LT6454B - Button producing method - Google Patents

Abstract

The invention relates to light industry products, in particular to production of buttons and can be used to light industry new button examples made from polyester, a polyamide, nylon, copper - zinc - aluminum alloys and production of similar products. The result is achieved using computer program AUTOCAD to design the sketches of the needed button models and sizes and placed in a computer database. All selected buttons are photographed and then all types of materials, textures and colors are placed in a computer database. Using the database the button configurator generates the wanted virtual button models. PROJET660 or similar brand of professional 3D printer prints the required button model, size, color and texture. To make models examples visually match to the original the model the lacquer process is added. There process is technically simple, easily workable, economical but effective way of transferring buttons concept from idea to final product manufacture for the user, button examples prototyping enables rational and efficient use of raw materials, skilled labor, energy and other material resources, greatly accelerate the production of the button samples and the production process.

Description

BACKGROUND OF THE INVENTION The present invention relates to light industrial products, specifically to the manufacture of buttons, and can be used in the light industry for the production of new button model designs from polyester, polyamide resin, nylon, copper - zinc - aluminum alloys, and the like.

There is a known button mold that allows the resulting button design to be molded so that the button tab does not protrude outward. Such buttons fit well on the garment and look very aesthetically visually (see patent description KR20140106019 (A) 09-09-2014).

Known installations for casting hardening materials, such as plastic or other resins, for casting rods from which projection button blanks are subsequently cut, are known (see Patent Specification TW224957 (B) -1994-06-11).

Buttons made from non-saturated polyester resins are known in the art, 1 to 2 to 5 wt.% Of flame retardant to give a corresponding color and texture effect. After casting the workpiece bars, they are mechanically cut into the workpieces according to the thickness of the designed fabricated button, laser-engraved with the required surface relief and polished until the desired effect is obtained (see Patent Specification CN103182785 (A) -2013-07-03).

BACKGROUND OF THE INVENTION There is a known method of making buttons and accessories from polyester resin by designing buttons and accessories from a polyester resin feedstock having a lower amount of negative ions. The workpieces are dried, hardened, cut to size and configuration according to the prepared project, polished and polished until the buttons of the desired shape are obtained. (see Patent Specification JP2010000168 (A) -2OIO01-07).

All of these techniques have the disadvantage that in cases where a small amount of output is required, such as a button model to produce 5 sample buttons (this is the standard number of buttons provided to prepare the production order), the amount of buttons (1,000 to 10,000 units, depending on the material, size, model of the button being manufactured). The minimum amount of polyester resin to make a single color or texture model kit is 50 kg. From this quantity, 10,000 units of button collars are made, whereas, for example, 5 units of the sample button are actually needed. After using a few units of buttons, the remainder is stored, hoping that the model will be accepted for mass production. According to the statistics and the competitive situation in the market and the wide range of the product range, only about 20% of the manufactured buttons are left in mass production, the remaining 80% of the manufactured buttons remain in stock, difficult to market and often write off production losses.

The production of model projects, although not directly profitable for the manufacturer, requires a large amount of raw materials, electricity, skilled labor and time resources. One highly skilled turning miller can produce up to 18 button sample kits in a single semiautomatic operation. For comparison, Table I gives the size of the different button sets.

table

Size L Buttons diameter (mm) Quantity of buttons included 18th 14th 12th 24th 15.24 12th 28th 18th 12th 32 20.32 9th 36 23rd 9th 44 28th 6th 54 34.3 4

The technology uses special turning, milling, and drilling tools, which must be properly installed and matched in the semi-automatic button manufacture before each new button model is prepared. In order to match a semiautomatic machine for the production of a new model, the minimum working time of the technician is 1 hour. The production speed of semi-automatic buttons is 30-90 pcs / min. It takes at least 2 hours to produce the minimum amount of one button sample production program. The buttons are then polished for 24 hours using a variety of special polishers. The technological one-time required loading of the polishing machine with polished buttons is 30 kg (6000 pieces of coat size buttons).

After polishing, a special semiautomatic machine performs a button size sorting operation. Sorting by model and original texture color is done manually. If the original color of the button texture differs from the color of the garment by at least one shade of tone, the buttons shall be painted using special paints and locking devices on special equipment.

The final quality control of the buttons is 100% manual.

The proportion of technological resources used in the production of design samples reduces the proportion that can be devoted to mass production that generates direct profit. Qualified labor resources are being used, which are not only very expensive but also limited and shrinking due to the ongoing demographic changes in society.

The expediency of producing sample designs of buttons also becomes a problem.

Using known production methods, the minimum production time for button samples is 5 (when raw materials are available) - 12 (no raw materials) working days.

The purpose of the present invention is to shorten the time it takes for a design example of a button to reach customers, to save raw materials, energy and labor resources, and to reduce production costs. The proposed method of sample production is easy to implement, economical, and ensures fast production of button design samples.

The stated purpose is achieved by the designers drawing and sketching the designs of all desired buttons models and their sizes using the computer program AUTOCAD. These sketches are compiled into a computerized database of button sample models.

Providing proper lighting, the camera is set to a special mode for superb sharpness and color depth of the subject, capturing all selected textures and colors of all types of button materials (polyester, polyamide, nylon, metal, etc.) and combining them in a special format material texture and color database.

A custom-built computer program creates the desired unique virtual button patterns from the presented material, texture, color, size and model variations using a special programmed button configurator. These models are rendered on a computer screen in 3D format, generated by ALL required technical parameters.

In the WRL file format, in accordance with all 3D printer information acceptance requirements, the 3D Max computer program prepares the final drawing of the required technical parameters, required model, color and required raw material texture. This information is transmitted to a PROJET660 or similar multi-color professional 3D printer computer, setting the print mode and printing a sample of the required model, size, color and texture.

To print a sample of the correct color and texture button (not deviating from the original), a color calibration of the computer monitor in RGB color mode and the 3D printer in CMYK color mode is performed. Calibration is performed using special software using actual iterations, i.e., if the color and texture of the first printed button sample does not match the color and texture of the original raw material, the color is corrected in the prepared WRL file and reprinted as many times as necessary. Once a sample of the required color and texture is printed, its color and texture code is stored in the printer database and can be used to print any other model of this raw material without additional calibration and iterative test prints.

The printed models are varnished by spray-spraying a colorless varnish to give them a visual appearance closer to the original and to achieve a gloss effect.

An example.

Button sample designer designers use the AUTOCAD software to draw and draw sketches of all desired button models and sizes. These sketches are added to the computerized database of button sample models on the manufacturer's website.

With the right lighting, the camera's special mode allows you to get the perfect photo sharpness and color depth of the subject. The button manufacturer takes all the selected textures and colors of all types of buttons (polyester, polyamide, nylon, metal, etc.) and combines them j Computer database of texture and color of button sample material on the sample manufacturer's website. The buyer of the buttons creates a custom virtual button model on the website of the sample manufacturer using a specially programmed button configurator, from the presented material, texture, color, size and model variants using a special programmed button configurator. This model is rendered on a computer screen in 3D format, generated by all required technical parameters, and sent to the sample manufacturer along with the order and the completed technical task.

The Sample Maker in the WRL file format prepares the final drawing of the required technical parameters, required model and raw material texture button model in accordance with all 3D Printer Information Receiving Requirements. This information is transmitted to a PROJET660 or similar brand of multi-color professional 3D printer computer. Sets the print mode and prints a sample of the required pattern, size, color, and texture.

With one 3D printer, one IT professional can print 200 to 400 button sample kits in one business day.

In order to give the printed sample models a visual appearance closer to the original and to achieve the gloss effect, they are varnished by spray-spraying a colorless varnish.

It takes 3-5 business days for the buyer of the buttons to receive a sample of the button model they want.

By transferring the concept of the button from the idea to the final product and its presentation to the user in this technically not complicated, easy to implement, economical but effective way, production of button models enables rational and economical use of raw materials, skilled labor, energy and other material resources. manufacturing process.

Claims (1)

DEFINITION OF INVENTION 1. A method of manufacturing a polyester resin button, in which the molded buttons are molded from a raw material of polyester resin, dried, cured, cut to size and configuration according to the design, polished, polished to the desired shape, characterized in that the pattern of the button is designed. , color, and raw texture are embedded in special computer databases, using these databases to generate a new desired button pattern, generate a desired pattern, size, color, and raw texture saga on a multicolor 3D printer and stamp it.