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EP2117808A1 - Procédé de fabrication d'un article thermoformé faisant appel à une distorsion de pré-impression - Google Patents

Procédé de fabrication d'un article thermoformé faisant appel à une distorsion de pré-impression

Info

Publication number
EP2117808A1
EP2117808A1 EP08719663A EP08719663A EP2117808A1 EP 2117808 A1 EP2117808 A1 EP 2117808A1 EP 08719663 A EP08719663 A EP 08719663A EP 08719663 A EP08719663 A EP 08719663A EP 2117808 A1 EP2117808 A1 EP 2117808A1
Authority
EP
European Patent Office
Prior art keywords
image
sheet
initial
cavity
making
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP08719663A
Other languages
German (de)
English (en)
Inventor
Stanley Michael Marcinkowski
Michael Brown
Perry Shaun Rigler
John Arthur Hunt
Michael Scott Moren
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Plastique Ltd
Leading Edge Labels Ltd
Gillette Co LLC
Placon Corp
Original Assignee
Plastique Ltd
Leading Edge Labels Ltd
Gillette Co LLC
Placon Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Plastique Ltd, Leading Edge Labels Ltd, Gillette Co LLC, Placon Corp filed Critical Plastique Ltd
Publication of EP2117808A1 publication Critical patent/EP2117808A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/08—Deep drawing or matched-mould forming, i.e. using mechanical means only
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M5/00—Duplicating or marking methods; Sheet materials for use therein
    • B41M5/025—Duplicating or marking methods; Sheet materials for use therein by transferring ink from the master sheet
    • B41M5/035—Duplicating or marking methods; Sheet materials for use therein by transferring ink from the master sheet by sublimation or volatilisation of pre-printed design, e.g. sublistatic
    • B41M5/0353—Duplicating or marking methods; Sheet materials for use therein by transferring ink from the master sheet by sublimation or volatilisation of pre-printed design, e.g. sublistatic using heat shrinkable film material; Thermotransfer combined with the shaping of the workpiece; Recto-verso printing; Image correction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2795/00—Printing on articles made from plastics or substances in a plastic state
    • B29C2795/002—Printing on articles made from plastics or substances in a plastic state before shaping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/02—Combined thermoforming and manufacture of the preform
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2027/00—Use of polyvinylhalogenides or derivatives thereof as moulding material
    • B29K2027/06—PVC, i.e. polyvinylchloride
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/712—Containers; Packaging elements or accessories, Packages
    • B29L2031/7162—Boxes, cartons, cases
    • B29L2031/7164—Blister packages

Definitions

  • thermoformed articles relate to thermoformed articles and methods of making the same. More particularly, this invention relates to making thermoformed articles carrying words and images, such as packaging for commercial products.
  • Processes for forming a three dimensional profile in a flat sheet of material are well known. Such processes are often used to produce plastic packaging, often called "blister" packaging, which can include stylized words and images to attract attention.
  • the words and images may be created separate from and disposed in or on the packaging or created directly on packaging.
  • the technique of reverse printing lays down an image on the surface of a transparent layer, which, when viewed through the layer, shows a positive image.
  • the image is reverse printed using a conventional printing technique, for example a UV flexographic or a gravure method using up to ten different colors.
  • the image printed may be a plain design or one involving graphics for catching a viewer's attention.
  • half tone techniques near-photographic image quality can be achieved.
  • An image may be reverse printed on blister packaging before forming the three dimensional profile. Because forming stretches the image, some processes apply an initial image (i.e., distorted from the desired image) to the sheet so that, after forming, the distorted image (i.e., distorted from the initial image) resembles the desired image.
  • an initial image i.e., distorted from the desired image
  • the distorted image i.e., distorted from the initial image
  • One example process prints a grid on a sample sheet, which is thermoformed to a desired shape.
  • An initial image is computed based on the distortion of the grid caused by the thermoforming and a desired image.
  • the initial image is reverse printed on to the surface of a transparent thermoplastic film.
  • the film is laminated to a thermoplastic sheet, trapping the initial image between the film and the sheet, which helps prevent cracking in the image during thermoforming.
  • the laminate is thermoformed to the desired shape with the desired image thereon.
  • a layer of expandable foam is covered on one side by a layer of Lycra® and on the other side by a layer of polyethylene to form a laminate.
  • a pre- distortion version of desired image is applied to the outer Lycra® surface.
  • the laminate is thermoformed to a three dimensional profile having the desired image, during which the foam layer expands.
  • a rotating or moving electronic digital scanner is used to scan a distorted grid created by forming a flat grid in a mold.
  • Numerical values representing the areas and degree to which a two dimensional image would have to be compressed are collected.
  • a comparison between the numerical values and the scanned copy of the two- dimensional image determines the change needed to bring the two dimensional image and the numerical values into co-alignment at certain reference points.
  • the change is applied to the two dimensional image to form an altered or compressed two-dimensional image.
  • the altered image is printed onto a plastic stock, which is aligned with the mold and formed into a quasi three dimensional image.
  • This invention relates to thermoformed articles and methods of making the same. More particularly, this invention relates to making deep draw thermoformed articles carrying images, such as packaging for commercial products.
  • Initial images different from a desired image, are printed onto a thermoformable material. The material is thermoformed, thereby distorting the initial images into desired images.
  • the invention features, in general, a method of making a thermoformed article carrying an image.
  • a first sheet carrying a grid image and a mold having at least two cavities a deep draw forming carrying a grid distortion pattern is made for each cavity.
  • An initial image for each cavity is computed based on the corresponding grid distortion pattern and a desired image.
  • the initial images are applied to a second sheet.
  • the second sheet and the mold at least two deep draw articles are made. Each article carries a distorted image that is substantially similar to the desired image.
  • An L/D ratio of the article is less than about 4:1.
  • the L/D ratio is about 3: 1.
  • the L/D ratio is about 2:1.
  • the initial images are applied by reverse printing.
  • the initial images are applied by selectively applying patterns of ink in high strain areas to prevent image cracking.
  • the initial images are applied by at least one of the following techniques: gravure printing, UV flexographic printing, lithographic printing, or offset printing.
  • the first sheet is registered with the mold.
  • the second sheet is registered with the mold.
  • a coating is selectively applied on the applied initial images.
  • the coating is a UV resistant varnish containing a slip agent.
  • the sheets are pre-heated to about 130° F.
  • the grid image includes relatively more lines disposed where the first sheet will experience relatively more deformation.
  • An initial test image is made for each cavity.
  • the initial test image is applied to a test sheet.
  • a distorted test image is formed for each cavity.
  • the computation of each initial image is based on a corresponding
  • Image is defined as words, images, pictures, characters, or graphics that could be found on consumer product packaging.
  • FIG. 1 is a perspective view of an embodiment of a formable sheet carrying a grid
  • FIG. 2 is a perspective view of the sheet formed into two articles
  • FIG. 3 is a perspective view of an embodiment of a formable sheet carrying two images
  • FIG. 4 is a top partial view of a formable sheet carrying rows of ink dots
  • FIG. 5 is a perspective view of the sheet formed into two articles each carrying an image
  • FIG. 6 is a top view of an embodiment if a formable sheet carrying a grid.
  • Multi-cavity thermoforming is a well known process for manufacturing high volumes of blister packaging components. But maintaining relatively tight dimensional tolerances over a large number of cavities (e.g. twelve or sixteen) is difficult and expensive.
  • Some sources of cavity-to-cavity variation may be the temperature profile across a web of material spanning several cavities (e.g., material has a different temperature toward middle cavities than toward edge cavities) and cycle-to-cycle process (e.g., temperature, pressure) variation, using different thermoforming machines, and cavity dimensions.
  • Sheet 10 carries a precisely printed grid pattern 12.
  • a multi-cavity thermoforming process forms two blister packaging shells 14 in sheet 10, thereby distorting grid pattern 12 into unique distortion patterns 16 and 18 for each shell 14.
  • initial images 20 and 22 are computed and reverse printed on sheet 24.
  • the same multi-cavity thermoforming process forms shells 26 with initial images 20 and 22 formed into distorted images 28, which are each substantially similar to the desired image.
  • grid pattern 12 is printed on sheet 10.
  • grid pattern 12 includes both a grid lines 30 and form lines 32.
  • Grid lines 30 are spaced uniformly over sheet 10 while form lines 32 instead are disposed in areas that will undergo high strain during forming, which allows more accurate calculation of strain and deformation in those areas.
  • grid lines 30 or form lines 32 could be omitted.
  • the grid is printed using the same printing process used to print the initial images as discussed below.
  • Grid pattern 12 includes registration marks 34.
  • Initial images 20 and 22 must register with the thermoforming mold so that, after thermoforming, distorted images 28 will be substantially similar to the desired image.
  • Sheet 10 must register in the same way so that the distortion of grid pattern 12 accurately represents how initial images 20 and 22 will be distorted. Otherwise, distorted images 28 will be different than the desired image.
  • the thermoforming machine index is linked to a set position on sheet 10 indicated by registration marks 34 to register sheet 10 with the thermoforming mold.
  • a photo electric cell may be used to read marks 34 and establish the link.
  • grid pattern 12 allows collection of accurate data over one or more extended manufacturing runs for each cavity of thermoforming tooling and, thus, more accurate process capabilities for each cavity.
  • the data contributes to the calculation of initial images 20 and 22 that are more robust in the thermoforming process, thereby making the production of distorted images 28 more capable.
  • a preferred example of sheet 10 is a print grade PVC material, such as Klockner TH 280 having a thickness of at least about 0.015 inches.
  • An alternative example of sheet 10 is a PET material, such as Klockner PETG Release TR having a thickness of about at least 0.015 inches. Both examples are available from Klocnker Pentaplast of America in Rural Treatment, Virginia.
  • sheet 10 could be a portion of a web of material fed through printing and thermoforming process as is well known in the art. In other examples, sheets 10 could be individually fed as is also well known in the art.
  • shells 14 are formed in sheet 10 by a thermoforming process.
  • sheet 10 is indexed through an auxiliary pre-heat station, gradually warming sheet 10 to about 130° F.
  • Sheet 10 then enters a thermoforming oven system where it is heated to its glass transition state by top and bottom heating sections set between 600° and 980° F.
  • Sheet 10 proceeds to the forming station where marks 34 are registered with the thermoforming mold.
  • Shells 14 are formed when the mold plate and assist plate come together with vacuum on the mold side and pressure on the assist side force sheet 10 to conform with the mold.
  • Sheet 10 is then indexed to a trim station which precisely cuts the material to a usable size.
  • Other thermoforming process could be used to form shells 14.
  • Shells 14 are formed with a deep draw thermoforming process.
  • the depth of draw in a thermoformed part may be expressed as a ratio of length to depth (L/D).
  • the length is the minor length L of the part and the depth is the thickness D of the part in the area to carry the image.
  • a "deep draw" thermoformed part has an IVD of less than about 4:1.
  • shell 14 in area 40, shell 14 has an L of about 3.75 inches and a D of about 1 inch, resulting in an IVD ratio of about 3.75:1.
  • shell 14 could have a length of about 3.75 inches and a depth of about 1.625 inches for an L/D ratio of about 2.3: 1.
  • initial image 20 may be calculated.
  • grid lines 30 relates to a computerized grid generated by the Grid Warp software program, available from Artwork Systems Inc. of Bristol, Pennsylvania Grid pattern 12 is scanned and the Grid Warp program is used to compare to the computerized grid with the scan. Each square of the computerized grid is mapped to mach the equivalent position on the scan. After mapping the entire computerized grid, a desired image is positioned and then modified using the "warp" function of the Grid Warp program, resulting in initial image 20. In a similar manner, initial image 22 is calculated based on the displacement of grid lines in area 40.
  • initial images 20 and 22 are reverse printed on to the lower surface 42 of sheet 24.
  • initial images 20 and 22 are printed using a UV flexographic process.
  • the cured ink film should have a high level of ink key to the sheet 24, be flexible to allow it to follow the contours of the thermoformed pack, and be elastic enough to enable the ink film to be stretched up to twice its initial printed surface area during the thermoforming process without displaying any cracking.
  • a gravure, or lithographic process may be used.
  • an offset printing process could be used with an individual sheet feed.
  • Ink printing patterns may improve the formation of distorted images 28.
  • solid colors are printed as a first screen 50 (i.e., a series of parallel lines dots rather than an overall solid covering) on a portion 58 of sheet 24 along lines 52 and a second screen 54 with the screen angle (i.e., the alignment of the dots) at a complementary angle to the first printed layer.
  • An example of such complementary angles would be 90 and 105 degrees.
  • the printing process applies a varnish (not shown) on initial images 20 and 22 as the final "color.”
  • varnish could be applied by a dedicated process after printing.
  • the varnish protects the images from being scratched and/or transferring to other surfaces.
  • shells 14 may be repeatedly formed in a web of material, which is fed onto a roll for subsequent packaging processes.
  • the varnish prevents ink from transferring from an inner surface 44 of one shell 14 to an outer surface 46 of another shell 14.
  • the varnish may also act as a slip agent for de- nesting shells 14 for assembly.
  • UVC 8785 available from Wikoff Color Corp, Fort Mill, South Carolina.
  • each shell 26 bears a distorted image 28 that is substantially similar to the desired image.
  • Some criteria for evaluating the similarity between distorted image 28 and the desired image may be, for example, color, clarity, image size and position, font size, and proper proportioning of the image.
  • shells 26 remain attached to sheet 24 and stored until product is to be packaged.
  • the packaging processes could be in-line with the thermoforming process.
  • images 20 and 22 are tuned in order to increase the overall capability of the printing and thermoforming processes. Tuning involves printing images 20 and 22 on sheet 24 in a single color and forming shells 14. Resulting single color images 28 are evaluated against the image specification and adjustments to images 20 and 22 are made, as necessary.
  • sheet 80 may carry a grid pattern 82 for forming twelve cavities of shells.
  • Other examples with other numbers of cavities are contemplated, limited only by the design of the thermoformed item and the thermoforming process itself.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
  • Printing Methods (AREA)

Abstract

Selon l'invention, un article thermoformé porte une image. À l'aide d'une première feuille (10) portant une image de grille (12) et d'un moule ayant au moins deux cavités, un formage portant un motif de distorsion de grille (16, 18) pour chaque cavité est produit. Une image initiale (20, 22) est calculée pour chaque cavité sur la base du motif de distorsion de grille (16, 18) correspondant et d'une image désirée. Les images initiales sont appliquées sur une seconde feuille (24). À l'aide de la seconde feuille (24) et du moule, au moins deux articles sont produits, chaque article portant une image déformée qui est sensiblement analogue à l'image désirée.
EP08719663A 2007-03-14 2008-03-12 Procédé de fabrication d'un article thermoformé faisant appel à une distorsion de pré-impression Withdrawn EP2117808A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US90687507P 2007-03-14 2007-03-14
PCT/IB2008/050907 WO2008111000A1 (fr) 2007-03-14 2008-03-12 Procédé de fabrication d'un article thermoformé faisant appel à une distorsion de pré-impression

Publications (1)

Publication Number Publication Date
EP2117808A1 true EP2117808A1 (fr) 2009-11-18

Family

ID=39620890

Family Applications (1)

Application Number Title Priority Date Filing Date
EP08719663A Withdrawn EP2117808A1 (fr) 2007-03-14 2008-03-12 Procédé de fabrication d'un article thermoformé faisant appel à une distorsion de pré-impression

Country Status (9)

Country Link
EP (1) EP2117808A1 (fr)
JP (1) JP2010520829A (fr)
KR (1) KR20100044729A (fr)
CN (1) CN101730617A (fr)
AU (1) AU2008224531A1 (fr)
BR (1) BRPI0808787A2 (fr)
CA (1) CA2681171A1 (fr)
RU (1) RU2009133093A (fr)
WO (1) WO2008111000A1 (fr)

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ES2370311B1 (es) * 2009-01-19 2012-10-29 Federal Signal Vama, S.A. Proceso de fabricacion de puentes de señalizacion por moldeo termoconformado
EP2613923A2 (fr) * 2010-09-08 2013-07-17 Avery Dennison Corporation Etiquetage thermoformé
WO2013025699A1 (fr) 2011-08-17 2013-02-21 Avery Dennison Corporation Procédé de formage et d'étiquetage à étapes multiples
EP3126483A1 (fr) * 2014-03-31 2017-02-08 The Procter & Gamble Company Sachet soluble dans l'eau
CN109922178B (zh) * 2019-01-31 2021-02-02 维沃通信科技有限公司 一种盖板制作的方法及盖板、移动终端

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JPS6178686A (ja) * 1984-09-26 1986-04-22 Dainippon Printing Co Ltd 真空成形用印刷フイルム
FR2639878B1 (fr) * 1988-12-01 1991-01-11 Cebal Procede de decoration d'une ebauche a conformer, utilisation de ce procede et produits obtenus
FR2676966A1 (fr) * 1991-05-30 1992-12-04 Telimmed Procede d'impression de matieres polymeriques.
JPH09193239A (ja) * 1996-01-19 1997-07-29 Dainippon Printing Co Ltd シート成形における予備加熱法
WO1997031358A1 (fr) * 1996-02-23 1997-08-28 The Coca-Cola Company Panneau indicateur pour distributeur automatique et procede de fabrication
JPH10272686A (ja) * 1996-10-25 1998-10-13 Nisshinbo Ind Inc 精密表示立体ディスプレイの製造方法
GB2329607B (en) * 1997-09-27 2002-05-01 Aep Borden Packaging Uk Ltd A method of making a thermoformed article
JP3191155B2 (ja) * 1999-01-08 2001-07-23 大日本印刷株式会社 深絞り容器底材
AU2002314995A1 (en) * 2002-06-16 2003-12-31 Westvaco Packaging Group, Inc. Method of forming packaging using thermoforming inks
JP2004017636A (ja) * 2002-06-20 2004-01-22 Noritz Corp 蛍光塗料によって印刷された成形体
JP4129198B2 (ja) * 2003-04-18 2008-08-06 株式会社ケイピー 容器成形用熱可塑性樹脂シート及び容器
US20060108704A1 (en) * 2004-10-11 2006-05-25 Geiwald Paul U Device and method for graphic transfer for packaging and other 3-D items
JP2006346979A (ja) * 2005-06-15 2006-12-28 Sakaiya:Kk 合成樹脂シート及び合成樹脂シートの絞り成形方法

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Also Published As

Publication number Publication date
AU2008224531A1 (en) 2008-09-18
CA2681171A1 (fr) 2008-09-18
CN101730617A (zh) 2010-06-09
RU2009133093A (ru) 2011-04-20
WO2008111000A1 (fr) 2008-09-18
JP2010520829A (ja) 2010-06-17
KR20100044729A (ko) 2010-04-30
BRPI0808787A2 (pt) 2014-09-16

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