Innovation Trends in Plastics Decoration and Surface Treatment

245 Pages·2014·7.024 MB·English

by  Edward B. Crutchley

In Innovation Trends Plastics
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The plastics industry is a major player for consumer items, notably for the automotive, t Decoration Surface
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consumer electronics and packaging industries, and is necessarily very active in n
innovation. As a result, moulded thermoplastics are achieving new heights in decorative
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appearance and quality. Many striking aesthetic effects are possible by employing re Treatment
new polymer blends coupled with a diverse range of decoration and surface treatment n
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technologies. These can produce three-dimensional and tactile finishes, high definition
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images, flawless high gloss and metallic surfaces, as well as effects ranging from
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imitation materials, interferential colours, colour gradients, colour change and travel, Decorative Effects on Moulded Plastics
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gloss and matte combinations, and even acoustic or olfactory effects. Manufacturing
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processes to achieve these include several types of in-mould film, coating or decorating
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technique, relatively recent technologies to improve surface quality, as well as traditional t
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separate decorating or coating processes such as dry offset; flexographic; inkjet; pad s
and screen printing; foil transfer; labelling; laser marking; plating; spray coating; and D
vacuum deposition. e
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This unique book analyses and compares recent trends in each of over 20 types of
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mainstream manufacturing process and 10 classes of sensory effect they can produce. a
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Supported by over 100 tables, a three-year sampling of over 1,000 mentioned patent io
documents and hundreds of commercial developments helps to identify the main trends n

and their innovators, key innovative clusters and the most sought-after effects, as well a • 3-year review
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as provide indications for the future.
d • Process-by-process perspective

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Ed Crutchley is a consultant in plastics decoration and surface treatment. After studying • Analysis of over 1,000 patents
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printing technology at the London College of Printing he has worked in the rigid plastics
r • Commercial developments
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packaging industry in the UK, France and the USA in the fields of manufacturing plant a
c • Innovating companies
management, running technical and quality departments, and R&D and innovation. He
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has contributed to several patents.
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Ed Crutchley
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ISBN: 978-1-909030-84-8 C
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Smithers Information t
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Shawbury, Shrewsbury, Shropshire, SY4 4NR, United Kingdom
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Telephone: [phone] Fax: [phone] y
http://www.smithers.com
Contents
Innovation Trends in Plastics
Decoration and Surface
Treatment
Decorative Effects on Moulded Plastics
Ed Crutchley
Figure 2
The vinyl chloride monomer production process
(after EVC International NV with permission)
A Smithers Group Company
Shawbury, Shrewsbury, Shropshire, SY4 4NR, United Kingdom
Telephone: [phone] Fax: [phone]
http://www.polymer-books.com
3
Contents
First Published in 2014 by
Smithers Rapra Technology Ltd
Shawbury, Shrewsbury, Shropshire, SY4 4NR, UK
©Smithers Information Ltd., 2014
All rights reserved. Except as permitted under current legislation no part
of this publication may be photocopied, reproduced or distributed in any
form or by any means or stored in a database or retrieval system, without
the prior permission from the copyright holder.
A catalogue record for this book is available from the British Library.
Every effort has been made to contact copyright holders of any material
reproduced within the text and the authors and publishers apologise if any
have been overlooked.

ISBN: 978-1-909030-84-8 (softback)
Typeset by SA Hall Typesetting, Brixham
Printed and bound by Lightning Source UK
4
Contents
Contents
Preface .......................................................................................................................................xi
PART A: OVERVIEW
1 Introduction .............................................................................................................................1
1.1 Scope.................................................................................................................................................1
1.2 Innovation and Patents ......................................................................................................................1
1.3 Prediction of Trends ...........................................................................................................................1
1.4 Innovators ..........................................................................................................................................2
1.5 Comments on Presentation ...............................................................................................................3
1.5.1 Subject Classification .................................................................................................................3
1.5.2 Year-to-year Analyses ................................................................................................................3
1.5.3 Text Formatting ..........................................................................................................................3
1.5.4 Definition of ‘Patents’ .................................................................................................................4
1.6 Disclaimers ........................................................................................................................................4
2 Sources ...................................................................................................................................5
2.1 Commercial Developments ...............................................................................................................5
2.2 Patenting Authorities and Obtaining Copies of Patents ....................................................................5
2.3 Approaches to Patents ......................................................................................................................5
2.4 Patent Coding ....................................................................................................................................6
2.5 How Patent Searches Were Carried Out ...........................................................................................6
2.5.1 Method 1 ...................................................................................................................................6
2.5.2 Method 2 ...................................................................................................................................6
2.5.3 Search Results ...........................................................................................................................7
3 Decorative Effects on Plastics ..............................................................................................8
3.1 Introduction to Decorative Effects ..................................................................................................10
3.1.1 Three-dimensional, Tactile and Depth Effects ...........................................................................10
3.1.2 Acoustic Effects .......................................................................................................................13
3.1.3 Colour Effects ..........................................................................................................................13
3.1.4 Definition, Detail and Contrast ..................................................................................................15
3.1.5 Gloss and Matte Effects ...........................................................................................................16
3.1.6 Interference Effects ..................................................................................................................17
3.1.7 Metallic or Reflective Effects .....................................................................................................18
3.1.8 Olfactory Effects ......................................................................................................................19
3.1.9 Selective Coating Deposition ....................................................................................................20
3.1.10 Surface Quality Improvement ..................................................................................................20
3.2 Functional Properties of Inks, Coatings, Films and Substrate Materials .........................................22
References ............................................................................................................................................24
PART B: MATERIALS
4 Materials and Additives for Colour or Reflectivity Changes ...........................................25
4.1 Background .....................................................................................................................................25
4.2 Recent Commercial Developments ................................................................................................25
4.2.1 Colour Change Materials ..........................................................................................................25
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Contents
4.2.2 General Subjects .....................................................................................................................25
4.2.3 Laser Additives ........................................................................................................................26
4.3 Patent Trends ...................................................................................................................................26
4.3.1 Subjects, Ranking and Innovators ............................................................................................26
4.3.2 Items of Particular Interest ........................................................................................................28
4.3.3 Principal Trends .......................................................................................................................28
4.4 Listed Patent Literature 2011-2103 .................................................................................................28
4.4.1 Colour Effects ..........................................................................................................................28
4.4.2 Definition, Detail and Contrast ..................................................................................................30
4.4.3 Metallic or Reflective Effects .....................................................................................................32
References .............................................................................................................................................32
5 Materials for Effects and Other Special Colours ..............................................................33
5.1 Background .....................................................................................................................................33
5.2 Recent Commercial Developments ................................................................................................33
5.3 Patent Trends ...................................................................................................................................35
5.3.1 Subjects, Ranking and Innovators ............................................................................................35
5.3.2 Items of Particular Interest ........................................................................................................36
5.3.3 Principal Trends .......................................................................................................................36
5.4 Listed Patent Literature 2011-2103 .................................................................................................36
5.4.1 Three-dimensional, Tactile and Depth Effects ...........................................................................36
5.4.2 Colour Effects ..........................................................................................................................36
5.4.3 Interference and Refraction Effects ...........................................................................................36
5.4.4 Metallic or Reflective Effects .....................................................................................................39
5.4.5 Surface Quality Improvement ..................................................................................................41
References .............................................................................................................................................42
6 Films, Foils and Labels .........................................................................................................43
6.1 Background .....................................................................................................................................43
6.2 Recent Commercial Developments ................................................................................................44
6.2.1 In-mould Films .........................................................................................................................44
6.2.2 Labels and Sleeves ..................................................................................................................45
6.2.3 Smart Labels ...........................................................................................................................45
6.2.4 Transfer Foils ...........................................................................................................................46
6.3 Patent Trends ..................................................................................................................................46
6.3.1 Subjects, Ranking and Innovators ..............................................................................................46
6.3.2 Items of Particular Interest ..........................................................................................................47
6.3.3 Principal Trends ..........................................................................................................................47
6.4 Listed Patent Literature 2011-2103 .................................................................................................47
6.4.1 Three-dimensional, Tactile and Depth Effects ...........................................................................47
6.4.2 Definition, Detail and Contrast ..................................................................................................49
6.4.3 Gloss and Matte Effects ...........................................................................................................50
6.4.4 Interference Effects ..................................................................................................................50
6.4.5 Metallic or Reflective Effects .....................................................................................................51
6.4.6 Olfactory Effects ......................................................................................................................51
6.4.7 Surface Quality Improvement ...................................................................................................52
References .............................................................................................................................................53
7 Inks, Paints, Coatings (Excluding Colour Change or Effect Materials) ...........................56
7.1 Background .....................................................................................................................................56
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Contents
7.2 Recent Commercial Developments ................................................................................................58
7.2.1 Three-dimensional Tactile and Depth Effects ............................................................................58
7.2.2 Olfactory Effects ......................................................................................................................58
7.2.3 Surface Quality Improvement ...................................................................................................58
7.3 Patent Trends ...................................................................................................................................58
7.3.1 Subjects, Ranking and Innovators ............................................................................................58
7.3.2 Items of Particular Interest ........................................................................................................59
7.3.3 Principal Trends .......................................................................................................................60
7.4 Listed Patent Literature 2011-2103 .................................................................................................60
7.4.1 Three-dimensional, Tactile and Depth Effects ...........................................................................60
7.4.2 Acoustic Effects ......................................................................................................................61
7.4.3 Colour Effects ..........................................................................................................................61
7.4.4 Definition, Detail and Contrast ..................................................................................................61
7.4.5 Gloss and Matte Effects ...........................................................................................................61
7.4.6 Olfactory Effects ......................................................................................................................62
7.4.7 Surface Quality Improvement ...................................................................................................62
References .............................................................................................................................................64
8 Substrate Polymer Resins, Blends and Additives .............................................................66
8.1 Background .....................................................................................................................................66
8.2 Recent Commercial Developments ................................................................................................66
8.2.1 Three-dimensional, Tactile and Depth Effects ...........................................................................66
8.2.2 Acoustic Effects ......................................................................................................................67
8.2.3 Olfactory Effects ......................................................................................................................67
8.2.4 Surface Improvement ...............................................................................................................67
8.3 Patent Trends ...................................................................................................................................67
8.3.1 Subjects, Ranking and Innovators ............................................................................................67
8.3.2 Items of Particular Interest ........................................................................................................68
8.3.3 Principal Trends .......................................................................................................................68
8.4 Listed Patent Literature 2011-2103 .................................................................................................68
8.4.1 Three-dimensional, Tactile and Depth Effects ..........................................................................68
8.4.2 Acoustic Effects ......................................................................................................................70
8.4.3 Gloss and Matte Effects ...........................................................................................................70
8.4.4 Olfactory Effects ......................................................................................................................70
8.4.5 Surface Quality Improvement ..................................................................................................70
References .............................................................................................................................................72
PART C: IN-MOULD PROCESSES
9 Coloration, Co-injection, Multilayer Moulding and Multiple Material Moulding .............75
9.1 Background .....................................................................................................................................75
9.2 Recent Commercial Developments ................................................................................................76
9.2.1 Colouring Processes ................................................................................................................76
9.2.2 Processing ...............................................................................................................................76
9.3 Patent Trends ...................................................................................................................................77
9.3.1 Subjects, Ranking and Innovators ............................................................................................77
9.3.2 Items of Particular Interest ........................................................................................................78
9.3.3 Principal Trends .......................................................................................................................78
9.4 Listed Patent Literature 2011-2103 .................................................................................................78
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Contents
9.4.1 Three-dimensional, Tactile and Depth Effects ...........................................................................78
9.4.2 Colour Effects ..........................................................................................................................79
9.4.3 Metallic or Reflective Effects .....................................................................................................80
9.4.4 Surface Quality Improvement ...................................................................................................80
References .............................................................................................................................................81
10 In-mould Coating and On-mould Painting .........................................................................83
10.1 Background ...................................................................................................................................83
10.2 Recent Commercial Developments ..............................................................................................83
10.3 Patent Trends .................................................................................................................................84
10.3.1 Subjects, Ranking and Innovators ............................................................................................84
10.3.2 Items of Particular Interest ........................................................................................................84
10.3.3 Principal Trends .......................................................................................................................84
10.4 List of Patent Literature 2011-2103 ...............................................................................................84
10.4.1 Three-dimensional, Tactile and Depth Effects – In-mould Coating .............................................85
10.4.2 Three-dimensional, Tactile and Depth Effects – On-mould Painting ...........................................85
10.4.3 Surface Quality Improvement ....................................................................................................86
References .............................................................................................................................................86
11 In-mould Film Techniques....................................................................................................87
11.1 Background ...................................................................................................................................87
11.2 Recent Commercial Developments ..............................................................................................88
11.2.1 In-mould Film Processes ..........................................................................................................88
11.2.2 In-mould Labelling ...................................................................................................................88
11.3 Patent Trends .................................................................................................................................89
11.3.1 Subjects, Ranking and Innovators ............................................................................................89
11.3.2 Items of Particular Interest ........................................................................................................90
11.3.3 Principal Trends .......................................................................................................................90
11.4 Listed Patent Literature 2011-2103 ...............................................................................................90
11.4.1 Three-dimensional, Tactile and Depth Effects ...........................................................................90
11.4.2 Definition, Detail and Contrast ..................................................................................................95
11.4.3 Gloss and Matte Effects ...........................................................................................................95
11.4.4 Metallic or Reflective Effects .....................................................................................................95
11.4.5 Surface Quality Improvement ....................................................................................................96
References .............................................................................................................................................98
12 In-mould Printing, Marking, or Use of Engraved Cavities .............................................100
12.1 Background .................................................................................................................................100
12.2 Recent Commercial Developments ............................................................................................100
12.3 Patent Trends ...............................................................................................................................100
12.3.1 Subjects, Ranking and Innovators ..........................................................................................100
12.3.2 Items of Particular Interest ......................................................................................................101
12.3.3 Principal Trends .....................................................................................................................101
12.4 Listed Patent Literature 2011-2103 .............................................................................................101
12.4.1 Three-dimensional, Tactile and Depth Effects .........................................................................101
12.4.2 Colour Effects ........................................................................................................................102
12.4.3 Gloss and Matte Effects .........................................................................................................102
12.4.4 Interference Effects ................................................................................................................102
References ...........................................................................................................................................103
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Contents
13 In-mould Surface Improvement ........................................................................................104
13.1 Background .................................................................................................................................104
13.2 Recent Commercial Developments ............................................................................................105
13.2.1 Cooling Improvements ...........................................................................................................105
13.2.2 Other Surface Improvement Process Techniques ...................................................................105
13.2.3 Rapid Heat Cycle Moulding Techniques .................................................................................106
13.2.4 Tool Surface Polishing and Treatment ....................................................................................106
13.3 Patent Trends ...............................................................................................................................106
13.3.1 Subjects, Ranking and Innovators ..........................................................................................106
13.3.2 Items of Particular Interest ......................................................................................................107
13.3.3 Principal Trends .....................................................................................................................107
13.4 Listed Patent Literature 2011-2103 .............................................................................................107
13.4.1 Surface Quality Improvement .................................................................................................107
References ...........................................................................................................................................110
PART D: STAND-ALONE OR IN-LINE PROCESSES
14 Atmospheric Plasma Deposition or Thermal Spray ........................................................113
14.1 Background .................................................................................................................................113
14.2 Recent Commercial Developments ............................................................................................114
14.3 Patent Trends ...............................................................................................................................114
14.3.1 Subjects, Ranking and Innovators ..........................................................................................114
14.3.2 Principal Trends .....................................................................................................................114
14.4 Listed Patent Literature 2011-2103 .............................................................................................114
14.4.1 Three-dimensional, Tactile and Depth Effects .........................................................................114
14.4.2 Colour Effects ........................................................................................................................115
14.4.3 Metallic or Reflective Effects ...................................................................................................115
References ...........................................................................................................................................115
15 Dry Offset and Flexographic Printing ...............................................................................116
15.1 Background .................................................................................................................................116
15.2 Recent Commercial Developments ............................................................................................117
15.3 Patent Trends ...............................................................................................................................117
15.3.1 Subjects, Ranking and Innovators ..........................................................................................117
15.3.2 Items of Particular Interest ......................................................................................................118
15.3.3 Principal Trends .....................................................................................................................118
15.4 Listed Patent Literature 2011-2103 .............................................................................................118
15.4.1 Definition, Detail and Contrast ................................................................................................118
15.4.2 Surface Quality Improvement ................................................................................................119
References ...........................................................................................................................................119
16 Embossing ..........................................................................................................................121
16.1 Background .................................................................................................................................121
16.2 Recent Commercial Developments ............................................................................................121
16.3 Patent Trends ...............................................................................................................................121
16.3.1 Subjects, Ranking and Innovators ..........................................................................................121
16.3.2 Principal Trends .....................................................................................................................122
16.4 Listed Patent Literature 2011-2103 .............................................................................................122
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Contents
16.4.1 Three-dimensional, Tactile and Depth Effects .........................................................................122
16.4.2 Gloss and Matte Effects .........................................................................................................122
17 Flocking ...............................................................................................................................124
17.1 Background .................................................................................................................................124
17.2 Recent Commercial Developments ............................................................................................125
17.3 Patent Trends ...............................................................................................................................125
17.4 Listed Patent Literature 2011-2103 .............................................................................................125
17.4.1 Selective Coating Deposition ..................................................................................................125
References ...........................................................................................................................................125
18 Foil Transfer Processes .....................................................................................................126
18.1 Background .................................................................................................................................126
18.2 Recent Commercial Developments ............................................................................................129
18.3 Patent Trends ...............................................................................................................................130
18.3.1 Subjects, Ranking and Innovators ..........................................................................................130
18.3.2 Items of Particular Interest ......................................................................................................131
18.3.3 Principal Trends ......................................................................................................................131
18.4 Listed Patent Literature 2011-2103 .............................................................................................131
18.4.1 Three-dimensional, Tactile and Depth Effects .........................................................................131
18.4.2 Definition, Detail and Contrast ................................................................................................131
18.4.3 Metallic Effects .......................................................................................................................131
18.4.4 Surface Quality Improvement ..................................................................................................131
References ...........................................................................................................................................132
19 Inkjet and Droplet Printing .................................................................................................133
19.1 Background .................................................................................................................................133
19.2 Recent Commercial Developments ............................................................................................137
19.2.1 Conveyor/Single Pass Machines ............................................................................................137
19.2.2 Flatbed Machines ..................................................................................................................137
19.2.3 Inks and Effects .....................................................................................................................137
19.2.4 Machines for Three-dimensional Objects ...............................................................................137
19.2.5 Printing Heads .......................................................................................................................138
19.2.6 Products ................................................................................................................................138
19.3 Patent Trends ...............................................................................................................................138
19.3.1 Subjects, Ranking and Innovators ..........................................................................................138
19.3.2 Items of Particular Interest ......................................................................................................138
19.3.3 Principal Trends ......................................................................................................................139
19.4 Listed Patent Literature 2011-2103 .............................................................................................139
19.4.1 Three-dimensional, Tactile and Depth Effects .........................................................................139
19.4.2 Definition, Detail and Contrast ................................................................................................140
19.4.3 Gloss and Matte Effects .........................................................................................................140
19.4.4 Metallic or Reflective Effects ...................................................................................................141
19.4.5 Surface Quality Improvement ................................................................................................141
References ...........................................................................................................................................142
20 Labelling, Sleeving and Form Over Part ...........................................................................145
20.1 Background .................................................................................................................................145
20.2 Recent Commercial Developments ............................................................................................146
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Contents
20.3 Patent Trends ...............................................................................................................................146
20.3.1 Subjects, Ranking and Innovators ..........................................................................................146
20.3.2 Items of Particular Interest ......................................................................................................147
20.3.3 Principal Trends .....................................................................................................................147
20.4 Listed Patent Literature 2011-2103 .............................................................................................147
20.4.1 Three-dimensional, Tactile and Depth Effects .........................................................................147
20.4.2 Interference Effects ................................................................................................................147
20.4.3 Metallic and Reflective Effects ................................................................................................147
20.4.4 Surface Quality Improvement .................................................................................................148
References ...........................................................................................................................................148
21 Laser and Irradiative Marking, Engraving or Transfer ....................................................149
21.1 Background .................................................................................................................................149
21.2 Recent Commercial Developments ............................................................................................151
21.3 Patent Trends ...............................................................................................................................152
21.3.1 Subjects, Ranking and Innovators ..........................................................................................152
21.3.2 Items of Particular Interest ......................................................................................................153
21.3.3 Principal Trends .....................................................................................................................153
21.4 Listed Patent Literature 2011-2103 .............................................................................................153
21.4.1 Three-dimensional, Tactile and Depth Effects .........................................................................153
21.4.2 Colour Effects ........................................................................................................................153
21.4.3 Definition, Detail and Contrast ................................................................................................154
21.4.4 Gloss and Matte Effects .........................................................................................................155
21.4.5 Metallic or Reflective Effects ...................................................................................................155
21.4.6 Olfactory Effects ....................................................................................................................155
21.4.7 Surface Quality Improvement .................................................................................................155
References ...........................................................................................................................................156
22 Liquid Coating Techniques ...............................................................................................157
22.1 Background .................................................................................................................................157
22.2 Recent Commercial Developments ............................................................................................161
22.2.1 Materials ................................................................................................................................161
22.2.2 Miscellaneous ........................................................................................................................161
22.2.3 Processes ..............................................................................................................................162
22.2.4 Spray Booths .........................................................................................................................162
22.2.5 Spray and Coating Feed Equipment .......................................................................................162
22.3 Patent Trends ...............................................................................................................................162
22.3.1 Subjects, Ranking and Innovators ..........................................................................................162
22.3.2 Items of Particular Interest ......................................................................................................164
22.3.3 Principal Trends .....................................................................................................................164
22.4 Listed Patent Literature 2011-2103 .............................................................................................164
22.4.1 Three-dimensional, Tactile and Depth Effects .........................................................................164
22.4.2 Colour Effects ........................................................................................................................164
22.4.3 Gloss and Matte Effects .........................................................................................................165
22.4.4 Metallic or Reflective Effects ...................................................................................................165
22.4.5 Selective Coating Deposition ..................................................................................................166
22.4.6 Surface Quality Improvement .................................................................................................166
References ...........................................................................................................................................168
23 Pad Printing .........................................................................................................................170
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