Method and apparatus for manufacturing a shield

Abstract

Method for manufacturing a sign with at least one base plate (100) and at least one lettering element (300), wherein the labeling element (300) is inserted into a lower tool (14), and the base plate (100) is guided against the marking element (300) by means of a tool counterpart (11), characterized by the fact that the labelling element (300) has at least one fastening element (310), that the labeling element (300) is inserted into the lower tool (14) in such a way that at least one fastening element (310) is exposed, that the base plate (100) is guided against the marking element (300) by means of the tool counterpart (11) in such a way that at least one fastening element (310) pierces the base plate (100), and that a riveting tool (123) is lowered onto at least one fastening element (310).

Description

[0001] The invention relates to a method for manufacturing a sign with at least one base plate and at least one lettering element, which includes at least one fastening element. The invention further relates to a device for manufacturing a sign with at least one base plate and at least one lettering element. Signs of the type mentioned above can be used, for example, as vehicle license plates.

[0002] Such signs are known from WO 2011 / 107552 A1. These known signs have a slotted plastic base, which is covered with a film for color design. Lettering elements, such as individual letters or numbers, can be manufactured as plastic components with molded-on fastening elements on the back. When assembling the sign, the fastening elements are inserted through the slots in the base plate and crimped or welded on the back.

[0003] FR 2 692 323 A1 discloses a method according to the preamble of claim 1 or a device according to the preamble of claim 7.

[0004] Based on this state of the art, the invention aims to provide a method and a device for manufacturing such signs faster, more mechanically robust and more cost-effectively.

[0005] The problem is solved according to the invention by a method according to claim 1, a device according to claim 7 and a use according to claim 16.

[0006] According to the invention, it is proposed to assemble a sign from at least one base plate and at least one lettering element. The sign thus obtained can be used, for example, as a license plate for a motor vehicle. Of course, the sign can also serve other purposes, such as marking parking spaces, as a nameplate, or as a prohibition sign. The proposed sign has at least one base plate with a first side and an opposing second side. In this description, it is assumed that the first side faces the object supporting the sign, for example, the motor vehicle. The second side thus faces the viewer. In some embodiments of the invention, the base plate can have a thickness of approximately 1 mm to approximately 20 mm. In other embodiments, the base plate can have a thickness of approximately 2 mm to approximately 10 mm or of approximately 4 mm to approximately 7 mm.The base plate can be made of a relatively soft polymer. In some embodiments of the invention, the base plate can consist of or contain polypropylene.

[0007] The second side of the base plate can have a predefinable color design. For example, the base plate can be made of a colored plastic or be coated with a layer of lacquer or a film. A film layer can be applied to the base plate by bonding or using an in-mold process. Preferably, but not necessarily, the base plate contains no holes or openings, such as slots. In some embodiments of the invention, at least the second side of the base plate is flat and of a uniform color.

[0008] The proposed sign further comprises lettering elements with a first side and an opposing second side. After the sign is completed, the first side of the lettering element rests on the second side of the base plate. According to the invention, at least one protruding fastening element is proposed on the first side of the lettering element to secure it. The protruding fastening element can have a polygonal or round cross-section. During the manufacturing of the lettering element, the fastening element can be directly molded in by injection molding. In some embodiments of the invention, the fastening element can be hollow inside, so that it has the shape of a tube or a sleeve. The number of fastening elements can vary depending on the shape of the lettering element. For example, a simple letter or...A simple digit like an "I" or a "1" might only require two fasteners. More complex letters, such as an "M", can have five or seven fasteners. Generally, the number of fasteners can range from approximately 2 to approximately 12.

[0009] A single marking element can represent a single alphanumeric character or a group of alphanumeric characters, for example, a word or an abbreviation with several letters. In some embodiments of the invention, a marking element can be a round plate or a cup designed to receive an adhesive or solid label or a seal.

[0010] The diameter of a fastening element can be between approximately 1 mm and approximately 10 mm. In other embodiments of the invention, the diameter of a fastening element can be between approximately 1.5 mm and 4 mm. The marking elements consist at least partially of a comparatively hard material. In this case, the hardness and / or the modulus of elasticity are higher than the hardness or impact strength of the base plate material. In some embodiments of the invention, the marking elements can consist of or contain a terpolymer. In some embodiments of the invention, the marking elements can contain or consist of an acrylate ester-styrene-acrylonitrile compound.

[0011] According to the invention, it is proposed to insert the marking element into a lower tool so that at least one fastening element is exposed. The lower tool serves to hold the marking element at a predetermined position and to ensure unambiguous relative positioning to the base plate. Subsequently, the base plate is guided against the marking element by means of a tool counterpart such that the at least one fastening element penetrates the base plate. For this purpose, the base plate can be attached to the tool counterpart or held relative to the lower tool and the tool counterpart by means of a holding device. It was discovered, quite unexpectedly, that the comparatively long and thin fastening elements, which prima facie appear prone to breakage and compression, are nevertheless suitable for penetrating the base plate.This means that the base plate does not need to be drilled or slotted to accommodate the mounting elements of the lettering components. Therefore, the time-consuming process of creating holes, for example with a drilling template, is eliminated, and the base plate can be designed as a universal component that can be fitted with different lettering elements only during the manufacturing of the sign.

[0012] The fasteners are held in the base plate by friction. Furthermore, according to the invention, lowering a riveting tool onto the first side of the base plate, or onto partial surfaces of the first side, deforms a protruding longitudinal section of the fastener, thus increasing its cross-section. This allows for a positive-locking fastening of the lettering element. In the context of this description, a positive-locking fastening is understood to be a fastening in which one longitudinal section of the fastener is larger than a longitudinal section below it, such that the deformed longitudinal section can no longer be guided through the bore in the base plate. In some embodiments of the invention, the riveting tool can provide a flat and / or planar rivet head that does not protrude above the level of the first side of the base plate.

[0013] In some embodiments of the invention, the fastening elements can be hollow inside. In this case, at least some of the material ejected from the base plate when the fastening element is pierced can be contained inside the fastening element, so that no or only a small amount of waste is generated during the production of the shield.

[0014] In some embodiments of the invention, the tool counterpart can have a bore that receives the fastening element after it passes through the base plate. In this case, the tool counterpart can rest almost entirely on the base plate, thus ensuring good force transmission of the pressing pressure to the base plate. Nevertheless, the fastening elements can still exit on the first side of the base plate.

[0015] In some embodiments of the invention, at least one bore in the tool counterpart can have a countersink. This creates an additional receiving space between the base plate and the tool counterpart, which receives the material thrown up when the fasteners pass through. Depending on the depth and shape of the countersink, it can be designed to pre-shape the material thrown up by the fasteners in the base plate according to the shape of the countersink, so that the material can form part of the rivet head.

[0016] In some embodiments of the invention, the diameter of the bore is approximately 30% to approximately 100% larger than the diameter of the fastening element. In other embodiments of the invention, the diameter of the bore is approximately 40% to approximately 60% larger than the diameter of the fastening element. This allows the base plate to split open on the first side in the vicinity of the fastening elements. This avoids the wasteful process of punching out material from the base plate. Furthermore, the material, together with the protrusion of the fastening elements, can serve to form the rivet head.

[0017] In some embodiments of the invention, the riveting tool can be heated, so that a thermoplastic material of the base plate and / or the fastening elements can be more easily formed by heating it to its glass transition temperature. This can prevent the occurrence of mechanical stresses, thus improving durability.

[0018] In some embodiments of the invention, a plurality of riveting tools can be arranged on a riveting block. This allows a plurality of fasteners to be mounted in a single operation.

[0019] In some embodiments of the invention, the riveting block can be connected to the tool counterpart via at least one elastic spacer. In this case, a hydraulic press or roller can act on the riveting block and, in a single operation, first push the fasteners through the base plate without the riveting tools coming into contact with the base plate or the fasteners. After the fasteners have penetrated the base plate, a further increase in the pressing pressure compresses the at least one elastic spacer, allowing the riveting tools to enter through the bores in the tool counterpart and deform the protruding ends of the fasteners. In some embodiments of the invention, a compression spring, a leaf spring, an elastomer, or a bellows can be used as the elastic spacer.

[0020] In some embodiments of the invention, the lower tool has a recess designed to receive the marking element. For this purpose, the recess can be shaped to complement the outer contour of the marking elements. This prevents the marking elements from slipping, allowing them to be positioned and attached to the base plate with high precision.

[0021] In some embodiments of the invention, the depth of the recess in the lower tool can be less than the thickness of the marking element. This ensures that the base plate comes into contact with the marking element and does not rest on the lower tool beforehand. In some embodiments of the invention, the marking element can penetrate the base plate when the material of the base plate is plastically deformed by the marking element. For this purpose, the depth of the recess can be approximately 1 mm to approximately 3 mm less than the thickness of the marking element.

[0022] In some embodiments, multiple lower tools, tool counterparts, and riveting tools can be accommodated in a mounting frame. Each individual lower tool with its associated tool counterpart and riveting tool is designed to hold a specific marking element. A specific marking element comprises one or more letters, numbers, or special characters. By assembling different tools in the mounting frame, a predefined text or character sequence can be applied to the sign.

[0023] In some embodiments of the invention, a plurality of lower tools can be aligned along an adjustment groove. For this purpose, a guide rail can be inserted into this adjustment groove, wherein the tools remain movable along the longitudinal extent of the guide rail, so that predetermined distances between the lower tools can be set or the tools can be pushed together without any gap between them.

[0024] In some embodiments of the invention, a lower tool can be pivotally connected to its associated counterpart. This ensures that the correct counterpart is positioned over each lower tool. Furthermore, the pivoting connection allows the counterpart to be swivelled to provide access to the lower tool for inserting the marking element.

[0025] The invention will now be explained in more detail with reference to figures, without limiting the general concept of the invention. This will show Fig. 1 a base plate with labeling elements. Fig. Figure 2 shows the front and back of an example labeling element. Fig. Figure 3 shows a lower tool with a tool counterpart in a closed form. Fig. Figure 4 shows a lower tool with its counterpart in an open position. Fig. Figure 5 shows a cross-section through the tool during a first process step. Fig. Figure 6 shows a cross-section through the tool during a second process step. Fig. Figure 7 shows a cross-section through the tool during a third process step. Fig. Figure 8 shows a magnified view through the base plate of the shield and the tool counterpart. Fig. Figure 9 shows an enlarged section from Fig. 7.

[0026] Fig. Figure 1 shows a base plate 100 with a first side 101 and an opposing second side 102. The first side 101 is intended to be in contact with the object to which the sign is attached. In the illustrated example of a license plate, the first side 101 faces the motor vehicle. The second side 102 is the visible side, which faces the viewer.

[0027] The second page, 102, can be designed in color to provide the user with desired or prescribed color impressions. For this purpose, the second page, 102, can be coated with a layer of varnish or a foil, for example.

[0028] The base plate 100 is made of a relatively soft material, such as polypropylene or polyvinyl chloride.

[0029] Furthermore time Fig. 1 Labeling elements 300, each comprising a plurality of fastening elements 310. The fastening elements 310 can be manufactured together with the labeling element 300 in an injection molding process so that the fastening elements 310 are integrally attached to the labeling element 300.

[0030] The marking elements 300 consist of a comparatively hard material, for example a terpolymer such as ASA or ABS.

[0031] Fig. Figure 2 shows a detailed view of a labeling element 300. The letter "E" is shown as an example. The labeling element 300 has a first side 301 and a second side 302. After the labeling element 300 is mounted on the base plate 100, the first side 301 comes into contact with the second side 102 of the base plate. In some embodiments of the invention, this joint can additionally be provided with an adhesive or double-sided adhesive tape.

[0032] In the illustrated embodiment, nine fastening elements 310 are arranged on the first side 301. The fastening elements 310 can be cylindrical or conical. In some embodiments of the invention, the fastening elements 310 can be hollow internally, so that they can penetrate the base plate 100 more easily, since less material has to be displaced from the insertion channel. In some embodiments of the invention, the distal end 311 of the fastening elements 310 can have a reduced cross-section, so that the tip of the fastening elements 310 can penetrate the base plate 100 more easily.

[0033] The relative positioning of the base plate and the labeling elements is achieved using the [tool / method - context needed] in [location / method - context needed]. Fig. 3 and Fig. 4 tools are shown. This shows Fig. 3. the tool in a closed position and Fig. Figure 4 shows the tool in an open position.

[0034] The tool consists of a lower tool 14, which in the illustrated embodiment has an approximately cuboid shape. A recess 143 is arranged in the lower tool 14. The recess 143 has a shape complementary to the outer contour of the marking element. This allows the marking element 300 to be inserted into the recess 143 and secured there against transverse displacement. In some embodiments of the invention, the depth of the recess 143 can be less than the thickness of the marking element 300, so that the latter projects beyond the base of the lower tool 14. Furthermore, the lower tool 14 has a guide groove 144. By inserting a rail into the guide groove 144, a plurality of tools 14 can be positioned relative to one another and prevented from shifting relative to each other.This allows several labeling elements 300 to be applied to a base plate 100 in one operation.

[0035] Furthermore, the tool has a counterpart 11. In the counterpart 11, bores 113 are arranged at the locations where fasteners are positioned on the first side 301 of the marking element 300. Thus, when the tool closes, the fasteners can exit the base plate through the bores 113. For this purpose, the fasteners 310 are longer than the thickness of the base plate 100. The bores (113) can have a countersink or chamfer, at least on the side of the counterpart 11 facing the base plate 100. This chamfer can accommodate excess material during the forming of the fastener 310, preventing it from rising into the space between the bore 113 and the riveting tool 123. In this way, jamming of the tool can be avoided.

[0036] The tool counterpart 11 is connected to the lower tool 14 by means of a joint 114. This allows the tool counterpart 11 to be opened by pivoting, so that a marking element can be inserted into the recess 143. At the same time, the tool counterpart 11 remains firmly connected to the lower tool 14, so that the tool counterpart 11 cannot be misplaced and the correct tool counterpart 11 is always available for the respective lower tool 14.

[0037] Furthermore, a base plate 100 is held relative to the marking elements in the lower tool 14 by means of an adjustment and holding device. A recess 144, which is arranged in the counterpart tool 11 and receives the base plate, can serve for this purpose.

[0038] To produce a sign with a predefined character sequence, the required lower tools 14 are first positioned in a mounting frame or fixed relative to each other using the groove 144. In the next process step, the required lettering elements are inserted into the recesses 143. The base plate 100 can then be inserted into the tool, with the second side 102 facing the first side 301 of the lettering elements 300. Finally, the counterpart tool 11 and the riveting block 12 are positioned, and the tool is placed in a pressing device, for example, a roller or a hydraulic press.

[0039] The further course of the procedure will be based on the Fig. 5, Fig. 6 to Fig. 7 explained in more detail. The figures show a cross-section through the tool. Fig. Figure 5 shows the lower tool 14 with the inserted marking element 300. A protruding fastening element 310 is arranged on the first side 301 of the marking element 300. Furthermore, Figure 5 shows the lower tool 14 with the inserted marking element 300. Fig. Figure 5 shows the base plate 100 and the tool counterpart 11 arranged above it. The bore 113 in the tool counterpart 1 is positioned above the fastening element 310. The riveting block 12 is arranged above the tool counterpart 11 and is in contact with the tool counterpart 11 via elastic spacers 13. In the illustrated example, compression springs 13 made of spring steel are used as spacers. The riveting block 12 contains a plurality of riveting tools 123, which are designed to engage in the bore 113. For this purpose, the diameter of the riveting tool 123 can be between approximately 0.1% and approximately 5% smaller than the diameter of the bore 113.

[0040] Fig. Figure 6 shows the tool after the next process step. For this, a compressive force is applied to the riveting block 12, causing the fastening element 310 to pierce the base plate 100. This brings the second side 102 of the base plate 100 into contact with the first side 301 of the marking element 300. Optionally, in some embodiments of the invention, an adhesive can be applied to the first side 301 of the marking element 300, so that the marking element not only holds the fastening elements 310 but is also bonded to the base plate 100 over its entire surface. To prevent the base plate 100 from breaking, the force of the press is transferred over its entire surface via the tool counterpart 11 to the base plate 100. The base plate 100 is only exposed in the bores 113, allowing the fastening elements 310 to protrude there.

[0041] Furthermore, it is from Fig. 6 can be seen that the recesses 143 have a lesser depth than the marking elements 300, so that the base plate 100 comes into contact with the marking element 300 before it rests on the lower tool 14.

[0042] Fig. Figure 7 shows the tool during a further increase in pressure. This causes the marking element 300 to penetrate the base plate 100, so that the base plate comes into contact with the lower tool 14 in its final position. Furthermore, the springs 13 are compressed, allowing the riveting tool 123 to enter the opening 113 and form the protruding portion of the fastening element 310 into a flat rivet head. This achieves a positive-locking fastening of the marking element 300 to the base plate 100.

[0043] Fig. Figure 8 shows an enlarged view of the fastener 310 after it has passed through the base plate 100. The bore 113 in the tool counterpart 11 has a slightly larger diameter than the fastener 310, so that material from the entry channel forms a bead 110 on the first side 101 of the base plate 100. This bead 110 prevents material from the base plate from being ejected as waste, thus eliminating the need for extensive tool cleaning and disposal costs. Furthermore, the material in the bead 110 can be formed together with the protruding portion of the fastener 310, so that both components together form the rivet head.

[0044] Fig. Figure 9 shows an enlarged view from Fig. 7. In Fig.Figure 9 shows how the labeling element 300 penetrates the material of the base plate 100, causing plastic deformation of the base plate 100. This leads to a constriction 120 of the base plate at the edges of the labeling element 300.

[0045] Naturally, the invention is not limited to the embodiments illustrated in the figures. The preceding description is therefore not to be considered limiting, but rather explanatory. The following claims are to be understood as meaning that a named feature is present in at least one embodiment of the invention. This does not preclude the presence of further features. Where the claims and the preceding description define "first" and "second" features, this designation serves to distinguish between two similar features without establishing any hierarchy.

Claims

[1] Method for manufacturing a sign comprising at least one base plate (100) and at least one lettering element (300), wherein the labeling element (300) is inserted into a lower tool (14), and the base plate (100) is guided against the marking element (300) by means of a tool counterpart (11), characterized by , that the labelling element (300) has at least one fastening element (310), that the labeling element (300) is inserted into the lower tool (14) in such a way that at least one fastening element (310) is exposed, that the base plate (100) is guided against the marking element (300) by means of the tool counterpart (11) in such a way that at least one fastening element (310) pierces the base plate (100), and that a riveting tool (123) is lowered onto at least one fastening element (310). [2] Method according to claim 1, characterized by , that at least one fastening element (310) is received in an associated bore (113) in the tool counterpart (11). [3] Method according to claim 2, characterized by , that the riveting tool (123) is inserted into the bore (113). [4] Method according to any one of claims 1 to 3, further comprising the following step: inserting a plurality of lower tools (14), tool counterparts (11) and optional riveting tools (123) into a receiving frame. [5] Method according to any one of claims 1 to 4, further comprising the following step: aligning a plurality of lower tools (14), tool counterparts (11) and optional riveting tools (123) along an alignment groove (144). [6] Method according to any one of claims 1 to 5, characterized by , that the labeling element (300) is at least partially recessed into the base plate (100). [7] Device for manufacturing a sign with at least one base plate (100) and at least one lettering element (300), comprising at least one lower tool (14) designed to receive the marking element (300), and at least one tool counterpart (11) with which the base plate (100) can be guided against the marking element (300), characterized by , that the marking element (300) has at least one fastening element (310), that the base plate (100) can be guided against the marking element (300) with the tool counterpart (11) in such a way that the at least one fastening element (310) pierces the base plate (100), and that the device has at least one riveting tool (123) which can be lowered onto the at least one fastening element (310). [8] Device according to claim 7, characterized bythat the tool counterpart (11) has at least one bore (113) into which the at least one fastening element (310) can be received. [9] Device according to claim 8, characterized by , that the diameter of the bore (113) is approximately 30% to approximately 100% or approximately 40% to approximately 60% larger than the diameter of the at least one fastening element (310) . [10] Device according to claim 8 or 9, characterized by that at least one bore in the tool counterpart has a countersink and / or a chamfer. [11] Device according to any one of claims 7 to 10, characterized by , that at least one riveting tool (123) can be inserted into the bore (113). [12] Device according to claim 11, characterized by , that a plurality of riveting tools (123) are arranged on a riveting block (12). [13] Device according to claim 12, characterized by, that the riveting block (12) is attached to the tool counterpart (11) by means of at least one elastic spacer. [14] Device according to any one of claims 7 to 13, characterized by , that the lower tool (14) has a recess (143) which is intended to accommodate the marking element (300). [15] Device according to claim 14, characterized by , that the depth of the recess (143) is equal to or less than the thickness of the labeling element (300) or that the depth of the recess (143) is approximately 0.1 mm to approximately 3 mm less than the thickness of the labeling element (300). [16] Use of a device according to any one of claims 7 to 15 for the manufacture of a vehicle registration plate.

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