ITMI20060209A1 - OWN CODING PROCESS IN CONTINUOUS CYCLE OF PRODUCTION OF THE IML CECORATION TECHNIQUE IN PLASTIC MATERIAL PRODUCTS - Google Patents

Description

title

PROCESS OF CUSTOMIZATION {OF CUSTOMIZED DECORATION (IE, CUSTOM DECORATION) AND OF OWN CODING (IE, CUSTOM CODING): IN MOLD PERSONALIZATION, IN THE ABBREVIATION IMP®} IN CONTINUOUS CYCLE OF PRODUCTION OF THE IML DECORATION TECHNIQUE (IN CUSTOM MOLD LAB LABELING IN THE MOLD) IN PLASTIC MATERIAL PRODUCTS

summary

The invention relates to a production process innovation that generates a product innovation.

With respect to the field of application, the invention constitutes an innovation in the context of the known decoration technique called IML (In Mold Labeling). This technique is currently used in the following industrial sectors for the transformation of plastic materials / resins:

- injection molding of thermoplastics / thermosets

- compression molding of thermosets / rubbers

- vacuum molding of thermoformed items

- blowing

The invention covers all these fields of application of the transformation of plastic materials / resins.

The invention, in its essential characteristics of technical realization, provides for the preparation of a production system which preferably includes the use of the following series of working cells:

- Graphic computer (preferable but not necessary; See figure Al of drawing N. JJ 057229)

- Graphic printing plotter (See figure A of drawing N. JJ 057229)

- Cutting machine (See figure B of drawing N. JJ 057229)

- Centering device (preferable but not necessary; See figure C of dis.

N. JJ 057229)

- Automatic loading and unloading system (See figure D of drawing N. JJ 057229)

Mold moved by press (injection or compression or thermoforming machine) or by blow molding machine (See figure E of drawing N. JJ 057229)

Exhaust system (See figure F of drawing N. JJ 057229)

The invention, in general, refers to the problem of the decoration and / or personalized coding of molded and blown parts in plastic materials and resins without using post-molding or post-blowing graphic techniques, but by innovating the IML technical note (In Mold Labeling, i.e. in-mold labeling).

The invention, in particular, consists of the possibility of customizing, in a continuous production cycle, the manufacture of plastic details normally decorated by means of the IML technique.

The invention is capable of making the traditional IML technique capable of satisfying the highest levels of customization, since it is capable of changing, within this technique, significant qualitative and quantitative aspects.

By means of this invention, any level of customization in a continuous cycle is available and at the discretion of the manufacturer.

In fact, thanks to it, on the one hand it is possible to customize, in a continuous production cycle, a lot of parts with a large, medium or small volume: e.g. 1000 pieces with the same X decoration, 500 pieces with the same Y decoration, 50 pieces with the same Z decoration;

on the other hand, it is even possible to obtain, always in a continuous production cycle, lots of pieces with decorations uniquely dedicated to them: e.g. n. (enne) pieces with unique decorations.

It is important to underline that the continuity of the cycle is also ensured in the passage from a batch customization - consisting of n. (enne) pieces - to another.

From the application of the invention, therefore, derives a process innovation capable of reaching a level of customization of serial manufacturing such as to make every single product a new product.

In fact, by means of this invention, it is possible to obtain manufactured articles (belonging to mass production batches) which have - each one wanting - aesthetic and / or coding performances of their own.

It is therefore legitimate to state that from the application of this invention comes the possibility of innovating, at will, the look of plastic products usually offered by the market of producers with decorative representations that are homogeneous or repetitive.

Finally, it should be noted that, while in the traditional technique of IML decorative labels are used made exclusively through the graphic printing of plastic film, this invention, on the other hand, also allows the use of labels made of all those materials that support decorative graphic printing: e.g. wood, cork, synthetic or natural fabric, aluminum, steel, paper, organic-natural plastic film, food (e.g. sugar paper, biscuits) etc.

state of the art

The fundamental elements, capable of profoundly modifying the current orientations of the market for plastic details with personalized decoration, are mainly two:

the evolution of graphic techniques in the industrial sectors of pad printing, flexography, screen printing, airbrushing, lithography, hot stamping, laser printing, digital printing, sublimation printing, laser or metal tip engraving, flat or rotary offset printing, rotogravure etc. and technological innovation within the decorative technique known as IML.

The first element is undoubtedly linked to the need to dispose of the artifact before starting to decorate it.

It can be said, in general, that this need - intrinsic to all graphic techniques - actually lengthens the execution times of the production / decoration of the pieces.

The second element, on the other hand, is connected to the possibility of decorating the product at the very moment it is produced.

Since the production of the piece coincides with its decoration, the execution times of the decoration are drastically reduced, with positive consequences on production costs.

This advantage, together with the progressive increase in the quality standards of decorative labels, has led in recent years to a real surge in demand for plastic details decorated by means of IML, spurred on by a particularly unfavorable economic situation.

In the details of the current state of the art, the production process of plastic parts decorated with the IML technique is described below.

An automatic system (e.g .: Cartesian or anthropomorphic robot or dedicated equipment such as horizontal or vertical linear axis) takes from a label-warehouse (or e.g .: from a label centering position or from a counterform, other) one or several printed, decorated and die-cut labels in the shape and design congruent to the particular plastic piece to be decorated and deposits it, in a predetermined position, in the figure (s) of the mold mounted on a press (injection or compression or thermoforming machine) or on a blow molding machine.

The label remains in a position held by a system operating by vacuum or by static charges.

At this point, the press or blow molding machine closes the mold, injecting - in the case of the injection molding machine - or compressing - in the case of the compression press - or thermoforming - in the case of the thermoforming press - or blowing - in the case of the blow molding machine - the plastic material.

At the end of the lamination cycle, the finished / decorated product is taken from the mold and a new label is inserted for a new cycle until the desired number of decorated plastic parts is obtained.

observations on the IML technique in use today

First of all, it should be noted that the traditional IML procedure described above - the only one in use today - requires the use of pre-printed plastic film labels in the desired decorations (e.g. printing of drawings and / or writings and / or codes) and pre-punched into shapes congruent to the particular model to be decorated.

In fact, the current IML technique is marked by the need to have and use labels from large dedicated serial runs. As a result, large label runs necessarily correspond to an equally consistent number of plastic details to be produced and decorated with them.

In particular, this means that the IML technique today is not flexible, or rather rigid with respect to customization needs, characterized, from the quantitative point of view, by low numbers and, from the qualitative point of view, by a high variability index of possible representations and shapes.

From the qualitative point of view, it should also be remembered that today's IML technique does not provide for the use of labels made of materials other than synthetic plastic film and which also support decorative graphic printing: e.g. wood, cork, synthetic or natural fabric, aluminum, steel, paper, organic-natural plastic film, food (e.g. sugar paper, biscuits) etc.

It goes without saying that this limitation to the use of labels made of synthetic plastic film leads to a further reduction in the possibilities of customization.

With respect to all these customization needs, the use of post-molding or post-blowing graphic decoration techniques (e.g. pad printing, flexography, screen printing, airbrushing, lithography, hot stamping, laser printing, digital printing, sublimation printing, laser or metal tip engraving, flat or rotary offset printing, rotogravure, etc.) is predominant and widespread today, as it still seems to be the only way to correspond to it in an economic and technically adequate way.

description of the invention

The invention is called IMP®, In Mold Personalization, that is customization in the mold, and is a process innovation of the usual IML decorative technique.

The innovation, which is intended to bring to the IML technique in use today, involves the use of decorative labels - made at will in all those materials that support decorative graphic printing, including synthetic plastic film: e.g. wood, cork, synthetic or natural fabric, aluminum, steel, paper, natural organic plastic film, food (e.g. sugar paper, biscuits) etc. - obtained by laser printing machine, or digital printing, or sublimation printing, or by other means (see figure A of drawing N. JJ 057229) and shaped by cutting plotter (blade or laser) or by die-cutting machine (cf. . figure B of drawing N. JJ 057229).

The invention provides that these 2 different machines (respectively see figure A and figure B of drawing N. JJ 057229) can have a double alternative logistic arrangement in the production environments: or be integrated in line with the production / decoration system or, alternatively, be located in separate work islands.

Once the decorative labels have been obtained by laser printing, or digital printing, or sublimation printing, or other and have been shaped by cutting plotter (blade or laser) or by die-cutting machine, the production / personalized decoration cycle of plastic parts using the IMP® technique begins its process, as indicated below.

The decorative labels taken from the cutting machine (See figure B of drawing N. JJ 057229) are deposited - preferably, but not necessarily - in a label centering bench (See figure C of drawing N. JJ 057229).

An automatic system (e.g.: Cartesian or anthropomorphic robot or dedicated equipment such as horizontal or vertical linear axis - see figure D of drawing N. JJ 057229 -) takes - preferably, but not necessarily - the labels centering bench (or e.g.: from a label centering position or from a counterform, other - see figure C of drawing N. JJ 057229 -) one or more labels printed, decorated and punched in the shape and design congruent to the particular plastic piece to be decorate and deposits it, in a predetermined position, in the figure (s) of the mold (see figure E of drawing N. JJ 057229) mounted on a press (injection or compression or thermoforming machine) or on a blow molding machine.

The decorative label remains in a position held by a system operating by vacuum or by static charges.

At this point, the press or blow molding machine closes the mold, injecting - in the case of the injection molding machine - or compressing - in the case of the compression press - or thermoforming - in the case of the thermoforming press - or blowing - in the case of the blow molding machine - the plastic material.

At the end of the plasticizing cycle, the finished / decorated product is taken from the mold and deposited on an unloading system (see figure F of drawing N. JJ 057229) and a new label is inserted for a new cycle until the number is obtained. of the desired decorated plastic details.

goals achieved

The current decorative technique of the details through IML guarantees a reduction of the decoration times, as it brings together and brings together, in a single operative moment, the production phase of the plastic particular to the phase of its decoration.

However, the degree of customization of plastic details achieved by the IML technique is nowadays severely limited by the need to use large serial runs of dedicated labels, under penalty of excessive cost of their production. In particular, this means that the quantitative level determines the qualitative level: the availability of the labels both in their possible representations and in their possible shapes is pre-determined together with their quantity.

Moreover, the qualitative level of customization, in the current IML technique, is also penalized by the use of labels made only of synthetic plastic film, with the exception of all those materials that also support decorative graphic printing: e.g. wood, cork, aluminum, steel, paper, natural organic plastic film, food (e.g. sugar paper, biscuits) etc.

The present invention delivers the cost effective production of the labels into the hands of the producer of decorated plastic parts, allowing him the utmost discretion in their personalization and in quantity and quality.

This advantage generates positive externalities regarding:

1) the most significant and usual cost center incurred in the context of the current decorative activity using the IML technique.

Since it is possible to produce labels in quantity and quality exactly corresponding to the desired production / decoration cycle, the stock of labels in the warehouse is reduced to the necessary minimum of just-in-time feeding. The costs of warehouse and storage of labels are eliminated. That is, only the warehouse costs of raw and raw materials such as support material for graphic printing and inks remain.

2) the times usually used in the context of the current decorative activity using the IML technique.

Since it is possible to produce cost effective labels according to the quantity (n. (Enne) pieces) and the desired quality (n. (Enne) types of representation and shapes) c / o the same manufacturer of the finished piece, we guarantee the final customer a greater speed and greater efficiency of order fulfillment. The final customer, that is, can take advantage of a service provided in real time.

3) the relationship between the innovative process and the innovation of the product created through it. The innovation of the present invention lies not only in the process, which improves the productivity of customized objects within the traditional IML technique, but also in the possibility of producing, by means of its application, novel and inventive products.

Finally it should be noted that:

1) the location of the machines necessary for putting the present invention into operation complies with the constraints of minimum overall dimensions;

2) considering the average production of plastic parts with personalized decoration recorded by the sector, the impact of the depreciation of these machines on the cost of the finished product is of low economic importance.

claims

1) Customization process of the IML decoration technique, characterized by a continuous production cycle

2) Customization process of the IML decoration technique, as in the previous claim, characterized by the use of labels made of all those materials that support decorative graphic printing: e.g. wood, cork, synthetic or natural fabric, aluminum, steel, paper, organic-natural plastic film, synthetic plastic film, food {e.g. : sugar paper, biscuits) etc.

3) Customization process of the IML decoration technique, as per the previous claims, characterized by the use of laser printing plotter, or digital printing, or sublimation printing, or other in line with the production system 4) Customization process of the IML decoration technique, as per the preceding claims (all except number 3), characterized by the use of laser printing plotter, or digital printing, or sublimation printing, or other located in a work island separate from the production

5) Customization process of the IML decoration technique, as per the previous claims, characterized by the use

Claims (1)

greater order fulfillment efficiency. The final customer, that is, can take advantage of a service provided in real time. 3) the relationship between the innovative process and the innovation of the product created through it. The innovation of the present invention lies not only in the process, which improves the productivity of customized objects within the traditional IML technique, but also in the possibility of producing, by means of its application, novel and inventive products. Finally it should be noted that: 1) the location of the machines necessary for putting the present invention into operation complies with the constraints of minimum overall dimensions; 2) considering the average production of plastic parts with personalized decoration recorded by the sector, the impact of the depreciation of these machines on the cost of the finished product is of low economic importance. claims 1) Customization process of the IML decoration technique, characterized by a continuous production cycle 2) Customization process of the IML decoration technique, as in the previous claim, characterized by the use of labels made of all those materials that support decorative graphic printing: e.g. wood, cork, synthetic or natural fabric, aluminum, steel, paper, organic-natural plastic film, synthetic plastic film, food {e.g. : sugar paper, biscuits) etc. 3) Customization process of the IML decoration technique, as per the previous claims, characterized by the use of laser printing plotter, or digital printing, or sublimation printing, or other in line with the production system 4) Customization process of the IML decoration technique, as per the previous claims (all except number 3), characterized by the use of laser printing plotter, or digital printing, or sublimation printing, or other located in a work island separate from the production 5) Customization process of the IML decoration technique, as per the previous claims, characterized by the use of a label cutting machine (e.g. die cutter, cutting plotter, laser cutting etc.) in line with the production system 6) customization of the IML decoration technique, as per the previous claims (all except number 5), characterized by the use of a label cutting machine (e.g. die cutter, cutting plotter, laser cutting, etc.) located in a work island separated from the production line