Method for manufacturing decorative element

Abstract

A method of manufacturing one or more decorative elements, comprising the steps of: thermoforming a multilayer film, thereby forming at least one recess in the multilayer film, thereby also forming at least one peripheral collection channel in the multilayer film; infusing a hardened polymer into the at least one recess; applying a cover sheet to the third layer of the multilayer film while the hardened polymer is still in the fluid state; the applying step is performed by applying a pressure on the cover sheet perpendicular and tangential to the multilayer film; pushing the hardened polymer into the at least one peripheral collection channel by a pressure perpendicular to and tangential to the multilayer film in the event that at least a portion of the hardened polymer flows out of the at least one recess by applying the pressure; the polymer previously poured and enclosed between the third layer of the multilayer film and the cover sheet is hardened by a hardening process, and the multilayer film is cut around the at least one recess, thereby obtaining the layered decorative element.

Description

Technical Field

[0001] This invention relates to the manufacture of decorative elements, particularly bright logos suitable for various articles, such as the bodies of motor vehicles and motorcycles, household appliances, bicycles, ships, etc. Background Technology

[0002] A typical example of this type of logo is the vehicle identification badge applied to the rear of a motor vehicle.

[0003] According to an example of existing technology, this type of bright logo is manufactured through a method involving two different steps. In the first step, a core with the desired shape is manufactured by injection molding of a plastic material (such as ABS). In the second step, this core is immersed in a chrome-plated bath, which coats it with a satin overlay that gives it a bright, mirror-like appearance.

[0004] However, this existing technology has many drawbacks. In fact, performing the injection molding and chrome plating stages requires vastly different skills, and few companies possess both. Therefore, they are typically carried out in different locations, resulting in complex logistics and organization. The chrome plating step also requires the use of chemicals harmful to health, making the handling of these products necessitated by stringent safety standards, and environmentally friendly disposal is inherently difficult. As for the injection molding step, it requires molds capable of withstanding the high pressures required by this technology. Consequently, these molds are very expensive, making their preparation only economically viable in the context of large-scale manufacturing. Summary of the Invention

[0005] Therefore, the purpose of this invention is to overcome the shortcomings of the prior art.

[0006] This objective is achieved by the method of manufacturing decorative elements as outlined in the appended claims, wherein the limitations of the claims form part of this specification. Attached Figure Description

[0007] The invention will be better understood through the following detailed description of preferred embodiments of the invention by way of non-limiting example and with reference to the accompanying drawings, wherein:

[0008] - Figure 1 A perspective view of the membrane 10 according to the method of the present invention is shown;

[0009] - Figure 2 The framework 18 of the method according to the invention is shown. Figure 1 A three-dimensional view of the membrane;

[0010] - Figure 3 It shows that it includes Figure 2 Within the framework Figure 1 A three-dimensional view of the membrane;

[0011] - Figure 4 a perspective view of the support frame of Figure 3 equipped at its top with a lamp 22;

[0012] - Figure 5 an exploded perspective view showing a step of the method according to the application, in which a punch 24 and a die 26 operate on the frame of Figure 3 ;

[0013] - Figure 6 is a perspective view of the film of Figure 1 in which recesses 28 have been formed according to the method of the application;

[0014] - Figure 7 is a perspective view of the film 10 of Figure 6 in which a hardening polymer 30 has been injected into the recesses 28 according to the method of the application;

[0015] - Figure 8 is a view of the film 10 of Figure 7 in which the polymer 30 has been injected and leveled according to the method of the application;

[0016] - Figure 9 is a perspective view of the film 10 of Figure 8 in which a cover sheet 32 has been applied to the film according to the method of the application;

[0017] - Figure 10 is a perspective view of the film 10 of Figure 9 but compared to Figure 9 , the film is configured upside down;

[0018] - Figure 11 is a perspective view of Figure 10 in which the film 10 is subjected to a cutting device 36 according to the method of the application;

[0019] - Figure 12 is a perspective view of a layered decorative element, in particular a logo 38, according to the application;

[0020] - Figure 13 is a perspective view of a step of the method according to the application, in which the web exerts a pressure on the cover sheet 32 perpendicular and tangential to the film 10.

[0021] In the attached drawings, identical or similar elements are denoted with the same reference numerals. DETAILED DESCRIPTION

[0022] Reference is made to Figures 1 to 13, shows the first object of the present application, namely a method which provides a series of steps that can be easily performed sequentially in the same device, without resorting to injection moulding and chrome plating techniques. The method is therefore easy to implement, suitable for small and large series, low cost and almost environmentally friendly.

[0023] Another object of the present application is a decorative element obtainable by performing the method described above.

[0024] This decorative element has the advantageous property of being flexible. It can therefore adapt to curved surfaces when applied, without having to be manufactured beforehand with a predetermined curvature. By contrast, the decorative elements of the prior art are undoubtedly rigid, and if they are applied to curved surfaces, they must already have a curved shape with the corresponding profile.

[0025] Further advantages and features of the present application will become apparent from the following detailed description, made by way of non-limiting example, with reference to the attached drawings, wherein:

[0026] Figures 1 to 13 The steps of the method for manufacturing a decorative element according to the present application are shown in the form of a schematic diagram.

[0027] The method for manufacturing a decorative element, in particular a logo, according to the present application is set up to use as starting material a multilayer film 10 ( Figure 1 ) comprising a first transparent protective layer 12, a second decorative layer 14, preferably metallized or containing one or more pigments, and a third support layer 16 made of thermoformable plastic.

[0028] The first transparent protective layer 12 can be made of, for example, polyester, polyvinylidene fluoride or poly(meth)acrylate. The second layer 14 contains, for example, metallic pigments, while the third layer 16 can be made of a material such as ABS or polyurethane or polyethylene terephthalate (PETG) or polymethyl methacrylate (PMMA). The metallic pigments of the second layer 14, preferably indium or indium / tin, give the film 10 a mirror appearance (bright reflective appearance) or a satin appearance or any known metallized appearance. However, it is also possible to use non-metallic pigments to give the film a colored appearance or design, for example by reproducing a carbon fiber effect. The total thickness of the film 10 can generally be between 200 and 500 pm.

[0029] A rectangular section of the multilayer film 10 described above is inserted ( Figure 2 ) into a frame formed by two substantially rectangular frames 18 hinged at their long sides 20. The two frames 18 are then closed one on the other ( Figure 3 ), thus sheltering the film portion 10 in the peripheral area. The film portion is then heated by exposing it to the irradiation of a lamp 22 ( Figure 4) to a temperature preferably comprised between 150 and 200°C and subsequently ( Figure 5 ) clamped between punch 24 and die 26 to have respectively the relief and the impression of the desired shape to be thermoformed. Thermoforming produces at least one recess 28 ( Figure 6 ), preferably a plurality of recesses 28, in the section of film 10, the shape of which corresponds to the shape of the logo to be obtained. In the Figure 6 , recesses 28 are shown having the shape of the letters constituting the word "DEMAK". Needless to say, they can all have the same shape as each other and / or different from the letters of the alphabet, and can exist in a substantially arbitrary number, even possibly equal to one, so that only one large logo is obtained.

[0030] Thermoforming also produces at least one peripheral collection channel 40 ( Figure 13 ) of recesses 28 in film 10;

[0031] Punch 24 is preferably made of a porous material. More preferably, the punch is made of porous aluminum, porous steel or porous synthetic resin. This feature of providing a porous punch has the advantage of obtaining a layered decorative element (in particular a logo) with better aesthetic definition.

[0032] In a subsequent processing step ( Figure 7 ), a hardening polymer 30, preferably having a fluid or liquid state, is infused into recesses 28 to fill them, the polymer adhering to third layer 16. Hardening polymer 30 is preferably a thermosetting polymer or is a thermoplastic polymer. When polymer 30 is a thermosetting polymer, it is preferably of the polyurethane type. Thermoformed film 10 ( Figure 8 ) has good consistency and is substantially self-supporting, so that it acts as a polymer containment tray without the need for dedicated support means during the infusion step.

[0033] When hardening polymer 30 is still in the fluid state, a cover sheet 32 is then applied ( Figure 9 and Figure 13 ) to third layer 16 of film 10, wherein the cover sheet 32 is of the adhesive or double-sided type, or is a removable semi-rigid protective film; wherein the application step is carried out by applying pressure to cover sheet 32 both perpendicular and tangential to film 10, wherein at least a portion of hardening polymer 30 flows out of at least one recess 28 in the case where it is carried out by applying pressure both perpendicular and tangential to film 10, the hardening polymer being pushed by the above-mentioned pressure and flowing into at least one peripheral collection channel 40. Preferably, when cover sheet 32 is of the adhesive or double-sided type, it can comprise a protective film on the face facing film 10, which can be removed when the decorative element is to be applied to a surface. On the other hand, when said cover sheet 32 is a semi-rigid protective film, it is preferably removed after polymer 30 has hardened.

[0034] This feature of providing collection channel 40 has the advantage of preventing polymer 30 from escaping from membrane 10, thereby avoiding contamination of the method equipment in contact with membrane 10.

[0035] The feature of providing pressure perpendicular and tangential to the membrane 10 on the cover sheet 32 ​​has the advantage of flattening it before the polymer hardens. It also allows the removal of excess polymer that may have been injected into the recess 28 by conveying excess polymer to the collection channel 40 created during thermoforming. Furthermore, it allows the removal of air bubbles in the polymer that may still be in a fluid or semi-fluid state and may form between the cover sheet 32 ​​and the polymer 30.

[0036] The step of applying the cover sheet 32 ​​onto the third layer 16 of the membrane 10 is preferably performed using a doctor blade, roller, or other suitable instrument for applying pressure to the cover sheet 32 ​​perpendicular to or tangential to the membrane 10. The doctor blade, roller, or other suitable tool is preferably pressed against the membrane 10 for sliding.

[0037] If polymer 30 is a thermosetting polymer, its curing process (within recess 28) can be accelerated by heating in an oven.

[0038] at last( Figure 11 Using cutting equipment such as a stamping machine or laser processing machine 36, the film 10 is cut around a plurality of recesses 28 filled with polymer 30 and sealed by sheet 32, thereby obtaining a logo 38 of the desired shape. Figure 12 Logo 38 has a layered structure, including an overlapping film layer 10, an infused polymer layer 30, and a cover sheet layer 32. The film layer 10 further includes a first transparent protective layer 12, a second decorative layer 14 containing at least one pigment, and a third support layer 16 of plastic material to which the infused polymer 30 is adhered.

[0039] Of course, without departing from the principles of the invention, structural details and implementation methods can be widely varied relative to what has been described by way of example only, without deviating from the scope of the claims. In particular, the method of the invention makes it possible, in principle, to obtain decorative elements of any number and shape.

Claims

1. A method for manufacturing one or more decorative elements, particularly a logo (38), the method comprising the following steps: - A multilayer film (10) is thermoformed to form at least one recess (28) in the multilayer film (10), characterized in that at least one peripheral collection channel (40) is also formed around the periphery of the recess (28) in the multilayer film (10), wherein the multilayer film includes a first transparent protective layer (12), a second decorative layer (14) containing at least one pigment and a third support layer (16) of thermoformable plastic material. - A hardened polymer (30) is infused into the at least one recess (28), the hardened polymer being adhered to the third support layer (16) of the multilayer film (10). -While the hardened polymer (30) is still in a fluid state, a cover sheet (32) is applied to the third support layer (16) of the multilayer film (10), wherein the cover sheet (32) is adhesive or double-sided, or a removable semi-rigid protective film; wherein the application step is performed by applying pressure perpendicular to and tangential to the multilayer film (10) on the cover sheet (32); wherein, when at least a portion of the hardened polymer (30) flows out from the at least one recess (28) by applying pressure perpendicular to and tangential to the multilayer film (10), the hardened polymer is pushed by the pressure and flows into the at least one peripheral collection channel (40); -The hardening polymer (30) previously infused and sealed between the cover sheet (32) and the third support layer (16) of the multilayer film (10) is hardened by a hardening process; and - Cut the multilayer film (10) around the at least one recess (28) to obtain a layered decorative element comprising a portion of the multilayer film (10), a portion of the cover sheet (32), and a layer of the hardened polymer (30).

2. The method according to claim 1, wherein the application step of applying the cover sheet (32) to the third support layer (16) of the multilayer film (10) is performed by means of a scraper, roller or other suitable tool for applying pressure to the cover sheet (32) perpendicular to and tangential to the multilayer film (10).

3. The method according to claim 1 or 2, wherein, The first transparent protective layer (12) of the multilayer film (10) comprises a plastic material selected from the group consisting of polyester, polyvinylidene fluoride and poly(meth)acrylate.

4. The method according to any one of the preceding claims, wherein, The second decorative layer (14) of the multilayer film (10) contains a metallic pigment, thereby giving the multilayer film (10) a good mirror or satin appearance, wherein the metallic pigment is preferably indium or indium / tin.

5. The method according to any one of the preceding claims, wherein, The third support layer (16) of the multilayer film (10) comprises a material selected from the group consisting of ABS, polyurethane, polyethylene terephthalate and polymethyl methacrylate.

6. The method according to any one of the preceding claims, wherein the thickness of the multilayer film (10) is in the range of 200 μm to 500 μm.

7. The method according to any one of the preceding claims, wherein the multilayer film (10) is thermoformed at a temperature in the range of 150°C to 200°C.

8. The method according to any one of the preceding claims, wherein, During the thermoforming step, a plurality of recesses (28) are formed in the multilayer film (10).

9. The method according to any one of claims 1 to 7, wherein, During the thermoforming step, a single recess (28) is formed in the multilayer film (10).

10. The method according to any one of the preceding claims, wherein the thermoformed multilayer film serves as a self-supporting container, and the hardened polymer (30) is subsequently infused into the self-supporting container.

11. The method according to any one of the preceding claims, wherein the hardening polymer (30) is a thermosetting polymer or a thermoplastic polymer.

12. The method of claim 11, wherein the thermosetting polymer (30) is of the polyurethane type, and is subjected to a heating step in order to accelerate the curing of the thermosetting polymer.

13. The method according to any one of the preceding claims, wherein, The cutting step is performed using a stamping machine or a laser processing machine (36).

14. The method according to any one of the preceding claims, wherein, The thermoforming step is performed using a punch (24) and a die (26), wherein the punch (24) is made of a porous material.

15. A layered decorative element, particularly a logo (38), the decorative element being manufactured by a method according to any one of the preceding claims, the decorative element comprising a film layer (10) stacked on top of each other, an infused polymer layer (30) and a cover sheet layer (32), the film layer (10) further comprising a first transparent protective layer (12), a second decorative layer (14) containing at least one pigment and a third support layer (16) of plastic material.

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