METHOD FOR PRODUCING INTEGRATED EMBLEMS

Abstract

A method for producing an integral emblem, comprising: marking an IMD film (20) with a reference point (71) on it; feeding the IMD film (20) into a cavity (50) of the mold (40); detecting the reference point (71) by the position detector (70); injecting a molten injection material into the cavity (50); solidifying the injection material; and clear-coating a surface of the IMD film with a polyurethane-based lacquer containing a UV stabilizer, wherein at least three or more reference points (71) are marked in corners of the IMD film (20).

Description

BACKGROUND OF THE INVENTION

[0001] The present invention relates to an apparatus and a method for producing an integral emblem (logo), and more particularly to an apparatus and a method for injection molding an integral vehicle emblem by means of an injection molding machine equipped with a film feeder that continuously feeds in-mold decoration (IMD) foils to the mold. Description of related technology

[0002] In general, an emblem or logo is a pictorial representation of a company or organization formed in the form of a number, letter, symbol, or a combination thereof. A manufacturing company emblem is affixed to a surface of a product manufactured by the company and serves as an advertisement for the manufacturing company or product. Vehicle emblems are affixed to exterior and / or interior sections of a vehicle to represent the manufacturing company, including an airbag, the surface of a hood, a hubcap, a side trim, a gearshift, etc.

[0003] Fig. 1 shows a perspective view and an enlarged sectional view of a conventional hubcap with an emblem.

[0004] As in Fig. 1 shows a thin sheet 2 - 1'made of aluminum into a shape, e.g. a circular shape, compression-molded, washed, dried and then partially covered with an emblem or logo using a masking stencil 2 - 2' The logo is then 2 - 2' with a clear coat 30' coated to protect and gloss the dried paint film to ensure weather resistance and resistance to chipping.

[0005] In addition to the above operations, an injection-molded plastic article 10' for the emblem or logo to be affixed to the interior and / or exterior sections of the vehicle. The thin sheet of aluminum 2 - 1' with the emblem or logo 2 - 2' on it and the injection-molded plastic article 10' are combined into the final product using double-sided tape or an adhesive.

[0006] The current manufacturing process involves numerous processes, complicating production and exacerbating quality problems during the process. In particular, the aluminum thin sheet and the injection-molded plastic article are made of different materials, so they are prone to peeling or separation due to weak adhesion, and the back of the aluminum thin sheet will develop a white rust color due to erosion.

[0007] The information disclosed in this Background of the Invention section is provided only to facilitate understanding of the general background of the invention and is not intended as an acknowledgement or any form of indication that it represents prior art known to those skilled in the art. SHORT SUMMARY

[0008] Various aspects of the present invention are directed to providing a manufacturing apparatus and method for injection molding an integral emblem to be applied to vehicle elements using an injection molding machine connected to an in-mold decoration (IMD) film feeder.

[0009] An apparatus for manufacturing an integral emblem according to various embodiments of the present invention may include a mold having first and second molds and a cavity formed therein when closed; an IMD film feeder disposed on the first mold for feeding the IMD film; a position detector disposed in the mold and configured to detect the position of the IMD film; and an injector for the injection material disposed on the back of the second mold and combined with a fluid path of the second mold when the mold is closed.

[0010] Furthermore, according to an embodiment of the present invention, the mold may have a plurality of cavities.

[0011] Furthermore, according to an embodiment of the present invention, the IMD film may have at least three or more reference points that can be detected by the position detector.

[0012] Furthermore, according to an embodiment of the present invention, the position detector may comprise a camera detector arranged on the first mold.

[0013] Furthermore, according to an embodiment of the present invention, the cavity may have a first inner surface which may be embossed or engraved.

[0014] Furthermore, according to an embodiment of the present invention, the apparatus may also include a cooler configured to harden the injected material.

[0015] A method of manufacturing an integrated emblem according to various embodiments of the present invention may include applying and marking a reference point on an IMD film; feeding the IMD film into a cavity of the mold; detecting the reference point by the position detector; injecting a molten injection material into the cavity; and curing the injection material.

[0016] Furthermore, according to an embodiment of the present invention, at least three or more reference points may be marked at corners of the IMD film.

[0017] Furthermore, according to an embodiment of the present invention, the detection of the reference point by the position detector may include the detection of the reference point by a camera detector and the execution of a fine adjustment for positioning the IMD film in the cavity.

[0018] Furthermore, according to an embodiment of the present invention, the injection material may include one or more materials selected from a group consisting of acrylonitrile butadiene styrene (ABS), polycarbonate / acrylonitrile butadiene styrene (PC / ABS), modified polyphenylene oxide (mPPO), poly(methyl methacrylate) (PMMA), polyamide (PA), and polyphenylene ether (PPE).

[0019] Furthermore, according to an embodiment of the present invention, the method may include a clear coating of the surface of the IMD film after curing the injection material.

[0020] The methods and apparatus of the present invention have additional features and advantages which will be apparent from or more particularly illustrated in the accompanying drawings, which are hereby incorporated by reference, and the following detailed description, which together serve to explain certain principles of the present invention. Character list Fig. 1A is a perspective view of a hubcap with an emblem according to the related art; Fig. 1B is an enlarged sectional view of a hubcap with an emblem according to the related art; Fig. 2 is a sectional view of an in-mold decoration (IMD) film according to an embodiment of the present invention; Fig. 3 is a sectional view of an apparatus for manufacturing an integral emblem according to an embodiment of the present invention; Fig. 4A is a perspective view of an integral emblem according to an embodiment of the present invention; Fig. 4B is an enlarged sectional view of an integral emblem according to an embodiment of the present invention; and Fig. 5 is a flowchart schematically illustrating a method of manufacturing an integral emblem according to an embodiment of the present invention.

[0021] It should be understood that the accompanying drawings are not necessarily to scale, presenting a somewhat simplified representation of the various preferred features illustrative of the principles of the invention. The specific design features of the present invention disclosed herein, including, for example, particular dimensions, orientations, locations, and shapes, will be determined in part by the particular intended application and the environmental conditions at the site of use.

[0022] In the figures, identical reference numerals designate the same or equivalent parts of the present invention in the different figures of the drawing. DETAILED DESCRIPTION

[0023] Reference will now be made in detail to various embodiments of the present invention(s), examples of which are illustrated in the accompanying drawings and described below. While the invention(s) will be described in conjunction with exemplary embodiments, it is to be understood that the present description is not intended to limit the invention(s) to these embodiments. Rather, the invention(s) are intended to cover not only the exemplary embodiments, but also various alternatives, modifications, equivalents, and other embodiments within the spirit and scope of the invention as defined by the appended claims.

[0024] Not all elements of the embodiments of the present invention are described, and descriptions of what is generally known in the art or of overlaps in the embodiments are omitted.

[0025] The term “includes (or containing)” or “comprises (or having)” is inclusive or open-ended and does not exclude additional, unmentioned elements or process steps unless otherwise stated.

[0026] Although the terms "first," "second," "third," etc., may be used herein to describe various elements, components, regions, layers, and / or sections, it is understood that these elements, components, regions, layers, and / or sections should not be limited by these terms. These terms are used only to distinguish one element, component, region, layer, and / or section from another region, layer, or section.

[0027] It is understood that the singular forms “one, an, one” and “the, the, the” also include the plural forms, unless the context clearly dictates otherwise.

[0028] Reference symbols used for method steps are for convenience only and do not restrict the sequence of steps. Therefore, unless the context clearly dictates otherwise, the written sequence may be represented in other ways.

[0029] Various aspects of the present invention are directed to providing an apparatus and method for manufacturing an integral emblem. An emblem is a pictorial representation of a company or organization formed in the form of a number, a letter, a symbol, or a combination thereof, and includes a logo. An integral emblem according to various embodiments of the present invention relates to an emblem to be arranged on interior and / or exterior portions of a vehicle and is described using hubcaps of the four wheels of any vehicle type as an example. However, the scope of the present invention is not limited to the emblem on the hubcap, but includes any emblem to be arranged on any interior and / or exterior portions of the vehicle.

[0030] Fig. 2 is a sectional view of an in-mold decoration (IMD) film used in a manufacturing apparatus 100 according to an embodiment of the present invention. First, Fig. 2 an IMD film used in a manufacturing apparatus and method according to various embodiments of the present invention 20 described.

[0031] IMD is a technology for transferring a printed pattern to a surface, such as a plastic or ceramic product, in a mold simultaneously with injection molding. This technology involves inserting a film laminated with the printed pattern into the mold during injection molding of the plastic or ceramic product. An IMD film is a film used in the IMD process. IMD film is widely used for decorating and protecting the casing of a smartphone, laptop, personal computer (PC), and / or digital camera, the casing of various kitchen appliances, a cosmetic container, and / or the surface of automotive components.

[0032] The IMD film 20 can be an adhesive layer 1 , a printed layer 2 and a top layer 3 contain.

[0033] In an apparatus and method for producing an integral emblem, which will be described later, the adhesive layer 1 the adhesion force between an injection material and the printed layer 2 reinforce, whereby the IMD film 20 in a first form 41 is placed when a molten injection material is injected into a closed mold 40 is injected.

[0034] The printed layer 2 is on the adhesive layer 1 formed and can have a silver printed layer 2 - 1 corresponding to a thin film of aluminum 2 - 1' and a black printed layer 2 - 2 corresponding to a partial painting 2 - 2' The silver printed layer 2 - 1may contain a silver printing ink and thinner, where the silver printing ink contains, for example, chromium (Cr). The black printed layer 2 - 2 may contain black printing ink and thinner.

[0035] The top layer 3 can be printed on the layer 2 and be an elastic and flexible resin film. The top layer 3 can be, for example, a polyethylene terephthalate (PET) resin.

[0036] Fig. 3 is a sectional view of an apparatus for manufacturing an integral emblem according to an embodiment of the present invention.

[0037] As in Fig. 3 contains a device 100 for producing an integral emblem according to various embodiments of the present invention, the form 40 with the first form 41 and a second form 45and a cavity formed in the closed state 50 ; an IMD film feeder 60 , which is part of the first form 41 for feeding the IMD foil 20 arranged in the form 40 arranged and used to detect a position of the IMD foil 20 configured position detector 70 ; and an injection material injector 80 , which is attached to a rear surface of the second mold 45 arranged and provided with a fluid path of the second form 45 is connected when the form 40 is closed.

[0038] The shape 40 contains the first form 41 and the second form 45 . The first and second forms 41 and 45 are between a closed position in which the first and second form 41 and 45are in close contact with each other, and an open position in which the first and second forms 41 and 45 separated from each other, movable. In general, the second form 45 between the closed position and the open position by moving close to the first form 41 or from the first form 41 moved away, while the first form 41 remains immobile; but the opposite case is also possible.

[0039] If the first and second form 41 and 45 are closed, they can open the cavity 50 form a closed area corresponding to injection-molded articles of an integral emblem according to various aspects of the present invention. The cavity 50 may have a shape defined such that a first inner surface 43 of the cavity 50an upper surface of the injection-molded article of an integral emblem and a second inner surface 47 a lower surface of the injection-molded article of an integral emblem.

[0040] Although the form 40 with a single cavity formed within it 50 shown, the form 40 the manufacturing device 100 also with a plurality of cavities 50 For example, two or more cavities 50 to increase productivity. In this case, the IMD film feeder can 60 , which will be described later, the IMD foil printed with an emblem 20 according to the majority of cavities 50 supply.

[0041] The IMD film 20 can be fed from the IMD film feeder 60 be fed one after the other when the cavities 50 in the form 40are positioned.

[0042] The IMD film feeder 60 can be found in the first form 41 be arranged and the form 40 a roll or sheet of IMD film 20 which are arranged around the IMD film feeder 60 The IMD foil is wound 20 for the top layer 3 the IMD film 20 so that they reach the first inner surface 43 of the cavity 50 The IMD film feeder 60 the IMD film can 20 depending on the opening or closing of the mold 40 automatically. For example, if the form 40 opened after injection molding, the IMD film feeding device can 60 the IMD film 20 feed automatically.

[0043] In one embodiment of the present invention, the first inner surface 43 of the cavity 50embossed or engraved. Since the shape of an emblem or logo on the first inner surface 43 of the cavity 50 embossed or engraved, the emblem or logo of an injection-molded product may appear in intaglio or letterpress. In other words, in a case where the emblem is on the first inner surface 43 of the cavity 50 embossed, the emblem appears in intaglio, i.e. in a form concave inwards from the upper surface of the injection-molded product, and in a case where the emblem is on the first inner surface 43 of the cavity 50 engraved, the emblem appears in high pressure, i.e. in a form that protrudes from the surface of the injection-molded product due to the injection pressure.

[0044] Compared to the conventional process with the thin film of aluminum 2 - 1' can emboss or engrave the first inner surface 43of the cavity 50 according to the shape of the IMD film 20 to be printed, simplify a three-dimensional embodiment of the emblem or logo.

[0045] The form 40 IMD film to be fed 20 must be aligned with the cavity to position the emblem or logo 50 exactly match. If the emblem of the IMD foil 20 e.g. not exactly in the center of the cavity 50 of a round integral emblem, the final injection-molded product may be offset upwards, downwards, left or right on one side.

[0046] The device 100 for the production of an integral emblem contains the in the form 40 arranged and used to detect a position of the IMD foil 20 configured position detector 70 . The position detector 70 can detect whether the position of the IMD foil 20a required position in the cavity 50 If the position of the IMD foil 20 not the required position in the cavity 50 the IMD film feeder can 60 a foil position adjuster for fine adjustment of the position of the IMD foil 20 contain.

[0047] The position detector 70 can be found in the first form 41 or the second form 45 In a case where the position detector 70 on the first form 41 or the second form 45 arranged, the detector can 70 on an inner surface of the mold 40 be arranged, which when the form is open 40 shown to determine the position of the successively fed IMD foil 20 Optionally, the position detector 70 on one side of the first form 41 or the second form45 be arranged.

[0048] For fine adjustment, the IMD foil 20 a reference point 71 which the position detector 70 can detect. The reference point 71 can be placed on the outside of the IMD foil 20 printed emblem or logo, and at least three or more reference points may be provided. If only two or fewer reference points 71 are present, only a two-dimensional tilt of the IMD foil 20 be detected, which is why it is desirable to have three or more reference points 71 In the case where the form 40 For example, if the area is rectangular, four reference points can be marked.

[0049] The reference point 71 detecting position detector 70 may include a camera detector. The camera detector may be attached to the first form 41 or the second form45 to detect the reference point 71 on the supplied IMD foil 20 If the reference point detected by the camera detector 71 is not in the correct position, the shape 40 closed after fine adjustment of the position.

[0050] By adjusting the position of the IMD foil 20 using the position detector 7 The integral emblem produced according to various aspects of the present invention by the manufacturing apparatus 100 injection-molded, are located exactly in the middle or at a desired position during production.

[0051] An injection material injector 80 can be attached to the back of the second form 45 arranged and with an injection material fluid path in the second mold 45 be connected if the form 40 is closed. The injection material injector80 injects the injection material through the injection material fluid path into the cavity 50 to fill the cavity 50 to fill. Once the IMD film 20 has been supplied and the fine adjustment by the position detector 70 is finished, the form 40 closed and the injection material injector 80 can be combined with a combiner on the back of the second form 45 be moved when the shape 40 is closed, and the injection material flows through the injection material fluid path into the cavity 50 divert.

[0052] In one embodiment of the present invention, the device 100 for producing an integral emblem further comprising a cooler for hardening the injected injection material. The cooler may contain the material injected into the cavity 50 injected injection material by cooling the closed mold40 harden.

[0053] Fig. 4 shows a perspective view and an enlarged sectional view of an integral emblem according to an embodiment of the present invention.

[0054] As in Fig. 4 shows an integral emblem which is produced by means of the manufacturing device 100 manufactured according to an embodiment of the present invention, integral with the injection-molded article 10' manufactured, the conventional thin film of aluminum 2 - 1' and the partial painting 2 - 2' through the IMD film 20 A molten injection material of high temperature is bonded to the adhesive layer 1 on the back surface of the IMD film 20 not only chemically, but also physically by the injection pressure of the injection material from the injection material injector 80which solves the problem of chipping or peeling.

[0055] The integral emblem may also have a clear coat finish 30 on the upper surface of the IMD film 20 to improve weather resistance and resistance to chipping.

[0056] In the following, a method for manufacturing an integral emblem according to various embodiments of the present invention will be described.

[0057] Fig. 5 is a flowchart schematically illustrating a method of manufacturing an integral emblem according to an embodiment of the present invention.

[0058] The method may include marking a reference point on an IMD foil ( S10 ); feeding the IMD film into a cavity of the mold ( S20 ); the detection of the reference point by the position detector ( S30); injecting a molten injection material into the cavity ( S40 ); and the hardening of the injection material ( S50 ).

[0059] To prepare the IMD foil with a reference point marked on it ( S10 ) is an IMD film, e.g. the IMD film printed with an emblem 20 (see Fig. 2). As described above, the IMD film 20 a layer printed with an emblem 2 and the position detector 70 detectable reference point 71 can be marked at corners around the emblem.

[0060] The corners in which reference points 71 marked are not located in an upper surface of an injection-molded final product of the IMD film 20 . At least three or more reference points 71 be marked to ensure the correct position of the IMD foil 20to detect, and preferably four or more reference points 71 be marked.

[0061] The operation of feeding the IMD film into a cavity of a mold ( S20 ) contains the supply of the IMD film 20 through the IMD film feeder 60 , where a surface in which the cavity 60 opened first form 41 is formed, and the top layer 3 the IMD film 20 facing each other. The IMD film feeder 60 the IMD film can 20 one after the other, and the IMD foil 20 automatically as soon as the form 40 is opened after injection molding.

[0062] The operation of detecting the reference point by the position detector ( S30 ) contains the detection of the reference point 71 by the position detector 70 to print the image on the supplied IMD film 20printed emblem exactly in the middle of the cavity 50 to position. The position detector 70 can be a camera detector, and if the camera detector detects that the reference point 71 is not positioned correctly, fine adjustment can be carried out. If the reference point 71 is in the correct position or has been finely adjusted, the shape 40 closed.

[0063] The operation of injecting a molten injection material into the cavity ( S40 ) involves injecting an injection material into the cavity 50 the closed form 40 through the injection material injector 80 . The injection material injector 80 is moved to connect with a combiner for the injection material injector, which is mounted on the rear surface of the second mold 45 is arranged, and after the injection material injector80 connected to the combiner, the injection material is injected through the injection material fluid path in the second mold 45 into the cavity 50 The inlet of the injection material fluid path is combined with the combiner for the injection material injector, and the outlet of the injection material fluid path is connected to a point in the center of the second inner surface 47 of the cavity 50 tied together.

[0064] The injection material may contain a thermoplastic resin and may include one or more materials selected from a group consisting of acrylonitrile butadiene styrene (ABS), polycarbonate / acrylonitrile butadiene styrene (PC / ABS), modified polyphenylene oxide (mPPO), poly(methyl methacrylate) (PMMA), polyamide (PA), and polyphenylene ether (PPE). An ABS-based injection material has good adhesion properties, especially for the IMD film. 20 .

[0065] The process of hardening the injection material ( S50 ) involves forming an injection-molded final product, ie an integral emblem, by cooling the closed mold 40 to harden the cavity 50 injected molten injection material. A stable integral emblem can be achieved through the physical and chemical combination between the adhesive layer 1 the IMD film 20 and the injection material. To cool the closed mold 40 The above-mentioned cooler can be used for rapid cooling. Once curing is complete, the finished injection-molded product, i.e. the integral emblem, can be produced by opening the first and second molds. 41 and 45 be taken.

[0066] In addition, an embodiment of the present invention may further include coating the surface of the IMD film ( S60) after curing of the injection material ( S50 ) with clear varnish.

[0067] The upper surface of the removed integral emblem is made of IMD film 20 Formed for use in and on a vehicle, for which increased weather resistance and chipping resistance are required for an emblem, and in this case, a clear coat may be applied. A clear coat topcoat may be a polyurethane-based paint containing an ultraviolet (UV) stabilizer.

[0068] As described above, the first inner surface 43 of the cavity 50 embossed or engraved. Since the shape of an emblem or logo on the first inner surface 43 of the cavity 50embossed or engraved, the emblem or logo of an injection-molded product may appear in intaglio or letterpress. In other words, in a case where the emblem is on the first inner surface 43 of the cavity 50 embossed, the emblem appears in intaglio, i.e. in a form concave inwards from the upper surface of the injection-molded product, and in a case where the emblem is on the first inner surface 43 of the cavity 50 engraved, the emblem appears in high pressure, i.e. in a form that protrudes from the surface of the injection-molded product due to the injection pressure.

[0069] A three-dimensional emblem can be produced by using only the IMD method, and it is also possible to realize different designs even by combining it with an INS method or a combination with a metal-coated article. The INS method refers to a process in which a film is press-formed, the embossed or engraved film is transferred, and the transferred result is injection-molded. It is possible to produce combinations of emblems in various colors and with various three-dimensional figures by combining a three-dimensional injection-molded article according to the INS method and an injection-molded article according to the IMD method of the present invention.

[0070] For embodiments of an apparatus and method for manufacturing an integral emblem, the following advantages are expected: reducing the number of processes and thus ensuring cost competitiveness compared with the current process of separately manufacturing and attaching an aluminum thin sheet and an injection-molded article to each other, improving the degree of freedom in design for realizing an emblem or logo by using a pattern printed on an IMD film, easily expressing color and three-dimensional effect of the emblem or logo, which is difficult with the current aluminum thin film, and solving the possible erosion problem on the back surface of the aluminum thin film and the problem of chipping from the injection-molded article.

[0071] For ease of description and for precise definition in the appended claims, the terms "upper", "upper", "lower", "lower", "upward", "downward", "upward", "downward", "inward", "outward", "inside", "outside", "inside", "outside", "inwardly", "outwardly", "internally", "externally", "front", "backward", "forward" and "backward" are used to describe features of the embodiments with reference to the positions of such features as shown in the figures.

[0072] The above descriptions of specific embodiments of the present invention are provided for purposes of example and description. They are not intended to be exhaustive or to limit the invention to the forms disclosed, and obviously numerous modifications and variations are possible in light of the above teachings. The embodiments were chosen and described in order to explain certain principles of the invention and their practical application to enable others skilled in the art to make and utilize various embodiments of the present invention, as well as various alternatives and modifications. It is intended that the scope of the invention be defined by the appended claims and their equivalents.

Claims

[1] Apparatus for producing an integral emblem, the apparatus comprising: a mold having a first and a second mold and a cavity formed therein when closed; an in-mold decoration (IMD) film feeder arranged on the first mold for feeding an IMD film; a position detector arranged in the mold and configured to detect the position of the IMD film; and an injector for the injection material, which is arranged at the rear of the second mold and is combined with a fluid path of the second mold when the mold is closed. [2] The device of claim 1, wherein the mold includes a plurality of cavities. [3] The device according to claim 1, wherein the IMD film has at least three or more reference points that can be detected by the position detector. [4] The apparatus of claim 1, wherein the position detector includes a camera detector disposed in the first mold. [5] The device of claim 1, wherein the cavity has a first inner surface that is embossed or engraved. [6] The apparatus of claim 1, further including a cooler configured to harden the injected injection material. [7] A method of manufacturing an integral emblem, the method comprising: Marking an in-mold decoration (IMD) film with a reference point on it; Feeding the IMD film into a cavity of the mold; Detecting the reference point by the position detector; Injecting a molten injection material into the cavity; and Hardening of the injection material. [8] The method of claim 7, wherein at least three or more reference points are marked in corners of the IMD film. [9] The method of claim 7, wherein the detection of the reference point by the position detector includes: Detecting the reference point by a camera detector; and Performing a fine adjustment to place the IMD film in the cavity. [10] The method of claim 7, wherein the injection material comprises one or more materials selected from a group consisting of acrylonitrile butadiene styrene (ABS), polycarbonate / acrylonitrile butadiene styrene (PC / ABS), modified polyphenylene oxide (mPPO), poly(methyl methacrylate) (PMMA), polyamide (PA) and polyphenylene ether (PPE). [11] The method of claim 7, further comprising, after curing the injection material, a clear coating of a surface of the IMD film.

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