WO2022060212A1

WO2022060212A1 - Method of creating a cover for a product

Info

Publication number: WO2022060212A1
Application number: PCT/MY2020/050088
Authority: WO
Inventors: Kok Yang NG
Original assignee: Tech Solutions International Limited
Priority date: 2020-09-18
Filing date: 2020-09-18
Publication date: 2022-03-24

Abstract

A method of creating a cover for a product comprising the steps of selecting a template for the product if it is available in a database, or designing a template for the product if it is not in the database, selecting a cutting machine and a cover material at a retailer location, and sending formatted instructions to the cutting machine in order to cut the cover material in accordance with the template, wherein base instructions are stored in the database which are converted into the corresponding formatted instructions depending on the cutting machine selected.

Description

METHOD OF CREATING A COVER FOR A PRODUCT

Field of Invention

The invention relates to a method of creating a cover for a product, such as, but not limited to, a protective film for a mobile phone.

Background

Portable electronic devices such as mobile phones have become increasingly widespread in recent years and as they are often susceptible to damage from being dropped it has been become customary to cover at least part of the device with a protective film to reduce the risk of such damage.

It is desirable for the protective film to be light and thin, yet still provide the required protection. In addition the film should allow functional access, particularly with smartphones which use touch-screen operation. It is noted that noted that films tend to become worn after time, due to ingress of dirt or air, and/or accumulation of damage. Therefore it is also desirable for the film to be replaced after a while.

Protective films are typically obtained from retailers who hold stocks for the relevant devices. However, as the number of devices available on the market proliferates, and the film for each device is different due to the shape, size and configuration thereof, it has become increasingly difficult for a retailer to maintain a suitable selection of films due to space limitations and commercial reasons.

As such retailers tend to hold a limited number of stocks of the films for the most recent models only, as these are the most likely to sell. As a result it can be difficult for a customer with an old device to obtain a film, for example if they have purchased the device second-hand or wish to replace a damaged film.

One way of addressing this issue is to provide the retailer with access to a database of cutting templates so that a film can be cut to size in accordance with the template for a particular device, as for example described in EP2729907. However, existing systems are limited with regard to the particular fdms and/or cutting machines required and the personalisation options.

An aim of the invention therefore is to provide a method of producing a cover such as a protective film which overcomes at least some of the above issues.

Summary of Invention

In an aspect of the invention, there is provided a method of creating a cover for a product comprising the steps of: selecting a template for the product if it is available in a database, or designing a template for the product if it is not in the database; selecting a cutting machine and a cover material at a retailer location; and sending formatted instructions to the cutting machine in order to cut the cover material in accordance with the template; characterised in that base instructions are stored in the database which are converted into the corresponding formatted instructions depending on the cutting machine selected.

Advantageously since the base instructions can be converted to any machine they can be sent to any retailer to cut the cover material as required, for subsequent collection of the resulting cover by a user. This is more convenient for the user as they will have more retailers to choose from, and can therefore pick the closest location.

In one embodiment the user creates and/or selects a design to apply to the template, and a printer is selected at the retailer location, wherein base instructions stored in the database are converted to formatted instructions depending on the printer selected, which are sent to the printer in order to print the design onto the cover material.

Advantageously the cover material can be easily customised with a graphical design as selected or designed by a user, In one embodiment the design can include any or any combination of photos, stickers, shapes, user-generated images, and/or the like. Typically these design components can be manipulated by the user.

In one embodiment the cutting machine and/or printing machine is selected from a range of brands, makes and/or models. Typically the formatted instructions are processable by the machine selected.

In one embodiment the cover material is in sheet form up to 5mm thick and comprises any or any combination of fdm, plastic, paper, wood, cardboard, foam, duct tape, fabric, leather, sheet metal, vinyl, and/or the like. Advantageously this allows users not only to design protective fdms for electronic devices such as mobile phones, but also to design and personalise covers for other items such as clothing, shoes, bags, cars, and/or objects in home, office or industrial settings. Thus the invention is not limited to protective films but can also be used to create aesthetic coverings, or a combination thereof.

In one embodiment the base instructions are converted into formatted instructions by translating into HPGL, GPGL, SVG, or the like, and making modifications to accommodate various parameters. Advantageously this allows compatibility to be maximised to give the greatest choice to the user. As a result it is straightforward to configure the system for new printing or cutting machines as they become available.

Typically the base instructions are stored in the database in the SVG language, but it will be appreciated that other languages may be used.

In one embodiment the parameters include any or any combination of the cutting machine’s default unit size, required orientation, blade pressure, number of cut cycles required, positioning holes, calibration cuts, order of cutting, and/or the like.

In one embodiment the cover material is a protective film designed to cover an electronic device such as a mobile phone. In one embodiment the template for a mobile phone comprises a number of holes and/or recesses corresponding to features on the mobile phone (e.g. microphone, camera, speaker, buttons, and/or the like) and the holes are cut in order from smallest to largest. As fdms may move or distort a small amount as they are cut, this ensures the holes are cut with the maximum precision, prior to the main outline cut, so that they are properly aligned when the fdm is fitted to the phone.

In one embodiment the template includes a predetermined number of positioning holes for the cover material, where the distance of the holes to the template is always constant such that the cover material can be installed on a mobile phone using an assisted installation jig, the jig comprising protrusions which correspond to the holes to ensure precise alignment of the film to the phone.

In one embodiment the template is designed by generating an outline from a photo or other image. In a further embodiment the user can draw a template or enter text to generate a template.

In one embodiment two or more templates may be overlaid to create a composite template. Multiple templates may also be positioned side by side on a film to reduce wastage.

In one embodiment the cover material comprises multiple transparent layers, and the templates are printed on respective layers in an overlaid fashion, such that a three- dimensional effect is generated by the printed cover.

In one embodiment each type of film includes a QR code. The QR code uniquely identifies the film type and the pre-set cutting recipe (for example, number of cut cycles, cutting speed, blade pressure, etc) for each of the film types. Advantageously the user or retailer can select from a plurality of film types, and by scanning the QR code, the appropriate cutting instructions will be automatically sent to the cutting machine to generate the correct cut for a particular type of blank film.

In one embodiment the printer is integrated with the cutting machine. In one embodiment the user is provided with a customer app for selecting or designing the template, creating or selecting a design to apply to the template if required, and selecting the retailer location for collection of the protective fdm. Typically the retailer is provided with a retail app for printing the design if required and cutting the film. Advantageously, actions requested in the customer app are communicated in real time to the retail app, such as customer order information.

In a further aspect of the invention, there is provided a jig for assisted installation of a cover material onto a mobile phone according to the method described herein.

In a yet further aspect of the invention, there is provided a protective film for a product created according to the method described herein.

In a further aspect of the invention, there is provided a method of creating a cover for a product comprising the steps of: selecting a template for the product if it is available in a database, or designing a template for the product if it is not in the database; creating and/or selecting a design to apply to the template; said design including any or any combination of photos, stickers, shapes, usergenerated images, and/or the like, which can be manipulated by the user if required; selecting a printing machine and a cover material at a retailer location; and sending formatted instructions to the printing machine in order to print the cover material in accordance with the template; characterised in that base instructions are stored in the database which are converted into the corresponding formatted instructions depending on the printing machine selected.

Brief Description of Drawings

It will be convenient to further describe the present invention with respect to the accompanying drawings that illustrate possible arrangements of the invention. Other arrangements of the invention are possible, and consequently the particularity of the accompanying drawings is not to be understood as superseding the generality of the preceding description of the invention.

Figure 1 is a method of designing a protective fdm for a product according to an embodiment of the invention.

Figure 2 is a method of printing and cutting a protective film for a product according to an embodiment of the invention.

Figure 3 illustrates the steps used to compute the cutting instructions for standard and assisted installation according to an embodiment of the invention.

Figure 4 is a schematic diagram of a template (a) in standard form; and (b) with easy installation positioning holes.

Figure 5 is a schematic diagram of a phone being fitted with an assisted installation jig and a template according to an embodiment of the invention (a) exploded view (b) fitted together.

Figure 6 is an example of a cover with a design created according to an embodiment of the invention.

Figure 7 illustrates an example of a creating a template (a) from a photo (b) generating a template by outlining an image; (c) applying the template outline to a chair; (d) applying the template and outlined image to a chair; (e) applying the template and outlined image to a backpack.

Detailed Description

With regard to Figure 1, the first stage of a method of creating a protective film for a product is illustrated. In this example a software app known as GoKaizen is used. The user can install this software on their computer, mobile phone, or other portable device. The user first identifies the product (2.3.1) which could be an electronic device such as a mobile phone, tablet, laptop, e-reader, watch but could also include furniture, stationery, vehicles and other items.

If a corresponding template is available in GoKaizen’s library, the user can then select the relevant product model and template. There are currently over 2000 templates, including most types of electronic device (e.g. iPhone X Back Cover), as well as shapes like stars, circles, or hearts. This library is continually being expanded to support a variety of non-device items, including templates for t-shirts, furniture, and even vehicles.

If the template is not in the library, or if the user wishes to modify the template, they are able to do so by creating a new template or modifying an existing template (e.g. for a similar model).

The software can also create a template by generating an outline from a photo (3.1.1.2). For example, they could use a photo of a lightbulb (uploaded, or found via web search) to generate a template in the shape of that lightbulb.

Alternatively, users can draw a template using free-hand drawing templates (3.1.1.3). For example, they can draw the outline of a tree to create a tree template.

Users could also enter text and adjust font or size to generate a series of letter templates (3.1.1.4) or create composite templates (3.1.1.5) by overlaying templates on top of each other. For example, a template of a circle may be placed inside a square to create a new “intersection” template.

A user can then add a design to their template if they wish, by adding media (3.1.2).

For example, photos or high-definition images in the foreground of the design, which can be obtained by taking a photo with the device camera, uploading images from device albums, selecting images from a curated library, some of which may be paid “premium” media (for example, a Disney photo), or searching for royalty-free images on the web.

Foreground stickers in the form of small images (e.g. hearts, emojis, flowers) can also be added to the foreground of the design.

Foreground shapes may be generated from an outline, for example stars, circles, and octagons. They are usually generated by a machine algorithm, rather than being a predesigned set of pixels. As a result users have more control over the appearance of the shape. For example they can change a star from 5 spokes to 7, shapes can be fdled with a chosen colour, or gradient of colours, and used as “containers” which hold child stickers or photos. For example, a user may choose to add a photo within a star shape, or within a circle shape. Shapes can be used as “negative space”, meaning they are cut out when produced. For example, users may wish to protect most of the surface of their phone, but leave a small portion of the original material exposed.

Users can also draw on their design using a variety of brush sizes and styles.

Users can add images to the ‘background’ of a design using the same sources as the foreground images. As an alternative to a background image, users can set a block colour as the background of their design. They can do this by selecting a colour from a palette , or by tapping on any part of the design, or they can automatically add a colour based on the colour range used by other media elements in the design.

Users may further personalize their design by manipulating media items (3.1.3). For example, they can resize items; crop items; rearrange items; change the angle of any item; add matrix-based fdters for image items adjusting blur, sepia, brightness, colour intensity, etc.; adjust font-size and colour for text; adjust the opacity / transparency of any item, allowing other items to appear partially underneath; adjust the layering order of items (allowing items to appear on top of, or below, other items); “Inverting” shapes to create cut-out spaces; adding content within shapes; removing the background from images (auto-cropping); and the like. Once a design has been created it is saved to the cloud and the current device (3.2). Optionally the design may be shared to allow other users to obtain or purchase the design from a marketplace, which can be integrated into the App and may allow sale/purchase of other items too.

Users may then proceed by completing a checkout flow. This transmits the order information to a retailer, who can fulfil the order using a Retail App, known as Kaizen OS in this example. It will be appreciated that having a Retail App (Kaizen OS) separate to the Consumer App (GoKaizen) advantageously allows the user to design the template at home in their own time, rather than being restricted to attempting the same within a retail environment having limited opening hours.

With reference to Figure 2, the Retail app workflow is illustrated, starting with a transaction (1.1.10). A “Cut” or “Transaction” refers to the act of cutting a piece of Film using a Cutting Machine in accordance with a set of Cutting Instructions.

Cuts are categorized into two types, printed cuts and blank cuts. Printed Cuts refer to the act of printing a custom Design onto a Film, and then cutting it to shape. This is generally used for personalizing and protecting non-interactive surfaces (e.g. the back of a phone). Blank Cuts refer to the act of cutting a Film to shape without printing on it first. This is generally used for protecting an interactive surface (e.g. the front of a phone)

The Retail App enables retail assistants to perform un-printed cuts referred to as “Blank Cuts” (4.2). These are suitable for customers who want a transparent film, usually for use as a screen protector or similar. This process involves several steps:

The first step in performing a blank cut is to select a device (4.2.1). The app then provides users with a list of compatible templates (4.2.2). Once a user has selected a template, they are required to select a film (4.2.4). The recommended approach is to scan a Film Code. This is a unique QR-code attached to each approved film that identifies that specific piece of film. The app then uses this QR code to fetch information about the film, in particular, the dimensions of the film, any special properties of the film, for example, whether it is classified as an “Easy Install” template, the history of the film, for example whether another user has attempted to use it before, and the chains and retail stores authorized to use that film.

The app then determines whether to permit the user to proceed with the cutting process. It may reject use under certain circumstances, for example if the selected film is too small for the selected template, not compatible with the selected template (for example, if the retailer attempted to use a Standard Install film with an Easy Install template), if it has been used to perform a cut before or is not authorized for use in the user’s current store.

This process streamlines the production experience and also helps to protect all parties:

• It protects customers from the use of low-quality, unauthorized films.

• It protects retailers from accidental use of incompatible or invalid films.

• It protects Kaizen OS from unauthorized use of its platform.

If for some reason a user is unable to scan a film code, they may choose instead to select a film type from a list of compatible film types. This list is determined based on several factors, such as film types which have been purchased by the retailer, authorized for use in the retailer’s country, and/or compatible with the template selected in the previous step.

Since this process of manual film selection is more vulnerable to abuse, Kaizen OS uses a system of Bypass Credits to limit use. In particular, Kaizen OS grants new retail stores a limited number of Bypass Credits when they join the platform (currently 10 credits). To perform a cut without scanning a Film Code, a retail store must have a positive balance of Bypass Credits, and one Bypass Credit will be deducted each time a retailer attempts to make a cut without scanning a Film Code.

After scanning a film code, users must select a compatible cutting machine (4.2.5). Kaizen OS supports a wide variety of machines, and a number of connection methods (including USB, Bluetooth and WiFi) and operating systems (including Android, iOS, Windows, Mac, and Web). To simplify the user experience, the app will attempt to automatically detect and display nearby cutting machines.

After the user has selected a cutting machine, the app attempts to a perform a cut (4.2.6). It does this in two phases.

In the first phase, the app generates the set of cut instructions required to cut the selected film. To do this, the app fetches a set of base instructions for the chosen template from the servers, translates the instructions into the appropriate language for the machine (HPGL, GPGL, or SVG) and then modifies the translated instructions to accommodate various parameters, including:

• the machine’s default unit size. For example, some machines treat “1 unit” as 0.025mm, whereas some treat “1 unit” as 0.05mm;

• the machine’s orientation. For example, some machines require cuts in a landscape format, whereas some require cuts in a portrait format;

• the machine’s blade pressure;

• the number of cycles required to safely cut through the selected film type, including any “overcutting” needed to ensure a clean cut;

• any positioning holes that must be added to improve the cutting process;

• the ability to differentiate templates and positioning holes in order to dictate how many cycles each should cut;

• calibration cuts to align the blade in the direction where it is cutting to produce a smoother finish;

• a sorting algorithm to optimize the order of cutting;

Figure 3 illustrates the steps used to compute the cutting instructions for standard and assisted installation, including:

1. take base instruction based on user input and break into segments;

2. sort segments based on desired product finish requirement;

3. remove duplicate segments or template design mistakes made by the user;

4. determine which segments are for standard templates and which are for assisted installation; 5. find the starting point of each segment and calibrate the blade before cutting the segment;

6. add specific setting for assisted installation segments;

7. depending on the type of film material, add specific closing instructions.

After a set of instructions has been generated, the app will transmit the instructions to the connected cutting machine (4.2.6.2). The exact method for doing this varies by connection method (USB, Bluetooth, Wifi). Where necessary, the app breaks the instruction set into a series of small “packets”, delivered in sequence. The app will constantly check the connection status with the machine to ensure no data loss when transmitting instructions to the cutting machine.

The Retail App also enables Retail Assistants to process customer orders - designs created via the Customer App that need to be printed and then cut, referred to as “Printed Cuts” (4.3).

The Retail Assistant starts the process by scanning a QR code generated by the Customer App (4.3.1). This allows the app to obtain an Order ID, which can then be used to fetch detailed order information from our servers.

Each customer order will contain one or more items (“Order Items”), which can be produced in sequence. To begin the production process, the Retail Assistant must choose one item (4.3.2), then scan a film code as described above.

Once a film code has been scanned, the app is ready to perform a print. To generate print instructions, the app downloads and caches the customer’s design as an image file, then modifies it as required. In particular, the app can rotate the image and position it to fit within the selected film’s printable area, while maximizing margins (allowing space for mechanical or human error); dynamically add registration marks to improve cutting accuracy on some machines; and/or dynamically alter print settings including size and colours to offset known quirks with specific printers. The app then transmits the generated printing instructions to the printer (4.3.4), and asks the user to confirm a successful print. After the film is printed the Retail Assistant selects the cutting machine (4.2.5) and performs the cut (4.2.6) as described above.

Once the film has been cut the user can collect the film from the retailer for installation on their product.

Figure 4a illustrates a traditional protective film template 8’ for a mobile phone, which includes a hole 10’ for the camera only. In contrast, Figure 4b illustrates a protective film template 8 which also includes a hole 10 for the camera but further comprises additional holes 12 for aligning the film accurately with the phone.

Thus with further reference to Figures 5a-b, for installation of a protective film template 8 on a phone 14, the retail assistant can use an assisted installation jig 16 for a fast and easy installation of the film onto the phone’s screen. The templates are designed with three positioning holes 12 on the film where the distance of the holes to the template is always constant. The jig is a device that is attached to the charging port 18 of the phone. There are three protruding pieces 20 of plastic on the jig and its distance to the phone is always constant. When the positioning holes on the film is fitted on top of the three protruding pieces of plastic on the jig, the template’s position will match the phone’s screen such that the template is centred on the screen. The retail assistant can then stick the film onto the phone’s screen immediately without needing to adjust the position of the template again.

Figure 6 is an example of a cover with a design created according to an embodiment of the invention. In this example images and text with a nature theme have been added to a template for a mobile phone, so that the cover material is printed with the same and cut to the correct specification accordingly.

Figures 7a-e illustrate an example of a creating a template by generating an outline 22 from a photo 30. The outline can be cut out with the original image to form the template 26, or other media can be added thereto 24, and applied to an item such as a chair 32 or backpack 34. It will be appreciated by persons skilled in the art that the present invention may also include further additional modifications which do not affect the overall functioning of the method.

Claims

1. A method of creating a cover for a product comprising the steps of: selecting a template for the product if it is available in a database, or designing a template for the product if it is not in the database; selecting a cutting machine and a cover material at a retailer location; and sending formatted instructions to the cutting machine in order to cut the cover material in accordance with the template; characterised in that base instructions are stored in the database which are converted into the corresponding formatted instructions depending on the cutting machine selected.

2. The method according to claim 1 wherein the user creates and/or selects a design to apply to the template, and a printer is selected at the retailer location, wherein base instructions stored in the database are converted to formatted instructions depending on the printer selected, which are sent to the printer in order to print the design onto the cover material.

3. The method according to claim 2 wherein the design can include any or any combination of photos, stickers, shapes, user-generated images, and/or the like, which can be manipulated by the user if required.

4. The method according to claim 2 or 3 wherein two or more templates may be overlaid to create a composite template.

5. The method according to claim 4 wherein the cover material comprises multiple transparent layers, and the templates are printed on respective layers such that a three-dimensional effect is generated by the cover.

6. The method according to any preceding claim wherein the cover material is in sheet form up to 5mm thick and comprises any or any combination of fdm, plastic, paper, wood, cardboard, foam, duct tape, fabric, leather, sheet metal, vinyl, and/or the like.

7. The method according to any preceding claim wherein the base instructions are converted into formatted instructions by translating into HPGL, GPGL, SVG, or the like, and making modifications to accommodate various parameters.

8. The method according to claim 7 wherein the parameters include any or any combination of cutting machine’s default unit size, required orientation, blade pressure, number of cut cycles required, positioning holes, calibration cuts, order of cutting, and/or the like.

9. The method according to claim 8 wherein a QR code is provided on the cover material which identifies the cover material and at least some of the parameters. 17

10. The method according to any preceding claim wherein the template is created by generating an outline from a photo or other image, or by the user drawing a template or entering text.

11. The method according to any preceding claim wherein the cover material is a protective fdm designed to cover an electronic device such as a mobile phone.

12. The method according to claim 11 wherein the template comprises a number of holes and/or recesses corresponding to features on the mobile phone, and the holes are cut in order from smallest to largest.

13. The method according to claim 11 or 12 wherein the template includes a predetermined number of positioning holes for the cover material, where the distance of the holes to the template is always constant such that the cover material can be installed on a mobile phone using an assisted installation jig, the jig comprising protrusions which correspond to the holes to ensure precise alignment of the fdm to the phone.

14. A jig for assisted installation of a cover material onto a mobile phone according to the method of claim 13.

15. A protective fdm for a product created according to the method of any preceding claim. 18 A method of creating a cover for a product comprising the steps of: selecting a template for the product if it is available in a database, or designing a template for the product if it is not in the database; creating and/or selecting a design to apply to the template; said design including any or any combination of photos, stickers, shapes, user-generated images, and/or the like, which can be manipulated by the user if required; selecting a printing machine and a cover material at a retailer location; and sending formatted instructions to the printing machine in order to print the cover material in accordance with the template; characterised in that base instructions are stored in the database which are converted into the corresponding formatted instructions depending on the printing machine selected.