GB2539381A

GB2539381A - Manufacturing method

Info

Publication number: GB2539381A
Application number: GB1508784.4A
Authority: GB
Inventors: William Burnside Neil
Original assignee: Burnsides (marketing Aids) Ltd
Current assignee: Burnsides (marketing Aids) Ltd
Priority date: 2015-05-22
Filing date: 2015-05-22
Publication date: 2016-12-21
Anticipated expiration: 2035-05-22
Also published as: GB2539381B; GB201508784D0

Abstract

Method of manufacturing a plurality of items, such as key rings, from sheet material comprising forming a first partial cut 22 on one side of the sheet, forming a second partial 24 cut on a second side, and a third cut 34 extending wholly through the sheet. Preferably first and second cuts extend 40% or 20-30% through the sheet. Preferably, designs and guide markings are printed using a high resolution printer on either side of the sheet to be cut out. Preferably, a transparent, settable coating 32, 36 is applied to the items after the second cut. Preferably, a removable laminate 30 supports the items after the third cut. Preferably, guide holes are cut into the sheet. Preferably, the sheet is metallic or plastic, such as aluminium or acrylic, and is less than 25mm, 1-6mm or 2-5mm thick. The invention aims to increase smoothness cut edge.

Description

Manufacturing Method This invention concerns a method of manufacturing, and particularly a method of manufacturing a plurality of items from a sheet of material, items made by this method, and especially keyrings made by this method.

Currently keyrings and tags are widely used in a range of areas. In the motor trade for instance, it is very common to supply one or more keyrings when a vehicle is purchased to identify the source of the vehicle and provide a reminder to purchasers of the vehicle as to the source of the vehicle. For such keyrings it is desirable for the keyring to be aesthetically pleasing and to appear of high quality, whilst also be inexpensive to manufacture.

One type of keyring is cut from a sheet of material, such as for instance aluminium. Conventionally the finish of the edge of such keyrings is not always particularly smooth. Furthermore, during manufacture a significant amount of handling of the product is often required, using for instance racks to receive the individual keyrings during the different manufacturing stages.

According to the present invention there is provided a method of manufacturing a plurality of items from a sheet of material, the method including making a first cut into one side of the sheet of material, the first cut extending only part way into the sheet of material and extending around the outer edge of the items when finished, providing a second cut into the other side of the sheet of material, the second cut extending only part way into the sheet of material and extending around the outer edge of the items when finished, providing a second cut into the other side of the sheet of material, the second cut extending only part way into the sheet of material and extending around the outer edge of the items when finished, making a third cut wholly through the sheet of material to separate the items from the remainder of the sheet of material.

A design may be printed onto the one side of the sheet of material at locations corresponding to the items prior to making of the first cut.

A design may be printed onto the other side of the sheet of material in locations corresponding to the items prior to making of the second cut, and may be printed onto the other side of the sheet of material prior to making of the first cut.

The designs may be printed by a digital printer, and preferably a high resolution digital printer. Guide markings may be printed onto the sheet of material for use during further manufacturing steps.

The first and second cuts may extend for up to 40% of the depth of the sheet material, and may extend for between 20% and 30% of the depth of the sheet material.

A coating of a settable material may be applied to the parts of the sheet material on the one side corresponding to the items, and the coating may be applied after the first cut has been made, and may be applied after the second cut has been made. A coating of a settable material may be applied to the parts of the sheet material on the other side corresponding to the items, and the coating may be applied after the second cut has been made.

The coating may be of a resin, which resin may be translucent or 25 transparent.

A removable laminate support layer may be applied onto a one side of the sheet material prior to the making of the third cut, which support layer retains the cut items in position relative to the remainder of the sheet of material for a required period after the third cut has been made.

Prior to or when the first cut is made, one or more guide holes may be cut into the sheet of material to facilitate further manufacturing steps being carried out on the sheet material.

The sheet of material may be of metal and may be of aluminium.

Alternatively the sheet of material may be of a plastics material and may be of an acrylic.

The sheet of material may be less than 25 mm thick, may be between 1 and 6 mm thick, and more particularly between 2 and 5 mm thick.

The invention further provides an item made by a method according to any of the preceding thirteen paragraphs.

The invention still further provides a keyring made by a method according to any of said preceding thirteen paragraphs.

An embodiment of the present invention will now be described by way of example only and with reference to the accompanying drawings, in which:-Fig. 1 is a diagrammatic perspective view of part of a first side of a sheet of material at a first stage of a manufacturing process according to the invention; Fig. 2 is a diagrammatic perspective view of part of a second side of a sheet of material at a second stage of a manufacturing process according to the invention.

Fig. 3 is a diagrammatic perspective view of part of the second side the sheet of material of Fig. 1 at a third stage of a manufacturing process according to the invention; Fig. 4 is a more detailed view of part of Fig. 3; Fig. 5 is a cross sectional view through part of the sheet of material of Fig. 1 at the third stage of a manufacturing process according to the invention; Fig. 6 is a similar view to Fig. 4 but of the first side of the sheet of material at a fourth stage of a manufacturing process according to the invention; Fig. 7 is a similar view to Fig. 5 but at a fourth stage of a manufacturing process according to the invention; Fig. 8 is a similar view to Fig. 3 but at a fifth stage of a manufacturing process according to the invention; Fig. 9 is a more detailed view of part of Fig. 8.

Fig. 10 is a similar view to Fig. 5 but at a fifth stage of a manufacturing process according to the invention; Fig. 11 is a similar view to Fig. 6 but at a sixth stage of a manufacturing process according to the invention; Fig. 12 is a similar view to Fig. 5 but at a sixth stage of a manufacturing process according to the invention; Fig. 13 is a similar view to Fig. 5 at a seventh stage of a manufacturing process according to the invention; Fig. 14 is a diagrammatic perspective view of the first side of the sheet of material at an eighth stage of a manufacturing process according to the invention; Fig. 15 is a more detailed view similar to Fig. 14; Fig. 16 is a similar view to Fig. 5 but at an eighth stage of a manufacturing process according to the invention; and Fig. 17 is a perspective view of an item made from a manufacturing process according to the invention, at a final ninth stage.

The drawings show different stages in the manufacture of a keyring 10 as illustrated in Fig. 17. Fig. 1 shows a first stage with a sheet 12 of material, which in this instance is 3mm thick aluminium. A plurality of A side patterns 14 are printed on an A side 16 of the sheet 12 using a high resolution digital printer. The A side patterns 14 are printed in a grid to maximise the best usage of the sheet 12. Guide markings (not shown) are printed onto the sheet 12, for instance towards each corner thereof, to be detected during other manufacturing stages to ensure correct alignment of the sheet 12.

Fig. 2 shows a second stage where B side patterns 18 are printed on a B side 20 of the sheet 12. In this instance the B side patterns 18 correspond to the A side patterns 14, but this may not always be the case. The locations of the B side patterns 18 on the sheet 12 correspond to the locations of the A side patterns 14.

In a third stage as shown in Figs. 3 to 5, a B side cut 22 is provided around each of the B side patterns 18 in the B side 20 to a depth of approximately lmm into the B side 20. The B side cut 22 is made by a digital cutting machine.

The cutting machine reads the guide markings with a camera to ensure correct alignment of the B side cuts 18 relative to the B side patterns 18. After the B side cuts 22 have been made, the cutting machine provides a cut through the sheet 12 corresponding to the guide markings, to provide a positional guide when the sheet 12 is turned over.

A fourth stage is now carried out as shown in Figs. 6 and 7. In the fourth stage an A side cut 24 is provided around each of the A side patterns 14 in the A side 16 again to a depth of approximately 1mm into the A side 16.

Figs. 8 to 10 show a fifth stage in which a clear B side coating 26 is applied onto the B side patterns 18. The B side coating 26 is provided by a settable resin 28 which is dripped onto the B side patterns 18.

In a sixth stage as shown in Figs. 11 and 12, once the resin 28 has set, a removable laminate backing sheet 30 is provided on the B side 20 to cover the B side patterns 18. A similar clear A side coating 32 is then applied onto the A side patterns 14 in a similar manner.

In a seventh stage as shown by Fig. 13, a third cut 34 is made by the cutting machine from the A side 16 to extend wholly through the sheet 12 to provide a plurality of fobs 36 as shown, with a main body 38 and a loop 40 extending therefrom. Whilst the fobs 36 are fully cut away from the remainder of the sheet 12, they are held in position by the backing sheet 30.

The fobs 36 can be pressed out as shown particularly in Figs. 14 to 16, away from the remainder of the sheet 12, and off the backing sheet 30. A ring 42 can then be attached to the loop 40 in a conventional manner as shown in Fig. 17.

There is thus described a method of manufacturing a keyring, and a keyring manufactured by this method, with a number of advantageous features. The use of digital printing enables a wide range of different designs to be applied, and for any required number of keyrings or other items to be made, with the design being readily changeable on the printer.

Providing the first and second partial cuts enables the coating to be applied thereto, but with the third cut extending wholly through the sheet, a single clean cut is provided around the fob, as opposed to previous arrangements which often had a line corresponding to the depth of any partial cuts. Retaining the fobs together on the sheet using for instance the backing sheet, means that all operations can be carried out on a single sheet, with the sheet only having to be turned over twice during the manufacturing process. With the two partial cuts and the two coatings, a keyring with a very pleasing finish and appearance can be produced.

Whilst the above described example relates to a keyring, it is to be realised that processes according to the invention can be used to make a wide range of different products.

Also, a number of modifications may be made without departing from the scope of the invention. For instance the sheet of material may be made of a different material such as another metal or a plastics material such as an acrylic. The sheet may be of a different thickness, and could be up to 25 mm thick. The first and/or second cuts could be to a different depth.

It may not always be required to apply a settable coating, or this may take a different form and be made of a different material. In general such a coating will be transparent, or at least translucent to enable the patterns to be visible.

Whilst endeavouring in the foregoing specification to draw attention to those features of the invention believed to be of particular importance it should be understood that the Applicant claims protection in respect of any patentable feature or combination of features hereinbefore referred to and/or shown in the drawings whether or not particular emphasis has been placed thereon.

Claims

CLAIMS1. A method of manufacturing a plurality of items from a sheet of material, the method including making a first cut into one side of the sheet of material, the first cut extending only part way into the sheet of material and extending around the outer edge of the items when finished, providing a second cut into the other side of the sheet of material, the second cut extending only part way into the sheet of material and extending around the outer edge of the items when finished, making a third cut wholly through the sheet of material to separate the items from the remainder of the sheet of material.
2. A method according to claim 1, in which a design is printed onto the one side of the sheet of material at locations corresponding to the items prior cr) to making of the first cut. T 15
3. A method according to claims 1 or 2, in which a design is printed onto the other side of the sheet of material in locations corresponding to the items (r) prior to making of the second cut.O
4. A method according to claim 3, in which a design is printed onto the other side of the sheet of material in locations corresponding to the items prior to making of the second cut prior to making of the first cut.
5. A method according to any of claims 2 to 4, in which the designs are printed by a digital printer.
6. A method according to claim 5, in which the designs are printed by a high resolution digital printer.
7. A method according to any of the preceding claims, in which guide markings are printed onto the sheet of material for use during further manufacturing steps.
8. A method according to any of the preceding claims, in which the first and second cuts extend for up to 40% of the depth of the sheet material.
9. A method according to claim 8, in which the first and second cuts extend for between 20% and 30% of the depth of the sheet material.
10. A method according to any of the preceding claims, in which a coating of a settable material is applied to the parts of the sheet material on the one side corresponding to the items.
11. A method according to claim 10, in which the coating is applied after the first cut has been made.

1- 15
12. A method according to claim 11, in which the coating is applied after the second cut has been made.

O
13. A method according to any of the preceding claims, in which a coating of a settable material is applied to the parts of the sheet material on the other side corresponding to the items.
14. A method according to claim 13, in which the coating is applied after the second cut has been made.
15. A method according to any of claims 10 to 14, in which the coating is of a resin.
16. A method according to claim 15, in which the resin is translucent or transparent.
17. A method according to any of the preceding claims, in which a removable laminate support layer is applied onto a one side of the sheet material prior to the making of the third cut, which support layer retains the cut items in position relative to the remainder of the sheet of material for a required period after the third cut has been made.
18. A method according to any of the preceding claims, in which prior to or when the first cut is made, one or more guide holes is cut into the sheet of material to facilitate further manufacturing steps being carried out on the sheet material.
19. A method according to any of the preceding claims, in which the sheet of material is of metal.
20. A method according to claim 19, in which the sheet of material is cr) aluminium. T 15
21. A method according to any of claims 1 to 18, in which the sheet of material is a plastics material.
22. A method according to claim 21, in which the sheet of material is an acrylic.
23. A method according to any of the preceding claims, in which the sheet of material is less than 25 mm thick.
24. A method according to claim 23, in which the sheet of material is between 1 and 6 mm thick.
25. A method according to claim 24, in which the sheet of material is between 2 and 5 mm thick.
26. An item made by a method according to any of the preceding claims.
27. A keyring made by a method according to any of the preceding claims.
28. A method of manufacturing a plurality of items from a sheet of material, the method being substantially as hereinbefore described and with reference 5 to the accompanying drawings.
29. An item made by a method substantially as hereinbefore described and with reference to the accompanying drawings.
30. A keyring substantially as hereinbefore described with reference to the accompanying drawings.
31. Any novel subject matter or combination including novel subject matter cr) disclosed herein, whether or not within the scope of or relating to the same invention as any of the preceding claims.O O