WO1997028944A1 - In-mold decoration of substantially tubular objects - Google Patents
In-mold decoration of substantially tubular objects Download PDFInfo
- Publication number
- WO1997028944A1 WO1997028944A1 PCT/IL1997/000043 IL9700043W WO9728944A1 WO 1997028944 A1 WO1997028944 A1 WO 1997028944A1 IL 9700043 W IL9700043 W IL 9700043W WO 9728944 A1 WO9728944 A1 WO 9728944A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- core
- plastic
- sleeve piece
- article
- mold
- Prior art date
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D1/00—Containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material, by deep-drawing operations performed on sheet material
- B65D1/22—Boxes or like containers with side walls of substantial depth for enclosing contents
- B65D1/26—Thin-walled containers, e.g. formed by deep-drawing operations
- B65D1/265—Drinking cups
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2713/00—Use of textile products or fabrics for preformed parts, e.g. for inserts
Definitions
- This invention refers to a process for the manufacture of plastic articles having, at least in part, a substantial tubular, in particular cylindrical or quasi-cylindrical or frusto-conical configuration, such as, e.g., cups, decorated, at least in part, with a fabric, viz. having a fabric covering on at least part of one of their outer and/or inner surfaces, to a mold for the injection molding of such articles and to the decorated articles produced by said process and said mold.
- the in-mold decoration process for making plastic articles comprising a portion having a substantially tubular, in particular cylindrical or quasi- cylindrical or frusto-conical configuration, decorated, at least in part with a fabric skin, according to the invention, is characterized in that it comprises the steps of: preparing a substantially cylindrical sleeve piece of the fabric to be used as skin for the decorated plastic article, said sleeve piece being of such size and dimensions and elasticity that it is adapted to being imparted the shape and dimensions desired for the final covering or skin of the finished plastic article, providing a mold which has a male half (hereinafter “male mold”) and a female half (hereinafter “female mold”), which define the surfaces of the substantially tubular portion of the finished plastic article, the male mold having a core the surface of which defines the inner surface of said article portion and the female mold having a cavity the surface of which defines the outer surface of said article portion, placing said sleeve piece about said core, injecting molten plastic material into said cavity towards said core, where
- substantially tubular portion of a plastic article is meant a hollow portion, having an inner and an outer surface, the cross-sections of which, taken on parallel planes, are equal or have the same shape but moderately different sizes.
- the line perpendicular to said planes will be called the "axis" of the article, and will be in most cases, though not necessarily, the axis of symmetry of the article. If said cross-sections are circular, the axis of the article is its axis of symmetry and the substantially tubular portion is cylindrical or quasi-cylindrical or frusto-conical.
- the process When the process is applied to decorating surface of the article with fabric, it comprises the following steps: preparing a substantially cylindrical sleeve piece of the fabric to be used as skin for the decorated plastic article, said sleeve piece being of such size and dimensions and elasticity that it is adapted to being imparted the shape and dimensions desired for the final covering or skin of the finished plastic article, providing a mold which has a male half (hereinafter “male mold”) having a core which defines the inner surface of the finished plastic article and having a female half (hereinafter “female mold”) having a cavity the surface of which defines the outer surface of the finished plastic article, placing said sleeve piece about said core, injecting molten plastic material into said cavity towards said core, whereby to cause it to flow between said core and said sleeve piece placed thereupon and to press said sleeve piece against said surface of said cavity, the injected plastic material filling the space between said sleeve piece and said core, allowing plastic material to solidify, and extracting
- the process When the process is applied to decorating the inner surface of the article with fabric, it comprises the following steps: preparing a substantially cylindrical sleeve piece of the fabric to be used as skin for the decorated plastic article, said sleeve piece being of such size and dimensions and elasticity that it is adapted to being imparted the shape and dimensions desired for the final covering or skin of the finished plastic article, providing a mold which has a male half (hereinafter “male mold”) having a core which defines the inner surface of the finished plastic article and having a female half (hereinafter “female mold”) having a cavity the surface of which defines the outer surface of the finished plastic article, placing said sleeve piece about said core, injecting molten plastic material into said cavity towards said core, whereby to cause it to flow between said surface of the cavity of said female mold and said sleeve piece and to press said sleeve piece against said core, the injected plastic material filling the space between said sleeve piece and said surface of said cavity, allowing plastic material to solid
- sleeves piece is meant herein a tubular body of fabric which has the dimensions of the fabric skin that will decorate the plastic article.
- the plastic article may have an open substantially tubular configuration, but, more often, will have a transverse wall closing it at one end, as in the case of a cup or the like.
- the molten plastic material will be injected into said cavity of said female mold so as to impinge on the end of said core and the direction of the injected stream will be along the axis of said core, so that said stream will flow symmetrically over said core end, towards its periphery, and form said transverse wall, before flowing between said sleeve piece and the core or the female mold cavity, to form the substantially tubular portion of the article.
- the preparation of the sleeve piece comprises: a) providing a fabric strip of the material which is to constitute the covering or skin of the article, either by making it directly from filaments, fibers or yarns, or by cutting a fabric into strips; b) winding said strip in spiral fashion to form a tube of the desired diameter, which is essentially endless, viz. may be as long as allowed by the length of the strip; and c) cutting said tube into sleeve pieces of a length determined by the length of the plastic article to be decorated.
- the fabric material is thermoplastic, at least in part, a 25% (by weight) content of thermoplastic fibers being a preferred minimum and the non-thermoplastic fibers being preferably cotton.
- the thermoplastic fibers can be of any kind, e.g. from polyamides, polyesters and blends thereof, etc.
- the cutting operations are carried out by or with the application of heat, so that the various threads will be welded along the cut and the fabric will not unravel. Woven fabrics are preferred because of their elasticity, but non-woven fabrics can be used as well.
- the winding of the fabric strip is made in spiral fashion, viz. in such a way that the edges of the strip form a spiral.
- the angle at which the fabric strip is wound to form a tube is important to the elastic behavior of the sleeve piece.
- the acute angle between the tangent to said spiral and the plane of the cross- section of the wound tube (when this latter is in its distended configuration) - hereinafter "the winding angle" - may vary between 15° and 45°, and preferably between 20° and 30°. If the fabric strip is directly woven as such or is derived from a woven fabric bolt cut along its length, said longitudinal direction coincides with the direction of the warp.
- a woven fabric bolt may be cut into strips at an angle to its length; or the strip may be of non-woven fabric, in which case a warp direction cannot be defined.
- the winding of the fabric strip into a tube preferably involves a certain overlap of adjoining fabric spiral turns.
- This overlap should preferably be 3 to 5 mm.
- the adjoining fabric spiral turns should preferably be bonded in their overlapping zones.
- an adhesive may be applied to said overlapping zones, e.g. by spraying at a sufficiently high temperature so that the adhesive be adequately fluid, applying pressure to said zones to promote penetration of the adhesive into the fabric, and cooling the adhesive.
- a thin strip of plastic adhesive may be applied between adjoining fabric spiral turns, where they overlap, and pressure may be applied to promote penetration of the adhesive into the fabric.
- ultrasound bonding may be applied to said overlapping zones by using apparatus available on the market.
- the inner diameter - hereinafter called “the diameter”, in view of the small thickness of the fabric - of the wound tube and therefore of the sleeve piece (in their distended condition) is equal to the outer diameter of the core, if this latter is cylindrical, or, if this latter is frusto-conical, is comprised between the minimum and the maximum diameter of the core.
- a moderate conicity, viz. taper, of the final product can be obtained by stretching the sleeve as a consequence of the pressure applied to it by the injected plastic material.
- a moderate conicity of the molded piece, and therefore of the core e.g. between 0 and 5°, is always desired to facilitate the ejection of the molded piece.
- the injection is carried out through the female mold in an average direction that is parallel to the axis of the male mold core. If the plastic article is closed at one end, the injection is carried out preferably through an injection channel that has an outlet port located in the female mold cavity and centered on said axis. Since the sleeve has a slightly larger circumference than the forward end of the core, viz.
- the plastic melt firstly flows over the core forward end towards its periphery, to form the closing wall of the article, and then penetrates into the gap between said sleeve and said core and flows all the way to the opposite or rearward end of the core, exerting an inside pressure on said sleeve which causes it to be applied to and pressed against the inner surface of the female mold cavity.
- the plastic material employed must have a high flowability, viz. a relatively low viscosity in the molten state and the injection temperature, and it must be injected at a slow rate, at least during the first portion of the injection and until about 30% of the volume of the plastic material has been injected. This is necessary to avoid excessive shear stresses in the fabric material.
- the plastic material has preferably a Melt Flow Index of at least 10 and not more than 30, and the injection is preferably effected so that the speed at which the front of the molten plastic stream advances is 20 to 56 mm per minute.
- Fig. 1 is a schematic view, at a reduced scale, of a fabric strip and the portion of it constituting a skin piece, according to an embodiment of the invention
- Fig. 2 is a lateral view of a cup covered with spirally wound fabric, according to an embodiment of the invention
- Fig. 3 is an axial cross-section ofthe same cup
- Fig. 4 is a block diagram of a process according to an embodiment of the invention.
- Fig. 5 is a schematic cross-section of a mold according to an embodiment of the invention, taken on a plane passing through the axis of the mold core, the mold being in the open condition;
- Fig. 6 is a schematic cross-section similar to that of Fig. 5, the mold being in the closed condition, at the end of the injection phase.
- a cup constitutes an example of a decorated plastic article according to an embodiment of the invention and made by a process and a mold according to an embodiment of the invention.
- Cup 10 has a plastic body which comprises a bottom 11 and a wall 12 having a conical portion 13 and a flared-out annular rim 14, which is not covered by sleeve piece 15, hereinafter described.
- the thickness of the wall 12, in this example, is constant over all its length, but this is not necessary and the thickness might be varied by suitably dimensioning the mold to be described. Further, reliefs or recesses may be provided in the plastic body for decorative or other purposes.
- Wall 12 is covered on the outside, for its most part, with a fabric covering or sleeve piece generally indicated at 15.
- the sleeve piece is formed from a tube, obtained from a fabric strip wound upon itself in spiral form with a winding angle from 15° to 45°, as indicated by the spiral edges 20, successive turns of the spiral having an overlap indicated at 17, and cut at the edges 18 and 19.
- Fig. 4 is a block diagram of a process according to an embodiment of the invention. In Fig. 4, the following numerals correspond to the following steps- materials or operations:
- the process according to a typical embodiment of the invention comprises winding (61) a fabric strip stock (60) at a convenient angle to the longitudinal direction (as hereinbefore defined) to provide (62) an essentially endless, cylindrical tube, viz. a tube the length of which depends only on the length of the available fabric strip, and then transversely cutting (63) said tube to pieces (64) of the length that is required for the decorated articles to be made - which pieces are called herein "sleeve pieces".
- the fabric strip stock (60) may be obtained by directly producing a fabric ribbon of the appropriate width, or by cutting a fabric stock, of any width, into strips ofthe appropriate width.
- a fabric strip 21 (shown as broken off in the drawing) is wound about a winding axis 22 at a winding angle ⁇ , said winding angle being the angle between the longitudinal direction of the fabric and the perpendicular to the winding axis.
- the winding angle is seen as the angle between the spiral, defined by the overlapping edges of the adjacent fabric spiral turns, and the transverse cross-section of the tubular article.
- the angle ⁇ may vary from 15° to 45° and preferably from 20° to 30°.
- the spiral defined by adjacent and overlapping fabric edges have only one turn over the entire article, or in other words, that the pitch of the overlap spiral be substantially equal to the length of the fabric covering, which is about the same or sUghtly less than the axial dimension of the article.
- the fabric preferably comprises at least 25% by weight of thermoplastic fibers, e.g., polyamide or polyester fibers, the non- thermoplastic fibers being preferably cotton, and is cut by or with the application of heat, in order to fuse the margins of the cut and prevent any unraveling of the fabric yarns.
- the edges 18 and 19 see Fig.
- the mold for the in-mold decoration of the plastic article is shown in the open condition in Fig. 5. It comprises a male half or male mold, generally indicated at 30, and a female half or female mold, generally indicated at 31.
- Male mold 30 has a core 32 and female mold 31 has a corresponding cavity 33.
- the end of core 32, indicated at 34 and called the forward end of the core, is the part thereof that penetrates most deeply into cavity 33.
- Core 32 has a mainly frusto-conical outer surface, which has a rounded connection 35 to core end 34 and a flared- out shoulder 36 at its rear end.
- a narrow groove 37 is formed at the base of the core.
- Female mold 31 has a plastic melt inlet 40, which conveys the molten plastic to injection channel 41, coaxial with core 32 and opening on an injection port 42.
- Sleeve piece 28 is placed on core 32 (66 in Fig. 4), as seen in Fig. 5.
- the thickness of the skin piece is exaggerated in the drawing, for illustrative purposes.
- the sleeve piece 28 has an inner diameter that is approximately equal or close to the average diameter of the core.
- the elasticity of the fabric sleeve piece permits to apply it onto the main, frusto ⁇ conical portion of the core, even though its diameter is slightly less than the largest diameter D of said main portion and is intermediate between said diameter D and diameter d of the forward end of the core.
- the sleeve piece is slipped onto the core, and, thanks to its elasticity, can be slipped to the end of the frusto-conical portion of the core. However, it does not penetrate into groove 37, where uncoated rim 14 of the finished article will form. Its forward end projects slightly from the forward end 34 of the core, actually by an amount that equal to or slightly less than the thickness of bottom 11 of cup 10.
- the injected plastic stream impinges on the forward end 34 of core 32 and flows symmetrically towards the periphery of said core end, between it and the bottom of cavity 33, which faces it. From said core end periphery, it penetrates and flows between core 32 and sleeve piece 28, towards the rear end or base of the core, finally to fill groove 37. In its flow, it exerts a pressure on the inner surface of the sleeve piece 28.
- the sleeve piece is sufficiently elastic, due to the properties of the fabric and to the fact that it is made from a strip cut at an angle to its longitudinal direction and spirally wound, to expand somewhat under the pressure of the injected stream, until it is retained by the female mold cavity 33.
- the plastic stream causes the sleeve piece to assume a distended, round shape against the female mold and forms a layer between it and the core.
- it in order to be sure that the sleeve piece does not have any wrinkles and is smooth and taught, it must not have at any point thereof, a diameter that exceeds by more than about 1- 4 mm that of the underlying portion of the core.
- the sleeve piece 28 When the sleeve piece 28 is in contact with the core and expands to contact the female mold, it becomes detached from the core by a distance equal to the thickness of the wall 12 of the finished article: it is sufficiently elastic to increase its diameter as required. Beyond the edge 19 of the sleeve, the plastic stream penetrates into cavity 37 and forms uncoated rim 16 of cup 10.
- the elasticity of the sleeve piece should be sufficient for it to permit to expand so as to contact the female mold at all points in spite of the possible conicity of the molded piece.
- it should be able to increase its diameter by an amount that may be in general in the order of 5% to 20%.
- a cup the conical portion of which has a maximum diameter of 75 mm and a minimum diameter of 64 mm. If the sleeve piece has a diameter of 67 mm, it must expand, at the point of maximum diameter o the cup, by about 10.7%.
- the corresponding conicity of the core in this case, is arctg(5.5/L), wherein L is the length of the conical portion ofthe cup, and if said length is 10.5 cm, the conicity angle is about 3°.
- the manufacture of cylindrical or quasi -cylindrical articles can be carried out in the same way, by using molds having a cylindrical core and a cylindrical female mold cavity.
- plastic materials that can be injection molded can be used.
- the most preferred ones are the polyolefins and soft PVC.
- the injection pressure varies preferably from about 100 to about 500 Bar.
- the plastic is preferably injected at such a speed that the injection is completed within a period of 3 to 20 seconds and the entire injection cycle lasts between 20 seconds and one minute: however, these times are only preferred and indicative and may be varied by persons skilled in the injection molding art to adapt the process to each particular case.
- the injected article is allowed to solidify, and the mold is opened and the article is ejected by ejectors, not indicated in the drawings as they are conventional in the injection molding art.
- the finished article is the obtained (69 in Fig. 4).
Abstract
Description
Claims
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU14557/97A AU1455797A (en) | 1996-02-08 | 1997-02-03 | In-mold decoration of substantially tubular objects |
EP97901246A EP0879127A1 (en) | 1996-02-08 | 1997-02-03 | In-mold decoration of substantially tubular objects |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
IL11708196A IL117081A (en) | 1996-02-08 | 1996-02-08 | In-mold decoration of substantially tubular objects |
IL117081 | 1996-02-08 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO1997028944A1 true WO1997028944A1 (en) | 1997-08-14 |
Family
ID=11068535
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/IL1997/000043 WO1997028944A1 (en) | 1996-02-08 | 1997-02-03 | In-mold decoration of substantially tubular objects |
Country Status (4)
Country | Link |
---|---|
EP (1) | EP0879127A1 (en) |
AU (1) | AU1455797A (en) |
IL (1) | IL117081A (en) |
WO (1) | WO1997028944A1 (en) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2004007167A1 (en) * | 2002-07-12 | 2004-01-22 | Hekuma Gmbh | Method and device for producing an injection moulded article, to the external peripheral surface of which an element, e.g. a label is applied |
AT500747A1 (en) * | 2004-08-20 | 2006-03-15 | Peter Steiner | METHOD AND DEVICE FOR PRODUCING A FILM OR BZW. COATING COATED CONTAINERS AND CONTAINERS |
US7165967B2 (en) | 2002-09-17 | 2007-01-23 | Hekuma Gmbh | Method for removing injection-moulded parts from an injection-moulding machine and injection-moulding machine with a handling system |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3101994A (en) * | 1957-10-12 | 1963-08-27 | Pellon Corp | Method of molding synthetic resin products |
GB1085536A (en) * | 1964-03-24 | 1967-10-04 | Billingsfors Langed Ab | Disposable cup |
GB2082113A (en) * | 1980-08-20 | 1982-03-03 | Breco Kunststoff | Method of producing a length of flexible tubing in the form of a toothed belt |
EP0395585A2 (en) * | 1989-04-28 | 1990-10-31 | Fuji Seal Industry Co. Ltd. | Method of manufacturing labeled objects. method of manufacturing labelled containers utilizing said method, and labeling preformer apparatus for use in carrying out the method |
EP0466947A1 (en) * | 1988-08-25 | 1992-01-22 | PepsiCo, Inc. | A process for molding a multiple layer structure and a container made therefrom |
-
1996
- 1996-02-08 IL IL11708196A patent/IL117081A/en not_active IP Right Cessation
-
1997
- 1997-02-03 EP EP97901246A patent/EP0879127A1/en not_active Withdrawn
- 1997-02-03 WO PCT/IL1997/000043 patent/WO1997028944A1/en not_active Application Discontinuation
- 1997-02-03 AU AU14557/97A patent/AU1455797A/en not_active Abandoned
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3101994A (en) * | 1957-10-12 | 1963-08-27 | Pellon Corp | Method of molding synthetic resin products |
GB1085536A (en) * | 1964-03-24 | 1967-10-04 | Billingsfors Langed Ab | Disposable cup |
GB2082113A (en) * | 1980-08-20 | 1982-03-03 | Breco Kunststoff | Method of producing a length of flexible tubing in the form of a toothed belt |
EP0466947A1 (en) * | 1988-08-25 | 1992-01-22 | PepsiCo, Inc. | A process for molding a multiple layer structure and a container made therefrom |
EP0395585A2 (en) * | 1989-04-28 | 1990-10-31 | Fuji Seal Industry Co. Ltd. | Method of manufacturing labeled objects. method of manufacturing labelled containers utilizing said method, and labeling preformer apparatus for use in carrying out the method |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2004007167A1 (en) * | 2002-07-12 | 2004-01-22 | Hekuma Gmbh | Method and device for producing an injection moulded article, to the external peripheral surface of which an element, e.g. a label is applied |
US7165967B2 (en) | 2002-09-17 | 2007-01-23 | Hekuma Gmbh | Method for removing injection-moulded parts from an injection-moulding machine and injection-moulding machine with a handling system |
AT500747A1 (en) * | 2004-08-20 | 2006-03-15 | Peter Steiner | METHOD AND DEVICE FOR PRODUCING A FILM OR BZW. COATING COATED CONTAINERS AND CONTAINERS |
Also Published As
Publication number | Publication date |
---|---|
IL117081A0 (en) | 1996-06-18 |
AU1455797A (en) | 1997-08-28 |
IL117081A (en) | 2000-02-29 |
EP0879127A1 (en) | 1998-11-25 |
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