KR101655111B1 - Foil stamped parts having asymmetrical edges - Google Patents

Abstract

A component (92) having an asymmetric edge (94) coated with a decorative or protective coating. The component is coated with an apparatus 90 that includes a film dispenser 110, a film dispenser 112, a mandrel 102, and a component holder 100. Preferably, one or both of the mandrel and the component holder move in a predetermined angular relationship with respect to each other, and the film dispenser and film dispenser move in an interactive manner at least two dimensions relative to the component holder. A film 108 having a first edge 114 and a second edge 116 is additionally provided and the film may be a decorative coating, a protective coating or a combination thereof. The film dispenser holds the first edge of the film, the film is positioned between the mandrel and the component holder, and the film picker holds the second edge of the film.

Description

FOIL STAMPED PARTS HAVING ASYMMETRICAL EDGES < RTI ID = 0.0 >

The present invention relates to a component having asymmetric edges and coated with decorative or protective foil stamping on an asymmetric surface.

Foil stamping on parts for decoration or protection purposes is known. Foils for decorating and protecting parts are also known. The foil is typically a thin multi-layer sheet or ribbon. The layers typically comprise a thin film carrier, a volatile release substance, a colored or protective coating, a metal layer and an adhesive. However, conventional machines and methods of using these machines are typically used on flat, symmetrical surfaces. For example, it is known to cover mated mandrels by simply rolling them over cylindrical and frusto-conical parts. The foil is fed between the part and the mandrel and is uniformly attached to the part. However, since mandrels can not maintain constant contact with asymmetric components, these systems can not handle components with asymmetric geometries.

Moreover, the complex shape can be foil stamped by creating a stamp, which is a negative image of the part to be stamped. Although virtually any shape can be stamped in this manner, there is one inherent drawback to this process. The foil is flat and, when stamped onto a complex feature, the foil must be stretched and folded over, which results in nonuniform coverage. Therefore, there is a geometric limitation for this type of foil stamping.

A flexible deformable stamp is also used to press the foil or label on the asymmetric surface. Soda bottles are often labeled in this manner. However, such flexible deformable stamp pads suffer the same drawbacks as discussed above. When a flat foil is pressed onto a curved surface, the foil must be matched to the surface by folding and stretching. This leads to non-uniform coverage without exception.

There is a need for an apparatus and method that overcomes these and other problems associated with conventional methods and apparatuses. More specifically, there is a need for an apparatus that is capable of applying a thin decorative or protective film on the surface of a component having an asymmetric portion.

The present invention relates to a component having an asymmetric edge, wherein the asymmetric edge is coated with a thin film applied by an apparatus having a component holder and a mandrel, the component is held by the component holder, The part is rolled over the mandrel and one or both of the mandrel and the component holder move in a predetermined angular relationship with respect to each other. The apparatus used to coat the components of the present invention further has a film dispenser and a film dispenser. In addition, the film dispenser and the film dispenser interactively move at least two dimensions relative to the component holder. The apparatus may further comprise a film having a first edge and a second edge, wherein the film is a decorative coating, a protective coating or a combination thereof. The film is preferably a multilayer film comprising a carrier, a release compound, a metal foil and an adhesive.

The present invention provides a component having an asymmetric edge coated with a decorative or protective foil in a fast, economical way resulting in a uniform coating. The components of the present invention do not suffer from the drawbacks of conventional methods and apparatus for stretching or pulling foils on irregularly shaped parts that cause visible stripes on the foil. The ability to coat irregularly shaped components gives designers considerable new freedom in design. Not only can the shape of the new part be manufactured, decorated or protected, but the addition of the various surfaces allows multiple decorations on one part. These and other advantages of the present invention will be apparent to those skilled in the art.

BRIEF DESCRIPTION OF THE DRAWINGS While the specification concludes with claims particularly pointing out and distinctly claiming the invention, it is believed that the invention will be better understood from the following detailed description taken in conjunction with the accompanying drawings, taken in conjunction with the accompanying drawings.

1 is a cross-sectional view of a component having an asymmetric edge;
2 is a cross-sectional view of a component having an asymmetric edge;
Figure 3 shows a prior art mandrel, part and part holder.
Figure 4 shows a mandrel, part and part holder according to the invention.
Figure 5 shows a device according to the invention.
Figure 6 shows a jar with a lid with an asymmetric edge according to the invention;
Figure 7 shows a lid having asymmetric edges that are differently decorated from the remaining surfaces of the lid according to the invention.
Figure 8 illustrates a transparent overcap with an asymmetric edge according to the present invention.
9 shows a block with a transparent overcap and pump with an asymmetric edge according to the invention.
10 shows a block with a pump with an asymmetric edge according to the invention;

The invention may be more readily understood by reference to the following detailed description of illustrative and preferred embodiments. It is to be understood that the scope of the claims is not limited to the specific components, methods, conditions, devices, or parameters described herein, and the terms used herein are not intended to limit the claimed invention. Also, as used in the specification, including the appended claims, the singular forms "a," "an," and "the" include plural forms, At least the specific value thereof. When a range of values is indicated, other embodiments include from one particular value and / or to another specific value. Similarly, it will be understood that when values are approximated by the use of the "about" prod- uct, certain "values" form another embodiment. All ranges are inclusive and combinable.

As used herein, a "part" refers to a container, e.g., a bottle, a jar, an overpack, A lid, such as a container cap, an overcap, etc.; Consumer products such as razors, toothbrushes, electric toothbrushes, skin care devices, pumps, electric shavers, household appliances, and the like. The parts can be made from known plastics and other polymeric compositions, naturally occurring compounds such as rubbers, metals, and other constituent materials known to those skilled in the art. Likewise, parts can be manufactured by methods known to those skilled in the art. Molding and high gloss molding is a preferred example of component manufacture, but stamping, heat forming, etc. are also acceptable methods of forming the components of the present invention.

As used herein, a "part having an asymmetric edge" is best defined by reference to FIGS. 1 and 2. 1 is a cross-sectional view of a generally circular lid 22 for a bottle or the like, according to the present invention. More specifically, in Fig. 1, the lid 22 has an upper edge 12, a first beveled edge 14, and a second beveled edge 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 the line 21 drawn parallel to the first beveled edge 14 to form an angle beta. Likewise, a line 23 drawn parallel to the second beveled edge 16 intersects the line 19 to form an angle a. Thus, to determine if a part has an asymmetric edge, a vertical section is taken through the center of the part, and? And? Are calculated. The part has an asymmetric edge when at least one vertical section through the center of the part results in? Not equal to?. Preferably, alpha is not equal to at least 3 DEG, more preferably at least about 5 DEG and even more preferably at least about 10 DEG. It is understood that alpha or beta may be 90 [deg.]. This will occur when there is no sloping edge (i.e., when the top edge 12 meets the sidewall 18 directly), but if the other angle is greater than or less than 90, even though part of the part, exist.

Turning now to FIG. 2, it is a cross-sectional view of a generally circular lid 32 for bottles, etc., according to the present invention. 2, the lid 32 has a top edge 42, a first beveled edge 34, and a second beveled edge 36. As shown in Fig. The lid 32 further includes a side wall 38, a thread 40 and a bottom 44. The first beveled edge 34 and the second beveled edge 36 are concave and convex, respectively. Figure 2 illustrates that none of the edges of the present invention need be flat. The angles? ',?' Can still be calculated as discussed above. The angle beta is measured using an outer intersection point 31 of the first bevel edge 34 and the side wall 38 and an outer intersection point 33 between the first bevel edge 34 and the upper edge 42 . A line 49 drawn parallel to the bottom portion 44 intersects the line 51 drawn through the outer intersection points 31 and 33 to form an angle β '. Similarly, a line 53 drawn through the outer intersection points 35, 37 intersects the line 49 to form an angle a '.

As used herein, the term "film" is generally used to describe any thin sheet-like material having a plurality of layers on which at least one layer is deposited. The deposit layer may be a protective, decorative coating or the like. Metals, colors, labels, decals, prints, plastics and many other materials can be applied to the components of the present invention by film. Exemplary films that may be suitable for use in the present invention are described, for example, in U.S. Patent Application Publication No. 2009/0286054 to Meiki et al., Published November 19, 2009, March 13, 2008 And US Patent No. 7,410,551 to Bethune, issued August 12, 2008, to Colella et al., Which is hereby incorporated by reference in its entirety.

While various films can be used for various end results, typical films will include carriers, mold release compounds, deposition layers and adhesives. The carrier holds the layer to be deposited, and after deposition, the carrier can be recovered, for example, by a film dispenser. The carrier is often a thin sheet of plastic or other inexpensive material that can withstand the heat, pressure, or both of the deposition process. The release compound is typically a liquid, gel, or semi-solid material that allows the carrier to be easily removed from the deposition layer without any of the deposition layers being taken with the carrier. Preferably, the heterogeneous compound is volatile such that when the carrier is detached, the heterogeneous compound is simply vaporized. Alternatively, the non-volatile dissimilar compound may be cleaned or wiped in a post-deposition step.

The deposition layer can be many materials, and can itself comprise multiple layers. A thin layer of vacuum metallized metal is a popular choice for both decoration and protection. Often a color layer will be added to the metal layer. The metal film may also be produced by other methods, and may be as thick or thin as the desired result requires. Obviously, a thinner deposit layer will be more economical and will have greater flexibility, but a thicker layer will be more durable and less color shifted when deposited. Finally, the adhesive simply acts to adhere the deposit layer to the component. Adhesives are well known in the art and they can be activated by temperature, pressure, active compounds or both. In the case of fast cure epoxy, the part can be coated with one chemical of epoxy, with other chemicals on the film. When the film contacts the part, a reaction takes place and an adhesive layer is formed. In most cases, the adhesive is simply activated by pressure and / or heat between the mandrel and the component. Inevitably, the carrier side of the film contacts the mandrel while the adhesive and the deposition side of the film are in contact with the component.

Turning now to FIG. 3, this is a conventional foil stamping operation shown to highlight the differences and advantages of the present invention. In Figure 3, there is a rotatable mandrel 60 attached to the mandrel holder 61. The part 63 is shown as being held in place by the part holder 66. The part 63 has a flat side wall 65 that rotates in a direction opposite to the mandrel 60. The film 62 is fed between the flat side wall 65 of the part 63 and the mandrel 60 and contacts both. As can be seen, the angle between the mandrel 60 and the part 63 never changes. This allows the film 62 to move only laterally without being twisted or moved out of one plane of motion. This configuration provides minimal or no stress to the film, and generally results in good coverage. This system is known to work well in symmetrical truncated conical parts. However, this simple system does not work well for parts with asymmetric edges.

Figure 4 shows a schematic view of an apparatus for coating parts comprising an asymmetric edge according to the invention. The device 69 has a mandrel 70 that rotates and is attached to the mandrel holder 71. The component holder 76 holds the component 73 having the asymmetric edge 80. The film 72 is disposed between the mandrel 70 and the component 73. The component 73 rotates in a direction opposite to the mandrel 70. [ As will be described in more detail, one or both of the mandrel 70 and the component holder 76 move in a predetermined angular relationship with respect to each other. In Fig. 4, the component holder 76 is placed on the plate 81 which is attached to the mandrel holder 71 via the hinge 82. This is just one way of achieving the required angular motion of the present invention. The mandrel and the component holder do not need to be connected because the component holder, mandrel or both are computer controlled in a pre-programmed manner, for example by a servo motor, a pneumatic motor, etc., Because it knows.

A mandrel suitable for use in the present invention may have a truncated cone shape (e.g., see mandrel 69 in FIG. 4), a cylindrical shape (e.g., mandrel 102 in FIG. 5), or another generally symmetrical shape Lt; / RTI > Likewise, the mandrel may be solid or deformable. By "deformable" it is meant that the mandrel can conform to an irregular shape, for example a concave or convex shape. A deformable mandrel will be used to coat each of the first beveled edge 34 and the second beveled edge 36 of, for example, the part 32 of FIG. Deformable mandrels are useful when coating parts with embossed or engraved markings, such as product names, trademarks, or logos directly molded onto the part to be decorated.

5 is a more detailed schematic view of an apparatus 90 of the present invention. The component 92 is shown having an asymmetric edge 94, a side wall 96 and an upper edge 98 and is attached to the component holder 100. The mandrel 102 is shown attached to the mandrel holder 104, and the mandrel heater 106 is also shown. The mandrel heater 106 is used when the adhesive layer of the film is thermally active, and is not necessary for pressure sensitive adhesives, epoxy, and the like. The film 108 is shown attached to the film dispenser 110 and the film dispenser 112. In the simplest form, the film 108 has a first edge 114 attached to the film dispenser 110 and a second edge 116 attached to the film dispenser 112, although the film 108 is shown as a roll, . As shown, mandrel 102 and mandrel holder 104 rotate, while component 92 and component holder 100 rotate in opposite directions. Film dispenser 110 and film dispenser 112 may also be rotated to supply film 108 between mandrel 102 and part 92. The film dispenser 110 and the film dispenser 112 may be rotated, or indexed, only between successive rotations or processing of each component. In addition, a new film sheet may be loaded between the film dispenser 110 and the film dispenser 112 for each part being processed, in which case the film dispenser 110 and the film dispenser 112 need to rotate none.

As shown in FIG. 5, the film dispenser 110 and the film dispenser 112 must be free to move about the axes 111 and 113. If they only move left or right about the axes 111, 113 or up and down, this would be considered a two-dimensional motion. If they move up and down and both left and right about the axes 111 and 113, this is a three-dimensional movement. Although not intending to be bound by any one theory, it is believed that since the angle of the asymmetric edge changes around the circumference of the part and the component holder (or mandrel, or both) ≪ / RTI > This stress is not experienced when coating flat parts or even truncated conical parts because the angle between the film, the mandrel and the part never changes.

As used herein, "interactively moving" means that at least one of the film dispenser or film dispenser moves two-dimensionally to account for angular changes in the part and mandrel having an asymmetric edge. Preferably, both the film dispenser and the film dispenser move in two dimensions, more preferably at least one of the film dispenser or the film dispenser moves in three dimensions, and even more preferably both the film dispenser and the film dispenser move in three dimensions Moves in dimension. In order to alleviate stress on the film during the film application process, how the film distributor and the film dispenser move depends on the geometry of each individual component. It is understood that while the intent and purpose of the present invention deals with parts having edges that change their angles at least once during the film application process, the degree of variation and the number of variations will vary from part to part. However, as a general principle, it is best to keep the surface area of the mandrel substantially parallel to the edge of the part to be coated, and to feed the film into the space between the mandrel and the part to be fairly flat, i.e. without warping, . Likewise, if the film is indexed (not continuously fed), the film can still be manipulated to keep the film substantially flat and in a parallel relationship to the interface of the mandrel and the component edge. Using this general teaching, one of ordinary skill in the art will be able to program the movement of the film dispenser, film dispenser, or both for each individual asymmetric component configuration. Methods of moving mechanical devices such as film dispensers and film dispensers of the present invention will be known to those skilled in the art. A pneumatic motor, servo motor or the like can be used to move the film dispenser and film dispenser, while a computer-aided controller can match this movement with the changing angles of the mandrel and component holder.

system

The apparatus of the present invention can be used as a stand alone actuator or as a module in a system with known components, i.e., in a system comprising at least two modules. Other modules for use with the modular device of the present invention include devices for coating parts with symmetrical edges, devices for applying labels or transfer designs, devices having a changeable mandrel for coating non-planar, etc. But are not limited thereto. In the system of the present invention, the part is moved from one module to the next in a predetermined order until a desired level of decoration or protection for the part is achieved.

Advantages of modular systems include that many different decorative or protective coatings can be applied to a single component without altering the film between each of the steps; That individual coating steps can be staged to provide the best viewing and most efficient overlap between the coatings of each step; And allowing layering of films, transfer designs, labels, etc. in the work flow. As an example to illustrate the benefits of the system claimed herein, FIG. 6 shows a component 120 that is a lid only or bottle. The component 120 has a bevelled edge 122, a flat side wall 124, and a top edge 126 that is a concave surface. As shown, all three edges have different decorative coatings, and there is a label 128 disposed on the decorative surface on the concave upper edge 126. The part 120 can be decorated and labeled in four steps in one station, including one, by changing the decorative material four times. This inefficient process can be eliminated by using four modular systems in accordance with the present invention.

How to use

The method comprising: positioning a film over an asymmetric edge of the component, and then rolling the component over the mandrel with the film interposed therebetween. In this method, one or both of the mandrel and the component holder move in a predetermined angular relationship with respect to each other. While the asymmetric edge changes the angle, it is also desirable that the film also change its orientation. To accomplish this, it is desirable that the edges of the film be held by a film distributor and film dispenser that interactively move to align the film with the angle of change of the asymmetric edge of the part being coated. The manner of movement to achieve proper film alignment has been discussed above.

part

The components of the present invention may be selected from the group consisting of, for example, bottles, jars, overcaps, pumps, lids, consumer products, and mixtures thereof. Examples of consumer products include, but are not limited to, razors, toothbrushes, electric toothbrushes, skin care devices, electric shavers, home appliances, and the like. The parts can be made from known plastics and other polymeric compositions, naturally occurring compounds such as rubbers, metals, and other constituent materials known to those skilled in the art. Likewise, parts can be manufactured by methods known to those skilled in the art. Molding and high gloss molding is a preferred example of component manufacture, but stamping, heat forming, etc. are also acceptable methods of forming the components of the present invention. The asymmetric edge can be molded in the part, physically stamped on the part, chemically etched, cut or polished, or can be made in any other way known in the art.

Additionally, the component of the present invention has an asymmetric edge coated with a thin film as described herein. Figures 7 to 10 illustrate exemplary non-limiting components of the present invention. Figure 7 shows a jar 130 having a lid 132 with an asymmetrical edge 133 decorated with a thin film 134. In this example, the part according to the invention is a lid 132. If it has a decorated asymmetric edge, then the jar 130 may also be a component according to the present invention. Figure 8 shows a transparent overcap 140 with an asymmetric edge 143 having a thin film decorative coating 144. As will be apparent to those skilled in the art, the overcap is typically used to protect or seal a pump or the like. Figure 9 shows a jar 150 having a transparent overcap 152 with an asymmetric edge 154 having a thin film decoration 153. Also shown is a pump 156 under the overcap 152. The pump 156 has an asymmetrical edge 158 with a film protective coating 157. The jar 160 and the pump 162 are shown in Figure 10 and the jar 160 has an asymmetric edge 162 with a protective film coating 163. The components illustrated in FIGS. 7 through 10 are merely illustrative, and those skilled in the art will be aware of numerous components and consumer products capable of implementing this particular technology.

All literature cited herein, including any cross-referenced or related patents or applications, is expressly incorporated herein by reference in its entirety, unless expressly excluded or otherwise limited. The citation of any document is intended to be illustrative only as to whether it is prior art to any invention disclosed or claimed herein, or that it teaches, proposes, or any combination of such inventions, either alone or in combination with any other reference or reference It does not acknowledge the initiation. Also, any meaning or definition of a term in the present specification will conflict with any meaning or definition of the same term in the document included by reference, the meaning or definition assigned to the term in the present specification will prevail.

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

Claims (10)

An apparatus for coating a component having an asymmetric edge with a thin film,
A mandrel and a component holder,
Wherein the component is held by the component holder and the component is rolled on the mandrel with a thin film interposed between the component and the component holder and one or both of the mandrel and the component holder And moving in a predetermined angular relationship with respect to the component. The apparatus of claim 1,
a. Film dispenser;
b. Further comprising a film pick-up,
Wherein the film dispenser and the film dispenser are adapted to interactively move at least two dimensions relative to the component holder. 3. The apparatus of claim 2, wherein the film has a first edge and a second edge, the film being a decorative coating, a protective coating or a combination thereof. 2. The apparatus of claim 1, wherein the film is a multilayer film comprising a carrier, a release compound, a metal foil and an adhesive. 4. The apparatus of claim 3, wherein the film dispenser holds the first edge of the film, the film being positioned between the mandrel and the component holder, the film picker holding a second edge of the film, Wherein both the film dispenser and the film dispenser rotate to move the film laterally between the mandrel and the component holder. The film dispenser according to any one of claims 2, 3 or 5, wherein the film dispenser and the film dispenser are arranged such that when the asymmetric edge of the part changes an angle, Wherein the component holder is operatively movable in three dimensions relative to the component holder when the component holder is rotated. The film dispenser of claim 2, 3 or 5, wherein the film dispenser and the film dispenser are continuously rotated while the component is rotated to continuously feed the film between the component and the mandrel Wherein the component has an asymmetric edge. The film dispenser of claim 2, 3 or 5, wherein the film dispenser and the film dispenser stop during rotation of the part and rotate after the part is coated to provide a new film surface , An apparatus for coating parts having asymmetric edges. 6. The apparatus according to any one of claims 1 to 5, wherein the mandrel is rotating, heated, deformable, and has an asymmetrical edge. 6. A method according to any one of claims 1 to 5, wherein the component is selected from the group consisting of a bottle, a jar, an over cap, a pump, a lid, a consumer product, , An apparatus for coating parts having asymmetric edges.

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