Information
-
Patent Grant
-
6701652
-
Patent Number
6,701,652
-
Date Filed
Monday, October 22, 200122 years ago
-
Date Issued
Tuesday, March 9, 200420 years ago
-
Inventors
-
Original Assignees
-
Examiners
Agents
- Andrus, Sceales, Starke & Sawall, LLP
-
CPC
-
US Classifications
Field of Search
US
- 040 615
- 040 616
- 040 675
- 428 174
- 428 187
- 428 201
- 428 203
-
International Classifications
-
Abstract
An emblem (20, 20a, 20b) with encapsulated embossed 3-D graphics is provided by a substrate (22) having a first side (24) and an opposite second side (26), an ink pattern (28) printed on the second side and providing embossed 3-D graphics, and a transparent layer (30) molded on the first side and through which the graphics are viewable. The substrate is softer than the ink pattern and deforms therearound during molding of the transparent layer, to provide differing depths. A mold (36, 38) has a smooth nonembossed surface (42) engaging the second side of the substrate without a 3-D mold-insert.
Description
BACKGROUND AND SUMMARY OF THE INVENTION
The invention relates to emblems such as medallions, tags, logos, and the like, having various uses including decoration, information, and identification.
The invention arose during efforts to provide an emblem having a transparent molded layer with encapsulated embossed 3-D graphics viewable therethrough and on the backside thereof. This is accomplished in the present invention in a particularly simple and effective manner.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1
is a top perspective view of an emblem in accordance with the invention.
FIG. 2
is a bottom perspective view of the emblem of FIG.
1
.
FIG. 3
illustrates a processing step.
FIG. 4
illustrates a further processing step.
FIG. 5
illustrates a further processing step.
FIG. 6
illustrates a further processing step.
FIG. 7
is a perspective view of a mold for forming the emblem of FIG.
FIG. 8
is a sectional view taken along line
8
—
8
of FIG.
7
.
FIG. 9
is like FIG.
8
and shows a further processing step.
FIG. 10
is like FIG.
9
and shows a further processing step.
FIG. 11
shows a processing step in accordance with a further embodiment.
FIG. 12
shows a further processing step.
FIG. 13
shows a further processing step.
FIG. 14
shows a further processing step.
FIG. 15
shows a further processing step.
FIG. 16
is a top perspective view of the resulting emblem of FIG.
15
.
FIG. 17
is a sectional view taken along line
17
—
17
of FIG.
16
.
DETAILED DESCRIPTION
FIG. 1
shows an emblem
20
having a substrate
22
with a first or frontside
24
facing upwardly, and an opposite second or backside
26
facing downwardly. An ink pattern
28
,
FIG. 2
, is printed on second or backside
26
to provide graphics, to be described. A transparent layer
30
is molded on first or front side
24
, and the noted graphics are viewable through such transparent layer. Substrate
22
,
FIG. 3
, is provided by a thin film transparent base layer
23
preferably of polycarbonate, acrylic or styrene, preferably having a thickness of 0.005 to 0.007 inch. An ink layer
32
, which in one embodiment is provided by chrome, aluminum, or metallic ink, is printed on second surface
26
of the substrate, followed by printing of ink pattern
28
on layer
32
, FIG.
4
. Ink pattern
28
is preferably provided by ultraviolet, UV, radiation hardenable ink, which is then UV hardened,
FIG. 5
, followed by cutting and trimming of the substrate to yield disc
33
, FIG.
6
.
Disc
33
is then placed in a mold
34
,
FIG. 7
, having an upper mold half
36
and a lower mold half
38
defining a cavity
40
therebetween, FIG.
8
. Disc substrate
22
is placed in the lower mold half
38
with second side
26
, ink layer
32
and ink pattern
28
facing mold surface
42
. The mold is then closed, and hot molding resin, preferably polycarbonate, acrylic, styrene, or the like, is injected or shot through feeder channel
44
into cavity
40
over first side
24
of the substrate. Ink pattern
28
is provided by a plurality of ink areas
46
,
FIGS. 4
,
8
, separated by gap regions
48
therebetween. Ink layer
32
printed on the substrate is not UV hardenable ink. After the UV hardening of ink pattern
28
, such ink pattern is harder than ink layer
32
and base layer
23
. The softer ink layer
32
and base layer
23
thus deform around ink pattern
28
during molding of molded transparent layer
30
, FIG.
9
. Base layer
23
and ink layer
32
deform around UV hardened ink areas
46
of ink pattern
28
and into gap regions
48
. After cooling and hardening of the injected resin, the mold is opened, and the part removed to yield emblem
20
, FIG.
10
. Ink layer
32
includes portions
50
,
FIG. 10
, in gap regions
48
. Ink layer
32
has differing depths in base layer
23
, including a first depth at ink areas
46
and a second different depth at gap regions
48
. Base layer
23
has differing depths in transparent layer
30
, including a first depth at the noted first depth of ink layer
32
at ink areas
46
, and a second depth at the noted second depth of ink layer
32
at gap regions
48
. As noted, ink layer
32
and base layer
23
are softer than ink pattern
28
and deform therearound during molding of transparent layer
30
, to provide the noted differing depths of ink layer
32
and base layer
23
. The differing depths provide embossed 3-D graphics, which are encapsulated by molded transparent layer
30
and viewable through the latter from above,
FIGS. 1
,
10
.
FIGS. 11-15
show an alternate embodiment, and use like reference numerals from above where appropriate to facilitate understanding. Substrate
22
is provided by a transparent base layer
23
having first and second ink layers
31
and
32
,
FIGS. 12
,
13
, printed on second side
26
. Layer
31
may be one or more different colors, and layer
32
is preferably chrome, aluminum or metallic ink as above. Ink pattern
28
,
FIG. 14
, is printed on ink layer
32
and includes the noted plurality of ink areas
46
separated by gap regions
48
therebetween. Ink layer
31
includes portions such as
52
in gap regions
48
. Ink layer
32
includes portions such as
54
in gap regions
48
. Ink layer
31
,
FIG. 12
, has a plurality of ink regions
52
separated by a second set of gap regions
56
therebetween. Ink layer
32
,
FIG. 13
, has a plurality of ink regions
54
separated by a third set of gap regions
58
therebetween. Ink regions
54
of ink layer
32
are in the noted second set of gap regions
56
. Ink regions
52
of ink layer
31
are in the noted third set of gap regions
58
. Ink regions
52
and
54
of each of ink layers
31
and
32
are in the first noted set of gap regions
48
, FIG.
14
. The substrate is then exposed to UV radiation,
FIG. 14
, as above, to UV harden ink pattern
28
, followed by the noted cutting and trimming, and then molding as in
FIGS. 7-9
, to yield emblem 20
a
, FIG.
15
. Ink layer
32
has differing depths in base layer
23
, including a first depth at ink areas
46
, and a second different depth at gap regions
48
. Base layer
23
has differing depths in molded transparent layer
30
, including a first depth at the noted first depth of ink layer
32
at ink areas
46
, and a second depth at the noted second depth of ink layer
32
at gap regions
48
. Ink layer
31
has a single depth in base layer
23
, without differing depths. As above, ink layer
32
and base layer
23
are softer than ink pattern
28
.
FIGS. 16 and 17
show a further embodiment, and use like reference numerals from above where appropriate to facilitate understanding. A second substrate
60
, preferably a thin film layer like layer
23
, is provided on the opposite side of molded transparent layer
30
from substrate
22
. Substrate
60
has a first or frontside
62
facing upwardly, and a second or backside
64
facing downwardly. Second side
64
of substrate
60
faces first side
24
of substrate
22
across molded transparent layer
30
. A second ink pattern
66
is printed on second side
64
of second substrate
60
. Substrate
60
is placed in upper mold half
36
prior to resin injection, and the molding operation is carried out as in
FIGS. 7-9
, to yield emblem
20
b
. In the preferred version of this embodiment, second ink pattern
66
is not formed to a 3-D image. Ink pattern
66
is composed of high temperature resistant ink directly contacted by the injected resin during molding and hence directly contacted by molded transparent layer
30
. In the embodiments of
FIGS. 1-15
, base layer
23
is transparent and is selected from the group consisting of clear, translucent and tinted materials. Molded layer
30
is transparent and is selected from the group consisting of clear, translucent and tinted materials. In the embodiment of
FIGS. 16 and 17
, second substrate
60
is also transparent and is selected from the group consisting of clear, translucent and tinted materials.
In a desirable aspect, the mold has a smooth nonembossed surface
42
,
FIGS. 8
,
9
, engaging the noted second surface or backside of substrate
22
without a 3-D or embossed mold-insert. This is desirable because it eliminates the need for such mold-inserts and enables universal application without a custom mold or a custom mold-insert for each pattern desired. Instead, a desired ink pattern
28
is merely printed on second surface
26
to yield the desired embossed 3-D graphic. The same mold may be used for different graphics by merely printing a different ink pattern
28
. This universal application of mold tooling is simple and cost effective. The embossed 3-D graphic is viewable from above in
FIGS. 1
,
10
,
15
,
16
,
17
, through transparent substrate
60
, if used, and through molded transparent layer
30
. In a further embodiment, a curved mold may be used, including a curved or arcuate mold surface
42
, to provide a curved emblem, which provides a lens effect magnifying the noted embossed 3-D graphic as viewed from above if the curvature is convex as viewed from above.
It is recognized that various equivalents, alternatives and modifications are possible within the scope of the appended claims which distinctly define the subject matter regarded as the invention.
Claims
- 1. An emblem with encapsulated embossed 3-D graphics comprising a substrate having a first side and an opposite second side, an ink pattern printed on said second side and providing the embossed 3-D graphics, a transparent layer molded on said first side and through which said graphics are viewable, wherein said ink pattern comprises a plurality of ink areas separated by gap regions therebetween, and wherein said substrate protrudes into said molded transparent layer, said molded transparent layer having differing depths comprising a first depth at said ink areas, and a second different depth at said gap regions, said molded transparent layer having a planar first side and an opposite nonplanar second side facing said substrate.
- 2. The emblem according to claim 1 wherein said substrate deforms around said ink pattern during molding of said molded transparent layer, to provide said differing depths.
- 3. The emblem according to claim 2 wherein said ink pattern is ultraviolet radiation hardened ink.
- 4. An emblem with encapsulated embossed 3-D graphics comprising a substrate having a first side and an opposite second side, an ink pattern printed on said second side and providing the embossed 3-D graphics, a transparent layer molded on said first side and through which said graphics are viewable, wherein:said substrate comprises a transparent base layer and an ink layer printed thereon; said ink pattern is printed on said ink layer and comprises a plurality of ink areas separated by gap regions therebetween; said ink layer comprises portions in said gap regions; said substrate protrudes into said molded transparent layer at said ink areas; said molded transparent layer has differing depths comprising a first depth at said ink areas, and a second different depth at said gap regions.
- 5. The emblem according to claim 4 wherein said ink layer deforms around said ink pattern during molding of said molded transparent layer, to provide said differing depths.
- 6. The emblem according to claim 5 wherein said ink pattern is ultraviolet radiation hardened ink, and wherein the ink of said ink layer is other than ultraviolet radiation hardenable ink.
- 7. The emblem according to claim 4 wherein both said ink layer and said base layer deform around said ink pattern during molding of said molded transparent layer, to provide said differing depths.
- 8. An emblem with encapsulated embossed 3-D graphics comprising a substrate having a first side and an opposite second side, an ink pattern printed on said second side and providing the embossed 3-D graphics, a transparent layer molded on said first side and through which said graphics are viewable, wherein said substrate comprises a first substrate, and comprising a second substrate on the opposite side of said molded transparent layer from said first substrate, said second substrate having a first side and an opposite second side, said second side of said second substrate facing said first side of said first substrate across said molded transparent layer, and a second ink pattern printed on said second side of said second substrate.
- 9. The emblem according to claim 8 wherein said second ink pattern is nonembossed.
- 10. The emblem according to claim 8 wherein said second ink pattern is composed of ink directly contacted by said molded transparent layer during molding.
- 11. The emblem according to claim 8 wherein:said second substrate is selected from the group consisting of clear, translucent and tinted materials; said transparent molded layer is selected from the group consisting of clear, translucent and tinted materials; said first substrate comprises a transparent base layer selected from the group consisting of clear, translucent and tinted materials.
- 12. An emblem with embossed 3-D graphics, and a mold for producing said emblem, comprising in combination a substrate having a first side and an opposite second side, an ink pattern printed on said second side and providing the embossed 3-D graphics, a transparent layer molded on said first side and through which said graphics are viewable, said ink pattern comprising a plurality of ink areas separated by gap regions therebetween, wherein said substrate protrudes into said molded transparent layer, said molded transparent layer having differing depths comprising a first depth at said ink areas, and a second different depth at said gap regions, a mold for molding said molded transparent layer on said first side of said substrate, said mold having a smooth nonembossed surface engaging said second side of said substrate without a 3-D mold-insert.
- 13. The combination according to claim 12 wherein said substrate deforms around said ink pattern and against said smooth nonembossed surface of said mold during molding of said molded transparent layer, to provide said differing depths.
- 14. The combination according to claim 13 wherein said ink pattern is ultraviolet radiation hardened ink.
- 15. The combination according to claim 12 wherein:said substrate comprises a transparent base layer and an ink layer printed thereon; said ink pattern is printed on said ink layer and comprises a plurality of ink areas separated by gap regions therebetween; said ink layer comprises portions in said gap regions; said ink layer deforms around said ink pattern and against said smooth nonembossed surface of said mold during molding of said molded transparent layer, to provide said differing depths.
- 16. An emblem with embossed 3-D graphics, and a mold for producing said emblem, comprising in combination a substrate having a first side and an opposite second side, an ink pattern printed on said second side and providing the embossed 3-D graphics, a transparent layer molded on said first side and through which said graphics are viewable, said ink pattern comprising a plurality of ink areas separated by gap regions therebetween, wherein said substrate protrudes into said molded transparent layer, said molded transparent layer having differing depths comprising a first depth at said ink areas, and a second different depth at said gap regions, a mold for molding said molded transparent layer on said first side of said substrate, said mold having a smooth nonembossed surface engaging said second side of said substrate without a 3-D mold-insert, wherein:said substrate comprises a transparent base layer having first and second ink layers printed thereon; said ink pattern is printed on said second ink layer and comprises a plurality of ink areas separated by gap regions therebetween; said first ink layer comprises portions in said gap regions; said second ink layer comprises portions in said gap regions; said second ink layer and said base layer deform around said ink pattern and against said smooth nonembossed surface of said mold during molding of said molded transparent layer, to provide said different depths.
- 17. An emblem with embossed 3-D graphics, and a mold for producing said emblem, comprising in combination a substrate having a first side and an opposite second side, an ink pattern printed on said second side and providing the embossed 3-D graphics, a transparent layer molded on said first side and through which said graphics are viewable, said ink pattern comprising a plurality of ink areas separated by gap regions therebetween, wherein said substrate protrudes into said molded transparent layer, said molded transparent layer having differing depths comprising a first depth at said ink areas, and a second different depth at said gap regions, a mold for molding said molded transparent layer on said first side of said substrate, said mold having a smooth nonembossed surface engaging said second side of said substrate without a 3-D mold-insert, and comprising a second substrate on the opposite side of said molded transparent layer from said first mentioned substrate, said second substrate having a first side and an opposite second side, said second side of said second substrate facing said first side of said first substrate across said molded transparent layer, and a second ink pattern printed on said second side of said second substrate.
US Referenced Citations (8)