled and peeled off by a suitable tick-off reel (68) shown in FIG. In this way, the die-cut transfer material (6G) is transferred to the carrier film (2
) is held at an appropriate position along the

Alternatively, the insert can be molded after the die cut is made and before the skeleton is removed.

These embodiments are also within the scope of the present invention.

As shown in FIG. 1, the transfer material (66) is thermoformed to form the product insert or shell (88'). The transfer material (66) is indexed into a thermoforming station (80). The station (80) is provided with a female mold half (82) in a lower position of the vacuum molding chamber, and at least one air outlet line (84) is provided to open the mold half (82).
) and the transfer film (66). The mold half (82) is formed with a smooth female mold surface (86), onto which the transfer film and its carrier are pressed.

The upper mold half (88) of the vacuum forming chamber (80) also serves as a means for applying heat to the transfer film (66), which softens the transfer film (66) and causes the surface (86) of the female mold to soften. It becomes easier to move in one direction. Entrance line (
For example, heated inert scum is introduced from 90) and applied to the transfer film (66) to soften the film, thereby facilitating the movement of the female-shaped surface (86)/\. After thermoforming is complete, transfer film (66
) constitutes the shape of at least a portion of the final three-dimensional product and appears as an insert or shell (66'), ready for final molding.

The foregoing description of vacuum forming is provided in a general manner and is for illustrative purposes only; the details of the equipment and operation used in vacuum forming are known in the art and may not be used. It does not itself form part of the invention. Furthermore, vacuum forming is only one technique for thermoforming plastic materials, and the present invention includes within the scope of the present invention other techniques such as hot stamping and blow molding.

In Figure 1, the insert (66') is removed from the thermoforming station (80) and then introduced into a suitable mold assembly (72) where it is inserted into the insert 1 of the final plastic product. Molding is performed.

The technique of in-mold decoration is known in the art and is described in U.S. Pat. ．． No. 202,663 and No. 4°0'59.
No. 471 each partially deals with in-mold decoration. However, the decoration method of the present invention differs in that the entire decorated transfer material (66) is formed into an insert (66'), which is permanently adhered to the rest of the molded product. This closes the mold and
This is done by inserting additional plastic material and applying appropriate heat and pressure. It is noted that this technique is one aspect of the in-mold decoration technique described herein.

Another embodiment of the invention is shown in FIG. The die-cutting of the transfer film (66) can be performed in a different process and at a corresponding position to that described above. That is, once the initial laminates 1-(52) have been formed, they will be intexed directly to the thermoforming station (80) where the shell or insert 1-(66') will be formed.

Die-cutting of the shell or insert (66') can be done in one of the four locations illustrated. 1st
and a second position, die cut station 56
) can be structurally coupled to either the thermoforming station (80) or the mold assembly (72). In the third embodiment, a die cutting station (5
6) can be provided between the two stations shown in FIG. In a fourth embodiment, a quick cut station (56) can be provided beyond the mold assembly (72) so that excess film can be removed after the final product is fully formed. . The exact position of the die cutter 1 station can be changed in this manner.

The in-mold decoration and final product molding techniques utilized in accordance with the present invention can vary depending on the plastic product and its method of manufacture. For example, the 4th and 20th
As shown in the No. 2,663 and No. 4,059.471 patents, plastic products may be heat stamped into the final shape of sheets, blocks, etc., or alternatively, placed in a mold cavity and blown. Parisons are suitable for forming hollow products. In all embodiments, the carrier film carrying the decorated transfer or insert material is indexed into the mold cavity and the printed mark or pattern is placed on the outer surface of the molded plastic article, where The transfer material and the surface of the plastic article in contact therewith are brought into contact and bonded together under pressure at a temperature sufficiently high to permanently bond.

Apparatus suitable for performing in-mold decoration is disclosed in U.S. Pat. No. 3,292,209 to Borfmann.

An advantage of the present invention is that the plastic snack product is manufactured from a continuous hese based on fin insert molding technology by creating a continuous piece of preformed and/or precut decorative inserts. The objective is to index easily and accurately when applied to Because the method of the present invention allows precise positioning of the decorative transfer material on the carrier film, a large number of coach inks can be easily and inexpensively applied to the decorated plastic product. Processing can also be omitted.

The present invention may be embodied in other forms without departing from its spirit or character.

Furthermore, the disclosure of the present invention is provided by way of example only, and is not intended to be limiting. shall be construed to include all changes therein.

[Brief explanation of the drawing]

Figure 1 is a schematic diagram showing the steps of the method of the invention in sequence;
(2I is a sectional view taken along the 11th line I-■, showing the first compound sound formed based on one embodiment of the present invention, and FIG. 3 is a cross-sectional view of another Lamy-- FIG. 4 is a sectional view similar to FIG. 2 showing the index marks according to the present invention, and FIG. 4 is a plan view of the area indicated by the line ■-■ in FIG. FIG. 1 shows a plurality of printing stations according to an embodiment of the invention.
6 is an enlarged sectional view similar to the line section 1, and FIG. 6 is an enlarged sectional view taken along the line 2--2 in FIG. 8 shows a state in which the skeleton and the laminate are separated from each other, and is a perspective view of the portion indicated by the line ■-■ in FIG. 1. FIG. 1 is a schematic diagram similar to FIG. (2) Carrier film (4) Transfer film (18) Printing station (38) Printed composite (44) Tick-up roll (46) Metallizing roll (52)...Composite with metal coating (54
)...Coating roller station (56)...
Die-cut station (58)...Cutting blade (60)...Anvil (66)...Transfer material (66')...Insert (68)/tique-off reel (72)...Mold assembly (80) ...Thermoforming Station Applicant Transfer Printed Foils Inc. FIG-2 FIG-4 3Q 30F/G
-5 Procedural amendment [spontaneous] February 23, 1988 1, Indication of case: Japanese patent application No. 61-3159952, Title of invention: Decoration method for three-dimensional molded products, Inc. 4, Agent: Osaka City, 535 4-10-1 Nakamiya, Asahi-ku
No. 2 No. 5, Drawings subject to amendment 6, Contents of amendment

Claims (27)

[Claims] (1) (a) forming a composite of a thermoformable carrier film and a printable thermoplastic transfer film that can be utilized in a thermal transfer decoration method; (b) forming a composite of a printable thermoplastic transfer film on said composite; printing at least one decorative mark on at least a portion of the free surface of the thermoplastic transfer film; (c) thermoforming the composite of step (b) to improve the outer surface of the final three-dimensionally formed product; (d) die-cutting the insert of step (c); (e) indexing the insert into a molding chamber and pressing against the insert; A method for decorating a three-dimensional molded product, comprising: a step of molding the remaining part of the molded product. (2) The method according to claim 1, wherein the die-cutting step is performed in a mold chamber where insert molding in step (e) is performed. 3. The method of claim 1, wherein the composite of step (b) is first thermoformed and the die cutting step is performed on the formed insert. 4. The method of claim 1, wherein the carrier film is selected from the group consisting of thermoformable polyester resins, polycarbonate resins, and cellulose derivatives. 5. The method of claim 4, wherein the carrier film is selected from the group consisting of cellulose acetate, cellulose acetate butyrate, ethylcellulose, and cellophane. 6. The method of claim 1, wherein the carrier film has a thickness of 0.5 mil or greater. 7. The method of claim 6, wherein the thickness is within the range of about 0.5 mils to about 7 mils. (8) The thermoplastic transfer film is thermoformable and the material is selected from the group consisting of vinyl resins, modified polyurethane resins, acrylic homopolymers, acrylic copolymers, and polyolefin resins. A method according to claim 1. (9) Thermoplastic transfer films include polyvinyl chloride, polyvinyl acetate, polyvinyl alcohol, homopolymers and copolymers thereof; polyacrylate, polymethacrylate, homopolymers and copolymers thereof; polyethylene, polypropylene, polystyrene. , homopolymers and copolymers thereof; substituted polyurethanes and unsubstituted polyurethanes. (10) The method of claim 9, wherein the thermoplastic transfer film has a thickness of 0.5 mil or more. 11. The method of claim 10, wherein the thermoplastic transfer film has a thickness in the range of about 1 mil to about 3 mils. (12) Claim 1, wherein the plurality of decorative marks are regularly printed on the composite material at regular intervals.
The method described in section. (13) A method according to claim 12, wherein the composite is a continuous piece on which an indeterminate number of identical decorative marks are printed. (14) During the printing process, during the thermoforming and die cutting process,
Claim 13 including printing at least one index mark on the thermoplastic transfer film spaced apart from the decorative mark to serve as a guide for aligning the composite. Method described. (15) A plurality of index marks are placed on the thermoplastic transfer film at regular and constant intervals with respect to each other and with respect to the decorative marks so that each of the decorative marks is properly aligned during the thermoforming and die-cutting process. 15. A method according to claim 14, printed above. (16) The method according to claim 15, wherein the decorative mark is printed in a single color in one printing pass. (17) The method according to claim 15, wherein the decorative mark is printed in a plurality of different colors. (18) The method of claim 17, wherein the different colors are applied in one printing pass. 19. The method of claim 17, wherein the different colors are applied sequentially at regularly spaced printing stations. (20) The method of claim 19, wherein the different colors are applied in the reverse order of the outermost appearing colors. (21) The method according to claim 16, comprising forming a layer of vapor-deposited metal on at least a portion of the decorative mark. 22. The method of claim 21, wherein after forming the layer of vapor deposited metal, a sizing coat is formed thereon. (23) The method according to claim 22, wherein the sizing coat is selected from the group consisting of polyurethane resin, acrylic resin, vinyl resin, and polyolefin resin. (24) At least a part of the die-cutting is performed in a controlled manner so that it does not penetrate into the surface of the carrier film in contact with the transfer film, but completely penetrates only the thickness of the transfer film. The method described in section. (25) Die-cutting is performed by pressing an appropriately shaped cutting die onto the surface of the composite made of the thermoplastic transfer film, and the composite is pressed against a support anvil during this process. The method according to item 24. (26) The die cutting is performed under a temperature gradient condition in which a low temperature is applied to the carrier film through an anvil, and heat is applied to the thermoplastic transfer film through a cutting blade. Method. (27) The method according to claim 1, wherein the die-cutting step is performed after the insert molding in step (e).