Method for producing decorative elements

Abstract

To provide a method for producing decorative elements, in particular insignia, that are applicable to various articles, such as the bodies of motor vehicles and motorcycles, household appliances, bicycles, boats and the like.SOLUTION: There is provided a method for producing decorative elements, the method comprising the steps of: thermoforming a multiple-layer film 10 comprising a first transparent protective layer, a second decorative layer containing pigments, and a third supporting layer of a thermoformable plastic material so as to form at least one recess 28; pouring a hardening polymer 30 into the at least one recess formed in the third supporting layer and applying a covering sheet 32 onto the third supporting layer; hardening the hardening polymer enclosed between the third supporting layer and the covering sheet through a hardening process; and cutting the film 10 around the at least one recess to obtain a stratified decorative element comprising a portion of the film 10, a hardening layer of the polymer and a portion of the covering sheet.SELECTED DRAWING: Figure 13

Description

[Technical Field]

[0001] The present invention relates to the production of decorative elements, in particular bright emblems, which can be applied to various articles such as automobile and motorcycle bodies, household appliances, bicycles, boats, etc. [Background technology]

[0002] A typical example of such an emblem is a model type identification badge attached to the rear of a motor vehicle.

[0003] According to one example from the prior art, this type of shiny emblem is produced by a two-step process. In the first step, a core of the desired shape is produced by injection molding a plastic material, such as ABS. In the second step, this core is immersed in a chrome plating bath to be coated with a glossy coating that gives it a bright, reflective appearance.

[0004] However, this conventional technology has several drawbacks. Indeed, the injection molding and chrome plating steps require distinctly different skills, rarely possessed by the same company. Therefore, they are usually performed in different locations, resulting in logistical and organizational complexities. Furthermore, the chrome plating process requires the use of chemicals that are hazardous to health, which require strict safety standards for their handling and, in both cases, make their disposal in an environmentally friendly manner difficult. The injection molding process requires molds that can withstand the high pressures required by this type of technology. Therefore, such molds are very expensive, and their provision is economically justified only for mass production. Summary of the Invention [Problem to be solved by the invention]

[0005] SUMMARY OF THE INVENTION It is therefore an object of the present invention to overcome the above-mentioned drawbacks of the prior art. [Means for solving the problem]

[0006] Such object is achieved by a method for producing a decorative element as outlined in the appended claims, the definitions of which form an integral part of this specification. [Brief explanation of the drawings]

[0007] The invention will be better understood from the following detailed description of preferred embodiments thereof, given by way of non-limiting example with reference to the accompanying drawings, in which:

[0008] [Figure 1] 1 is a perspective view of a film (10) of the method according to the invention. [Figure 2] 2 is a perspective view of the frame (18) of the film of FIG. 1 and the method according to the invention. [Figure 3] 3 is a perspective view of the film of FIG. 1 contained within the frame of FIG. 2. [Figure 4] 4 is a perspective view of the support frame of FIG. 3 with a lamp (22) mounted thereon in accordance with the method of the present invention. [Figure 5] 4 is an exploded perspective view of a step in the method according to the invention, in which a punch (24) and a die (26) operate on the frame of FIG. 3. FIG. [Figure 6] FIG. 2 is a perspective view of the film of FIG. 1 in which recesses (28) have been formed according to the method of the present invention. [Figure 7] FIG. 7 is a perspective view of the film (10) of FIG. 6, with a curable polymer (30) being injected into the recesses (28) according to the method of the present invention. [Figure 8] FIG. 8 is a view of the film (10) of FIG. 7, which has been infused with a polymer (30) and flattened according to the method of the present invention. [Figure 9] FIG. 9 is a perspective view of the film (10) of FIG. 8 to which a covering sheet (32) has been applied in accordance with the method of the present invention. [Figure 10] 9. This is a perspective view of the film (10) of FIG. 9, but in an upside-down configuration compared to the configuration of FIG. [Figure 11]11 is a perspective view of FIG. 10, in which the film (10) is subjected to the action of a cutting device (36) according to the method of the present invention. [Figure 12] 1 is a perspective view of a layered decorative element according to the invention, in particular an emblem (38). [Figure 13] 1 is a perspective view of a step in the method according to the invention, in which the web exerts pressure on the cover sheet (32) both normal and tangential to the film (10).

[0009] In the accompanying drawings, identical or similar elements are designated with the same reference numerals. DETAILED DESCRIPTION OF THE INVENTION

[0010] 1 to 13, the first object of the present invention is to provide a method for producing a series of processes that can be easily carried out continuously in the same plant without relying on injection molding and chrome plating techniques. As a result, it is easy to implement, adaptable to both small and large scale series production, inexpensive, and has little impact on the environment.

[0011] A further object of the invention is a decorative element obtained as a result of carrying out the method described above.

[0012] Such decorative elements have the advantageous property of being highly flexible, and therefore can adapt to curved surfaces at the moment of their application, without having to be already manufactured with a corresponding predefined curvature. In contrast, decorative elements of the prior art are clearly rigid, and when they are applied to curved surfaces, they must already have a curved shape with a corresponding contour.

[0013] Further advantages and features of the invention will become apparent from the following detailed description, given by way of non-limiting example with reference to the accompanying drawings, in which:

[0014] 1 to 13 show in schematic form the steps of a method for manufacturing a decorative element according to the invention.

[0015] The method for producing a decorative element, in particular an emblem, according to the invention uses as starting material (FIG. 1) a multilayer film 10 comprising a first transparent protective layer 12, a second decorative layer 14, which is preferably metallized or contains one or more pigments, and a third support layer 16 of a thermoformable plastic material.

[0016] The first transparent protective layer 12 can be formed, for example, from polyester, polyvinylidene fluoride, or poly(meth)acrylate. The second layer 14 contains, for example, a metallic pigment, and the third layer 16 may be made of a material such as ABS, polyurethane, polyethylene terephthalate glycol (PETG), or polymethyl methacrylate (PMMA). The metallic pigment in the second layer 14, preferably indium or indium / tin, gives the film 10 a brilliant reflective or satin appearance, or a known metallic appearance. However, it is also possible to use non-metallic pigments to give the film a colored appearance or design, for example, by recreating a carbon fiber effect. The overall thickness of the film 10 can typically be 200 to 500 μm.

[0017] The rectangular segment of the multilayer film 10 described above is inserted into a frame formed by two substantially rectangular frames 18 hinged at their long sides 20 (FIG. 2). The two frames 18 are then closed on top of each other (FIG. 3), thereby fixing the film segment 10 at its peripheral area. The film 10 is then heated to a temperature of preferably 150-200°C by irradiating it with a lamp 22 (FIG. 4) and then thermoformed by clamping it between a punch 24 and a die 26, each of which has a desired shape. (FIG. 5) Thermoforming produces at least one recess 28, preferably multiple recesses 28, in the segment of film 10 (FIG. 6), whose shape corresponds to the shape of the emblem to be obtained. In FIG. 6, the recesses 28 are shown as having the shape of the letters that make up the word "DEMAK." Needless to say, these may all be identical to one another or may have shapes different from the letters of the alphabet, and they can be present in virtually any number, even creating a single large emblem.

[0018] Thermoforming also creates at least one peripheral collection channel 40 in the recess 28 in the film 10 (FIG. 13).

[0019] The punch 24 is preferably made of a porous material, even more preferably porous aluminum, porous steel, or porous synthetic resin. This feature of providing a porous punch offers the advantage of obtaining layered decorative elements, especially emblems, with better aesthetic definition.

[0020] In a subsequent processing step (FIG. 7), a curable polymer 30, preferably in a fluid or liquid state, is injected to fill the recesses 28, and the polymer adheres to the third layer 16. The curable polymer 30 is preferably a thermosetting or thermoplastic polymer. If the polymer 30 is a thermosetting polymer, it is preferably of the polyurethane type. The thermoforming film 10 (FIG. 8) has good rigidity and is substantially self-supporting, so that it does not require a dedicated support device during the injection step and functions as a polymer receiving tray.

[0021] While the curable polymer 30 is still in a fluid state, a cover sheet 32 ​​is then applied to the third layer 16 of the film 10 (FIGS. 9 and 13). The cover sheet 32 ​​may be adhesive or double-sided, or may be a removable semi-rigid protective film. The application step is carried out by applying pressure to the cover sheet 32 ​​in both normal and tangential directions to the film 10. If the application of pressure to the film 10 causes at least a portion of the curable polymer 30 to flow out of at least one recess 28, it is pushed by the pressure and flows inside at least one peripheral collection channel 40. Preferably, if the cover sheet 32 ​​is adhesive or double-sided, it may have a protective film on its side facing the film 10 that can be removed when a decorative element is applied to the surface. On the other hand, if the cover sheet 32 ​​is a semi-rigid protective film, it is preferably removable once the polymer 30 has hardened.

[0022] The feature of providing collection channels 40 has the advantage that polymer 30 prevents the film 10 from leaking out, thus avoiding contamination of process equipment in contact with the film 10 .

[0023] The feature of applying pressure on the cover sheet 32 ​​both normal and tangential to the film 10 has the advantage of flattening the polymer before it hardens, and also allows for the removal of any polymer that may have been over-injected into the recesses 28 by directing it into the collection channels 40 formed during thermoforming, and further allows for the removal of any air bubbles that may have formed between the cover sheet 32 ​​and the polymer 30 while it is still in a fluid or semi-fluid state.

[0024] The step of applying cover sheet 32 ​​to third layer 16 of film 10 is preferably accomplished by use of a doctor blade, roller, or other tool suitable for applying pressure to cover sheet 32 ​​in a direction normal or tangential to film 10. The doctor blade, roller, or other suitable tool preferably slides as it presses against film 10.

[0025] If polymer 30 is a thermosetting polymer, its curing process (within recess 28) may be accelerated by heating, such as by passing through an oven.

[0026] Finally (FIG. 11), the film 10 is cut around the various grooves 28 filled with polymer 30 by a cutting device such as a punch or laser beam machine 36 and sealed with a sheet 32, thereby obtaining an emblem 38 of the desired shape (FIG. 12). The emblem 38 has a layered structure comprising, superimposed on one another, a layer of film 10, a layer of infused polymer 30, and a layer of covering sheet 32. The film layer 10 comprises 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 adheres.

[0027] Naturally, without prejudice to the principles of the invention, the details of the construction and the embodiment may vary greatly with respect to what has been described purely by way of example, without departing from the scope of the claims. In particular, the method of the invention makes it possible to obtain decorative elements of essentially any number and shape.

Claims

1. A method for manufacturing one or more decorative elements, in particular emblems (38), comprising the steps of: a thermoforming step of a multilayer film (10) comprising a first transparent protective layer (12), a second decorative layer (14) containing at least one pigment, and a third support layer (16) of a thermoformable plastic material, so as to form at least one recess (28) in said film (10), characterized in that at least one collection channel (40) is also formed in said film (10) around said recess (28); injecting a curable polymer (30) into the at least one recess (28) that adheres to the third layer (16) of the film (10); a covering sheet (32) is applied to the third layer (16) of the film (10) while the curable polymer (30) is still in a fluid state, the covering sheet (32) being an adhesive or a double-sided or removable semi-rigid protective film, the applying step being carried out by applying pressure to the covering sheet (32) in both normal and tangential directions to the film (10), such that when at least a portion of the curable polymer (30) flows out of the at least one recess (28) by applying both the normal and tangential pressure to the film (10), it is pushed by the pressure and flows inside the at least one peripheral collection channel (40); hardening the polymer (30) previously injected and encapsulated between the third layer (16) of the film (10) and the covering sheet (32) by a curing process; cutting the film (10) around the at least one recess (28), thereby obtaining a layered decorative element comprising a portion of the film (10), a layer of polymer (30) and a portion of the sheet (32); A method comprising:

2. 10. The method of claim 1, wherein the step of applying a cover sheet (32) to the third layer (16) of the film (10) is performed by use of a doctor blade, roller or other suitable tool adapted to apply pressure to the cover sheet (32) in both a normal and tangential direction to the film (10).

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

4. 4. The method of claim 1, wherein the second layer (14) of the multilayer film (10) contains a metallic pigment, preferably indium or indium / tin, to give the film (10) a brilliant reflective or satin appearance.

5. 5. The method of claim 1, wherein the third layer (16) of the multilayer film (10) is made of a material selected from the group consisting of ABS, polyurethane, polyethylene terephthalate glycol (PETG), and polymethyl methacrylate (PMMA).

6. The method according to any one of claims 1 to 5, wherein the multilayer film (10) has a thickness in the range of 200 to 500 μm.

7. The method according to any one of claims 1 to 6, wherein the multilayer film (10) is thermoformed at a temperature in the range of 150°C to 200°C.

8. The method of any one of claims 1 to 7, wherein a plurality of recesses (28) are formed in the film (10) during the thermoforming step.

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

10. A method according to any one of the preceding claims, wherein the thermoformed film acts as a self-supporting container into which the curable polymer (30) is then injected.

11. The method according to any one of claims 1 to 10, wherein the curable polymer (30) is a thermosetting polymer or a thermoplastic polymer.

12. 12. The method according to claim 11, wherein said thermosetting polymer (30) is of polyurethane type and is subjected to a heating step to accelerate its hardening.

13. The method according to any one of the preceding claims, wherein the cutting step is carried out by a punching machine or a laser beam machine (36).

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

15. A layered decorative element, in particular an emblem (38), which can be produced by the method according to any one of claims 1 to 14, said decorative element comprising a film layer (10), a layer of injected polymer (30) and a covering sheet layer (32) superimposed on one another, said film layer (10) 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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