A method for processing a blister-molded LED light-emitting cap shell

Abstract

This invention relates to the technical field of luminous cap shell processing, and discloses a method for processing a vacuum-formed LED luminous cap shell, comprising the following steps: (1) printing ink on a transparent sheet and then vacuum forming it to obtain a shaped cap shell; (2) placing the shaped cap shell on a fixed base with the ink layer facing upwards, and irradiating the area where the LED light strip needs to be embedded using a laser ink removal method to remove the printing ink from a local area, thereby obtaining a processed cap shell; (3) installing an LED light strip in the transparent area of ​​the processed cap shell after ink removal, and then covering it with an EPS layer, and integrally molding the processed cap shell, LED light strip, and EPS layer into a foam to obtain an LED luminous cap shell. This invention, through a laser ink removal process, eliminates the need to consider the LED light transmission position and reserve unprinted areas, and is applicable to vacuum-formed cap shell products that require high graphic precision and need to have no ink printing in designated areas.

Description

Technical Field

[0001] This invention relates to the technical field of processing light-emitting cap shells, and in particular to a processing method for vacuum-formed LED light-emitting cap shells. Background Technology

[0002] Hat shells are common items in people's daily life and work, and there are many types. Among them, luminous hat shells can not only increase safety when traveling or working at night, but also add decoration and aesthetic effects.

[0003] Currently, commonly used luminous hat shells include those that emit light using reflectors and those that emit light using LEDs. Hat shells that rely on reflectors primarily emit light by reflecting the light from the reflector, requiring extremely high intensity and angle of the external light source. In practice, they often exhibit weak light intensity and a small luminous area. Hat shells that rely on LEDs, on the other hand, primarily emit light from the LEDs themselves. They are less affected by external factors, and their light intensity better meets daily needs. Therefore, hat shells that emit light using LEDs are gradually gaining popularity.

[0004] The cap shell is usually made by printing ink first and then vacuum forming. Since LED light cannot penetrate ink, the conventional production process requires planning the position where the light strip needs to be installed during the printing stage and then not printing. However, since vacuum forming is a stretch forming process, the printed area will be stretched during the forming process, causing misalignment. It is greatly limited by the shape of the product and it is difficult to meet the functional requirements. Summary of the Invention

[0005] To address the aforementioned technical problems, this invention provides a processing method for vacuum-formed LED light-emitting caps. After conventional printing and vacuum forming processes, a subsequent laser ink removal process is added. This ensures excellent light transmittance in the ink-removed area without affecting the original shape of the molded product, making it better suited for light-emitting cap products that require integrated molding with embedded LED light strips.

[0006] The objective of this invention is achieved through the following technical solution: This invention provides a method for processing a vacuum-formed LED light-emitting cap shell, comprising the following steps:

[0007] (1) Print ink on the transparent sheet and then vacuum-form it to obtain the shaped cap shell;

[0008] (2) After placing the molded cap shell on the fixed base with the ink layer facing upward, the area to be pre-embedded with LED light strip is irradiated by laser ink removal to remove the printing ink in the local area and obtain the processed cap shell.

[0009] (3) Install LED light strips in the transparent area of ​​the processed cap shell after removing the ink, and then cover it with EPS layer. The processed cap shell, LED light strips and EPS layer are integrally molded into a foam to obtain an LED light-emitting cap shell.

[0010] This invention first uses a printing press to print the desired pattern onto a transparent sheet using ink. Then, the printed sheet is vacuum-formed to obtain a shaped cap shell. Next, the areas requiring ink removal are drawn on a laser machine, and the laser power and frequency are set. The laser irradiates the workpiece to remove the printed ink from its surface, making the designated areas transparent as they would be before printing. Subsequently, in the cap shell production process, an LED light strip is correctly installed in this transparent position. Finally, the cap shell, LED light strip, and EPS foam layer are integrally molded to obtain the desired LED-lit cap shell.

[0011] Laser ink removal is a post-processing step. The workpiece can be printed and shaped according to normal product requirements without considering the LED light transmission position or reserving unprinted areas. Furthermore, this process has almost no impact on the shape and ink pattern of the original shaped workpiece, making it suitable for blister-formed caps and similar products requiring high graphic precision and specific areas without ink printing. Additionally, the integrated foam molding enhances the overall integrity of the cap. The LED strip can be directly aligned with the transparent area after laser ink removal, and this transparent area also provides space for the LED strip, reducing the pressure during foam molding and ensuring the stability and integrity of the finished cap.

[0012] Preferably, the laser power for laser ink removal is 10~20W.

[0013] Preferably, the laser frequency for laser ink removal is 15~25KHz.

[0014] Preferably, the laser irradiation rate for laser ink removal is 300~500mm / s.

[0015] Preferably, during the laser ink removal process, the maximum distance between the laser focal point and the surface of the molded cap is 33-36 mm.

[0016] Preferably, the thickness of the ink layer in the molded cap shell is 0.12-0.14 mm.

[0017] Preferably, the curvature of the molded cap shell is Π / 6 to Π / 4.

[0018] The cap shell needs to have a large curvature. During the laser ink removal process, this curvature can cause laser focusing deviation, resulting in insufficient uniformity of ink removal. Therefore, it needs to be used with a base. The fixed base in this invention is a base that fits the shape of the molded cap shell structure, thereby enabling the cap shell to maintain a stable state during the laser ink removal process.

[0019] In addition, due to the large curvature of the cap shell and the thicker ink layer, the laser ink removal process in this invention has high requirements for parameter settings. These parameter settings (including laser power, frequency, irradiation speed, and distance, etc.) can avoid the problems of scorching of the blister packaging product or unsatisfactory ink removal effect.

[0020] Preferably, the transparent sheet is a PC sheet, a PET sheet, or a PVC sheet.

[0021] Transparent sheets formed by thermoforming need to meet the functional and production requirements of safety helmets. However, PC, PET, and PVC are all thermoplastic materials with low heat distortion temperatures. They are prone to product deformation or scorching during laser ink removal. Therefore, parameter settings are particularly important.

[0022] Preferably, the thickness of the transparent sheet is 0.4-0.7 mm.

[0023] The light transmittance of the transparent area can be adjusted according to the actual product requirements, achieving both full and semi-transparent effects.

[0024] Preferably, in step (3), during the foam integral molding process, an elastic colloid layer is provided between the LED light strip and the EPS layer; the elastic colloid layer is EVA double-sided adhesive material.

[0025] The integral molding of foam generates significant pressure and stress, which can easily damage LED light strips, which are embedded components. The added elastic colloid layer can alleviate the pressure and provide protection.

[0026] Preferably, the vacuum forming process includes: softening the transparent sheet at a high temperature of 300~600℃, then ejecting it through a mold, vacuuming, and cooling.

[0027] Compared with the prior art, the present invention has the following beneficial effects:

[0028] (1) After the conventional printing and vacuum forming process, the subsequent process of laser ink removal is added without considering the LED light transmission position and the reserved unprinted area. Moreover, this process has almost no impact on the shape and ink pattern of the original molded workpiece, and is suitable for vacuum-formed cap shell products with high graphic accuracy requirements and the need for ink-free printing in designated positions;

[0029] (2) The cap shell needs to have a large curvature. During the laser ink removal process, this curvature will cause the laser focusing deviation, resulting in insufficient ink removal uniformity. It can be used with a fixed base that matches the shape of the molded cap shell to maintain stability and achieve better ink removal effect.

[0030] (3) Laser ink removal process has high requirements for parameter settings. These parameter settings (including laser power, frequency, irradiation speed and distance, etc.) can avoid the problem of scorching of blister products or unsatisfactory ink removal effect.

[0031] (4) The light transmittance of the transparent area can be adjusted according to the actual product requirements, and can achieve full transparency and semi-transparency effects;

[0032] (5) By processing the cap shell, LED light strip and EPS layer foam into one piece, the stability and integrity of the finished cap shell can be guaranteed. Attached Figure Description

[0033] Figure 1 This is a schematic diagram of the structure of the processed cap shell in this invention;

[0034] Figure 2 This is a schematic diagram of the structure of the fixed base in this invention.

[0035] The attached diagram is labeled as follows: 1. Cap shell; 2. Laser ink removal area; 3. Fixing base. Detailed Implementation

[0036] The technical solution of the present invention is illustrated below with specific embodiments, but the scope of protection of the present invention is not limited thereto:

[0037] General Implementation Examples

[0038] A method for processing a vacuum-formed LED light-emitting cap shell includes the following steps:

[0039] (1) Print ink on PC transparent sheet, PET transparent sheet or PVC transparent sheet (0.4-0.7mm), and then vacuum form it, including softening at high temperature of 300~600℃, and then ejecting it through a mold, vacuuming and cooling steps to obtain the formed cap shell; the arc of the formed cap shell is Π / 6~Π / 4, and the ink layer (thickness of 0.12~0.14mm) is located on the inner surface of the formed cap shell (directly opposite the center of the circle);

[0040] (2) After placing the molded cap shell on the fixed base with the ink layer facing upward, the area to be pre-embedded with LED light strip is irradiated by laser ink removal to remove the printing ink in the local area and obtain the processed cap shell.

[0041] During the laser ink removal process: the maximum distance between the laser focus and the surface of the formed cap (i.e., the distance between the laser focus and the lowest point of the formed cap surface) is 33~36mm, the laser power is 10~20W, the laser frequency is 15~25KHz, and the laser irradiation rate is 300~500mm / s.

[0042] (3) Install LED light strips in the transparent area after removing ink from the processed cap shell, then cover the entire upper layer of the processed cap shell with an EPS layer, place the LED light strip in the middle, and stick EVA double-sided adhesive material between the LED light strip and the EPS layer as an elastic colloid layer. Then, mold the processed cap shell, LED light strip and EPS layer into a foam to obtain an LED light-emitting cap shell.

[0043] Example 1

[0044] A method for processing a vacuum-formed LED light-emitting cap shell includes the following steps:

[0045] (1) Print ink on a transparent PC sheet (thickness of 0.5mm), then vacuum form it, including softening at 300℃, then ejecting it through a mold, vacuuming and cooling to obtain a shaped cap; the arc of the shaped cap is 2Π / 9 (radius R150mm), and the ink layer (thickness of 0.12mm) is located on the inner surface of the shaped cap (directly opposite the center).

[0046] (2) such as Figure 2 The image shows the fixed base 3. After placing the molded cap shell on the fixed base with the ink layer facing upwards, the ink is removed by laser irradiation in the area where the LED strip needs to be embedded, thus removing the printed ink from the localized area. Figure 1 As shown, the processed cap shell is obtained, with the laser ink removal area 2 located on both sides of the cap shell 1;

[0047] During the laser ink removal process: the maximum distance between the laser focus and the surface of the formed cap (i.e., the distance between the laser focus and the lowest point of the formed cap surface) is 35mm, the laser power is 12W, the laser frequency is 20KHz, and the laser irradiation rate is 400mm / s.

[0048] (3) Install LED light strips in the transparent area after removing ink from the processed cap shell, then cover the entire upper layer of the processed cap shell with an EPS layer, place the LED light strip in the middle, and stick EVA double-sided adhesive material between the LED light strip and the EPS layer as an elastic colloid layer. Then, mold the processed cap shell, LED light strip and EPS layer into a foam to obtain an LED light-emitting cap shell.

[0049] Example 2

[0050] A method for processing a vacuum-formed LED light-emitting cap shell includes the following steps:

[0051] (1) Print ink on a transparent PC sheet (thickness of 0.7mm), then vacuum form it, including softening at 300℃, then ejecting it through a mold, vacuuming and cooling to obtain a shaped cap; the arc of the shaped cap is Π / 4 (radius R150mm), and the ink layer (thickness of 0.14mm) is located on the inner surface of the shaped cap (directly opposite the center).

[0052] (2) After placing the molded cap shell on the fixed base with the ink layer facing upward, the area to be pre-embedded with LED light strip is irradiated by laser ink removal to remove the printing ink in the local area and obtain the processed cap shell.

[0053] During the laser ink removal process: the maximum distance between the laser focus and the surface of the formed cap (i.e., the distance between the laser focus and the lowest point of the formed cap surface) is 33mm, the laser power is 16W, the laser frequency is 22KHz, and the laser irradiation rate is 450mm / s.

[0054] (3) Install LED light strips in the transparent area after removing ink from the processed cap shell, then cover the entire upper layer of the processed cap shell with an EPS layer, place the LED light strip in the middle, and stick EVA double-sided adhesive material between the LED light strip and the EPS layer as an elastic colloid layer. Then, mold the processed cap shell, LED light strip and EPS layer into a foam to obtain an LED light-emitting cap shell.

[0055] Example 3

[0056] A method for processing a vacuum-formed LED light-emitting cap shell includes the following steps:

[0057] (1) Print ink on a transparent PC sheet (thickness of 0.4mm), then vacuum form it, including softening at 300℃, then ejecting it through a mold, vacuuming and cooling to obtain a shaped cap; the arc of the shaped cap is Π / 4 (radius R150mm), and the ink layer (thickness of 0.13mm) is located on the inner surface of the shaped cap (directly opposite the center).

[0058] (2) After placing the molded cap shell on the fixed base with the ink layer facing upward, the area to be pre-embedded with LED light strip is irradiated by laser ink removal to remove the printing ink in the local area and obtain the processed cap shell.

[0059] During the laser ink removal process: the maximum distance between the laser focus and the surface of the formed cap (i.e., the distance between the laser focus and the lowest point of the formed cap surface) is 36mm, the laser power is 18W, the laser frequency is 18KHz, and the laser irradiation rate is 400mm / s.

[0060] (3) Install LED light strips in the transparent area after removing ink from the processed cap shell, then cover the entire upper layer of the processed cap shell with an EPS layer, place the LED light strip in the middle, and stick EVA double-sided adhesive material between the LED light strip and the EPS layer as an elastic colloid layer. Then, mold the processed cap shell, LED light strip and EPS layer into a foam to obtain an LED light-emitting cap shell.

[0061] Examples 1-3 all achieved excellent ink removal results, with high removal uniformity and transparency, and the thermoformed products did not show any damage to the shape or ink pattern, or scorching.

[0062] The above are merely preferred embodiments of the present invention and do not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made using the present invention specification, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A method for processing a blister-molded LED light-emitting cap shell, characterized in that, Includes the following steps: (1) Print ink on the transparent sheet and then vacuum-form it to obtain the shaped cap shell; (2) After placing the molded cap shell on the fixed base with the ink layer facing upward, the area to be pre-embedded with LED light strip is irradiated by laser ink removal to remove the printing ink in the local area and obtain the processed cap shell. (3) Install LED light strips in the transparent area of ​​the processed cap shell after removing ink, and then cover it with EPS layer. The processed cap shell, LED light strip and EPS layer are foamed together. During the foaming process, an elastic colloid layer is provided between the LED light strip and the EPS layer to obtain an LED light-emitting cap shell.

2. The processing method of the vacuum-formed LED light-emitting cap shell as described in claim 1, characterized in that, The laser power for laser ink removal is 10~20W.

3. The method of claim 1, wherein the thermoforming process is performed by using a thermoforming machine. The laser frequency for laser ink removal is 15~25KHz.

4. The method of claim 1, wherein the thermoforming process is performed by using a thermoforming machine. The laser irradiation rate for laser ink removal is 300~500mm / s.

5. The method of claim 1-4, wherein the method further comprises the step of: During the laser ink removal process, the maximum distance between the laser focus and the surface of the formed cap is 33~36mm. ​ 6. The method of claim 1-4, wherein the method further comprises the step of: The thickness of the ink layer in the molded cap shell is 0.12~0.14mm. ​ 7. The method of claim 1-4, wherein the method further comprises the step of: The curvature of the molded cap shell is Π / 6~Π / 4. ​ 8. The processing method of the vacuum-formed LED light-emitting cap shell as described in claim 1, characterized in that, The transparent sheet is a PC sheet, a PET sheet, or a PVC sheet.

9. The method of claim 1 or 8, wherein the method further comprises the step of: After the transparent sheet is softened by baking, it is ejected from the mold, vacuumed, and cooled. ​

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