WO1998009790A1 - Procede de fabrication d'un article plat fait de matiere synthetique et pouvant etre soumis a des micro-ondes, article ainsi produit et composant de type film a impression d'encre utilise dans la fabrication de cet article plat - Google Patents

Procede de fabrication d'un article plat fait de matiere synthetique et pouvant etre soumis a des micro-ondes, article ainsi produit et composant de type film a impression d'encre utilise dans la fabrication de cet article plat Download PDF

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Publication number
WO1998009790A1
WO1998009790A1 PCT/CA1997/000650 CA9700650W WO9809790A1 WO 1998009790 A1 WO1998009790 A1 WO 1998009790A1 CA 9700650 W CA9700650 W CA 9700650W WO 9809790 A1 WO9809790 A1 WO 9809790A1
Authority
WO
WIPO (PCT)
Prior art keywords
film
article
microwavable
manufacturing
synthetic material
Prior art date
Application number
PCT/CA1997/000650
Other languages
English (en)
Inventor
Ching Chong Wu
Pierre Tardif
Original Assignee
Genin, Trudeau & Cie Limitee
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Genin, Trudeau & Cie Limitee filed Critical Genin, Trudeau & Cie Limitee
Priority to AU41952/97A priority Critical patent/AU4195297A/en
Priority to EP97939904A priority patent/EP0925165A1/fr
Publication of WO1998009790A1 publication Critical patent/WO1998009790A1/fr

Links

Classifications

    • 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
    • B29C45/14688—Coating articles provided with a decoration
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B6/00—Heating by electric, magnetic or electromagnetic fields
    • H05B6/64—Heating using microwaves
    • 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
    • B29C45/14688—Coating articles provided with a decoration
    • B29C2045/14696—Coating articles provided with a decoration transparent decorated inserts
    • 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
    • B29C45/14688—Coating articles provided with a decoration
    • B29C2045/14704—Coating articles provided with a decoration ink decorations
    • 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
    • B29C45/14688—Coating articles provided with a decoration
    • B29C2045/14713—Coating articles provided with a decoration decorations in contact with injected material

Definitions

  • TITLE A METHOD OF MANUFACTURING A MICROWAVEABLE
  • the present invention relates to a process for manufacturing articles made of synthetic materials such as polycarbonate, that are decorated with a design element embedded under the surface of the article.
  • the invention is particularly well suited for manufacturing flatware such as dishes or cups that can be safely used m a microwave oven since the design element is encapsulated in the 5 surrounding material and thus it is unlikely to release harmful fumes when subjected to intense electromagnetic radiation.
  • the invention also extends to such novel microwaveable article with an embedded design element and to a film component bearing a design element for use in 0 manufacturing the microwaveable article.
  • the invention provides a microwaveable article for holding food products, said microwaveable article comprising:
  • main body including a first synthetic material
  • a decorative indicia placed on a surface of said main body; a film including a second synthetic material overlaying said decorative indicia; said film having a thickness and transparency selected to allow said decorative indicia to be visible to the human eye through the film; said film being bonded to said body along an area of juncture whereby said decorative indicia is encapsulated between said main body and said film;
  • said first and second materials being compatible with one another whereby said area of juncture Is resistant to delaminatlon when said article Is used in a microwave oven; and - said first and second materials being selected to substan ially prevent degradation and release of toxic vapours when used in a microwave oven.
  • the invention also provides a process for manufacturing a microwaveable article for holding food products, said process comprising the steps of:
  • said first and second materials being compatible with one another whereby said area of juncture when the second material solidifies is resistant to delaminatlon when, said article is used m a microwave oven,- and - said first and second materials being selected to substantially prevent degradation and release of toxic vapours when used in a microwave oven.
  • the microwaveable article is manufactured by Injection moulding.
  • a film with a printed indicia on one side Is placed inside the mould with the printed Indicia facing the mould cavity.
  • Polycarbonate that forms the main body of the article is then injected into the mould to bond with the film and thus encapsulate the decorative indicia.
  • Polycarbonate is the material of choose for manufacturing the mam body of the article because is has a high impact strength, is dimensionally stable, and can be used in a microwave oven with no risks of distorting, softening or releasing toxic fumes.
  • Polycarbonate is also characterised as having good resistance to chemicals and ultraviolet light and it is crack resistant .
  • the film is a cast type clear polycarbonate film, more particular, a polycarbonate Acrylonit rile-Butadiene-Styrene (hereinafter referred to as ABS) coated material with low shrinkage and glossy surface finish.
  • ABS polycarbonate Acrylonit rile-Butadiene-Styrene
  • the ABS coating allows to provide a surface with high impact resistance, excellent surface finish, high dimensional stability at high temperatures, good chemical resistance and good stress cracking resistance.
  • the film has a low flow index and a molecular weight between 27 000 and 30 000 g/mol.
  • the film has a thickness in the range from about 0.02mm to about 0.08mm and the surface of the film is treated to obtain a surface texture in the range from about 25 to 55 Dynes on which the decorative indicia is printed. The surface roughness allows the ink of the decorative indicia to adhere better to the surface.
  • the formed piece is subjected to a heat treatment process to relieve stresses that may have developed at the interface between the film and the main body.
  • the heat treatment process is an annealing process that consists of heating the piece to a constant elevated temperature for a period of time and then allowing It to cool at a slow rate.
  • Figure 1 is a perspective view of a flatware article well suited for use in a microwave oven, that is constructed in accordance to the invention
  • Figure 2 is a perspective view of a clear polycarbonate film coated on the underside with an ink impression providing a decorative Indicia for use in manufacturing the flatware article in figure 1;
  • Figure 3 is a cross sectional view taken along lines 3-3 in figure 2;
  • Figure 4a is a cross sectional view of an injection mould, for manufacturing the flatware article shown in figure 1;
  • Figure 4b is an enlarged cross sectional view of the mould cavity shown at figure 4a, the mould being closed and the injection process initiated;
  • Figure 5 is a further enlarged view of the mould cavity showing the distribution of the injected polymer and the clear polycarbonate film therein.
  • figure 1 illustrates a novel flatware article in the form of the dish 10 that is characterized by an aesthetic design indicia on the recessed food contacting surface of the dish.
  • the dish 10 is constructed such that it can be safely used in a microwave oven. In other words, the material of the dish 10 will not release toxic fumes that can contaminate the food under the effect of electromagnetic radiation and heat .
  • the dish 10 includes a cup-shaped main body 12 including a downwardly sloping side wall and a flat bottom wall 16.
  • the decorative indicia is applied to the flat bottom wall 16. Contrary to conventional processes where the indicia is simply printed on the surface of the dish, in the present case the indicia is embedded in the material of the dish so it is shielded from contact with the food.
  • the decorative Indicia which is an ink- impression 17 is shielded by a clear polycarbonate film 18 that is bonded with the base material of the dish 10.
  • the film 18 includes a thin clear cast type layer of polycarbonate (commercial designation Merlon Lexan) 20, one surface thereof being printed with the indicia and the other surface coated with a ABS layer 22 that is very thin by comparison to the polycarbonate layer 20.
  • the ABS layer provides a strong long lasting surface coating, resistant to stains, scratches, stress cracking and chemicals.
  • the film 20 possess a low flow index with a molecular weight between 27 ⁇ and 3 ⁇ 000 g/mol.
  • the thickness of the film (excluding the thickness of the Ink Impression) is in the range from about ⁇ .02mm to about 0.08mm. Most preferably the thickness of the film is of 0.03mm.
  • the surface of the film on which the ink- impression 17 is made is treated in a manner well known to those skilled in the art to obtain a surface texture between 25 to 55 Dynes. Most preferably, the surface of the film has a texture of 42 Dynes.
  • the surface roughness allows to retain well the ink-impression which has a typical thickness in the range from about 0.002mm and about 0.010mm. If the ink Impression is substantially less than 0.002mm it will be virtually transparent, while if it is too thick ie., substantially greater than 0.010mm, it will spread and botch the design on the film upon injection of the synthetic material forming the main body.
  • the manufacture of the dish 10 is accomplished in two stages, the first is the injection moulding process, depicted at figures 4, a and 6B and the final stage is an annealing step to release Internal stresses that may develop at the interface of the film 18 and the base material of the dish 10.
  • the film 18 which has previously been printed with the decorative indicia and die-cut to size is electrostatically charged ( in a manner well known to those skilled m the art) is placed in the injection old.
  • the film is placed such that the ABS coated side, la is attracted due to its charge against the old plunger 24 and the or Inked side faces the old cavity.
  • the old plunger is displaced in to close the mould cavity.
  • the injection process begins by heating (above 230 C) polycarbonate material and melting it into a polycarbonate resin.
  • An in-line feed screw injects the molten polycarbonate material through a passage 2B into the enclosed cavity as shown in figure 6B.
  • Polycarbonate is an amorphous polymer which when heated to a temperature above its glass transition point 150 degrees C and then subjected to shearing stress, the molecules will tend to align themselves in the general direction of the stress. If the mass is then cooled below its transition temperature while the molecules are still under stress, the molecules remain in an oriented state. Such an orientation can have significant effects on the properties of the polymer mass.
  • the shear stress action during the flow of the polycarbonate causes molecular orientation upon cooling.
  • the mould cavities are kept warm ie between 100 and 120 degrees C and the injection rates are fast.
  • the material gradually cools down and solidifies. During such cooling process the polycarbonate shrinks.
  • the film 18 that has been heated by the molten polycarbonate also cools down and shrinks. Since the film 18 and the polycarbonate forming the remaining part of the dish l ⁇ are
  • annealing refers to a heat treatment m which a material is exposed to an elevated
  • temperatures could range between 8 ⁇ C to 150 C and the treatment time between 0.5 hour to 4 hours.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)
  • Manufacture Of Macromolecular Shaped Articles (AREA)

Abstract

Cette invention concerne un procédé de fabrication d'un article plat, tel qu'un plat ou une tasse, lequel est décoré d'un motif multicolore qui est noyé dans la surface de l'article entrant en contact avec des aliments. Cet article plat peut être utilisé dans un four à micro-ondes sans entraîner de détérioration du motif multicolore, tel que le fanage, la formation de bulles ou l'émission de gaz toxiques et nocifs. Ce procédé consiste à injecter du polycarbonate dans un moule où se trouve un film transparent sur lequel est imprimé le motif. Le film va adhérer au matériau à base de polycarbonate de manière à former une structure stratifiée. L'encre est imprimée sur la surface du film qui va adhérer au polycarbonate, ceci de manière à ce qu'elle soit noyée dans la structure, à ce qu'elle soit protégée contre les rayures, et à ce qu'elle n'entre pas en contact avec les aliments. Cette invention concerne également un nouvel article plat obtenu d'après ce procédé.
PCT/CA1997/000650 1996-09-05 1997-09-04 Procede de fabrication d'un article plat fait de matiere synthetique et pouvant etre soumis a des micro-ondes, article ainsi produit et composant de type film a impression d'encre utilise dans la fabrication de cet article plat WO1998009790A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
AU41952/97A AU4195297A (en) 1996-09-05 1997-09-04 A method of manufacturing a microwaveable flatware article made of synthetic material, the article produced thereby and an ink-imprinted film component for use in making the flatware article
EP97939904A EP0925165A1 (fr) 1996-09-05 1997-09-04 Procede de fabrication d'un article plat fait de matiere synthetique et pouvant etre soumis a des micro-ondes, article ainsi produit et composant de type film a impression d'encre utilise dans la fabrication de cet article plat

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
CA2,184,851 1996-09-05
CA 2184851 CA2184851A1 (fr) 1996-09-05 1996-09-05 Methode de fabrication d'un article de couvert en materiau synthetique pouvant aller au four microondes; article ainsi obtenu et film imprime a l'encre entrant dans la fabricationde l'article

Publications (1)

Publication Number Publication Date
WO1998009790A1 true WO1998009790A1 (fr) 1998-03-12

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/CA1997/000650 WO1998009790A1 (fr) 1996-09-05 1997-09-04 Procede de fabrication d'un article plat fait de matiere synthetique et pouvant etre soumis a des micro-ondes, article ainsi produit et composant de type film a impression d'encre utilise dans la fabrication de cet article plat

Country Status (4)

Country Link
EP (1) EP0925165A1 (fr)
AU (1) AU4195297A (fr)
CA (1) CA2184851A1 (fr)
WO (1) WO1998009790A1 (fr)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0914923A1 (fr) * 1997-11-06 1999-05-12 General Electric Company Procédé de décoration dans le moule
EP1174240A1 (fr) * 2000-07-21 2002-01-23 Bayer Corporation Un article décoré fabriqué par moulage à insert en forme de film
EP1162148A3 (fr) * 2000-06-06 2004-03-17 FRIES PLANUNGS- UND MARKETINGGESELLSCHAFT m.b.H. Gobelet réutilisable
BE1017181A3 (fr) * 2004-12-23 2008-04-01 Aljuan S L Procede de fabrication d'un emballage plastique avec decoration indelebile.
CN101380811B (zh) * 2007-09-07 2011-03-16 深圳市群达行精密模具有限公司 制造壳体的模具组合及制造方法
JP2016198292A (ja) * 2015-04-10 2016-12-01 吉田テクノワークス株式会社 樹脂製食器および樹脂製食器の製造方法

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3270101A (en) * 1963-04-01 1966-08-30 Kaumagraph Co Method of using static charge to decorate molded thermoplastic articles
US4595611A (en) * 1985-06-26 1986-06-17 International Paper Company Ink-printed ovenable food containers
US5310980A (en) * 1988-11-28 1994-05-10 Beckett Industries, Inc. Control of microwave energy in cooking foodstuffs
EP0619171A1 (fr) * 1993-04-09 1994-10-12 Consorzio Eagle Procédé pour décorer des éléments en polymère et éléments décorés obtenus

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3270101A (en) * 1963-04-01 1966-08-30 Kaumagraph Co Method of using static charge to decorate molded thermoplastic articles
US4595611A (en) * 1985-06-26 1986-06-17 International Paper Company Ink-printed ovenable food containers
US5310980A (en) * 1988-11-28 1994-05-10 Beckett Industries, Inc. Control of microwave energy in cooking foodstuffs
EP0619171A1 (fr) * 1993-04-09 1994-10-12 Consorzio Eagle Procédé pour décorer des éléments en polymère et éléments décorés obtenus

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0914923A1 (fr) * 1997-11-06 1999-05-12 General Electric Company Procédé de décoration dans le moule
US6117384A (en) * 1997-11-06 2000-09-12 General Electric Co. In-mold decorating process
EP1162148A3 (fr) * 2000-06-06 2004-03-17 FRIES PLANUNGS- UND MARKETINGGESELLSCHAFT m.b.H. Gobelet réutilisable
EP1174240A1 (fr) * 2000-07-21 2002-01-23 Bayer Corporation Un article décoré fabriqué par moulage à insert en forme de film
WO2002007947A1 (fr) * 2000-07-21 2002-01-31 Bayer Corporation Article decore par moulage avec film rapporte
US6623677B1 (en) 2000-07-21 2003-09-23 Bayer Corporation Decorated article made by film insert molding
AU774114B2 (en) * 2000-07-21 2004-06-17 Bayer Corporation A decorated article made by film insert molding
BE1017181A3 (fr) * 2004-12-23 2008-04-01 Aljuan S L Procede de fabrication d'un emballage plastique avec decoration indelebile.
CN101380811B (zh) * 2007-09-07 2011-03-16 深圳市群达行精密模具有限公司 制造壳体的模具组合及制造方法
JP2016198292A (ja) * 2015-04-10 2016-12-01 吉田テクノワークス株式会社 樹脂製食器および樹脂製食器の製造方法

Also Published As

Publication number Publication date
EP0925165A1 (fr) 1999-06-30
CA2184851A1 (fr) 1998-03-06
AU4195297A (en) 1998-03-26

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