Innovation Trends in Plastics PDF

Innovation Trends in Plastics
Innovation Trends in Plastics Decoration and Surface Treatment

The plastics industry is a major player for consumer items, notably for the automotive,
consumer electronics and packaging industries, and is necessarily very active in
innovation. As a result, moulded thermoplastics are achieving new heights in decorative
Decoration and Surface
Treatment
appearance and quality. Many striking aesthetic effects are possible by employing
new polymer blends coupled with a diverse range of decoration and surface treatment
technologies. These can produce three-dimensional and tactile finishes, high definition
images, flawless high gloss and metallic surfaces, as well as effects ranging from
imitation materials, interferential colours, colour gradients, colour change and travel,
gloss and matte combinations, and even acoustic or olfactory effects. Manufacturing
Decorative Effects on Moulded Plastics
processes to achieve these include several types of in-mould film, coating or decorating
technique, relatively recent technologies to improve surface quality, as well as traditional
separate decorating or coating processes such as dry offset; flexographic; inkjet; pad
and screen printing; foil transfer; labelling; laser marking; plating; spray coating; and
vacuum deposition.
This unique book analyses and compares recent trends in each of over 20 types of
mainstream manufacturing process and 10 classes of sensory effect they can produce.
Supported by over 100 tables, a three-year sampling of over 1,000 mentioned patent
documents and hundreds of commercial developments helps to identify the main trends
and their innovators, key innovative clusters and the most sought-after effects, as well
• 3-year review
as provide indications for the future.
• Process-by-process perspective
Ed Crutchley is a consultant in plastics decoration and surface treatment. After studying • Analysis of over 1,000 patents
printing technology at the London College of Printing he has worked in the rigid plastics
packaging industry in the UK, France and the USA in the fields of manufacturing plant
• Commercial developments
management, running technical and quality departments, and R&D and innovation. He • Innovating companies
has contributed to several patents.
Ed Crutchley
Ed Crutchley
ISBN: 978-1-909030-84-8
Smithers Information
Shawbury, Shrewsbury, Shropshire, SY4 4NR, United Kingdom
Telephone: +44 (0)1939 250383 Fax: +44 (0)1939 251118
http://www.smithers.com
Contents

Treatment
Ed Crutchley
A Smithers Group Company

Telephone: +44 (0)1939 250383 Fax: +44 (0)1939 251118
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
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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
References..............................................................................................................................................32
5 Materials for Effects and Other Special Colours ............................................................... 33

5.1 Background......................................................................................................................................33
5.3 Patent Trends....................................................................................................................................35
5.4.2 Colour Effects...........................................................................................................................36
5.4.3 Interference and Refraction Effects............................................................................................36
References..............................................................................................................................................42
6 Films, Foils and Labels.......................................................................................................... 43

6.1 Background......................................................................................................................................43
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
6.4.4 Interference Effects...................................................................................................................50
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

7.2.1 Three-dimensional Tactile and Depth Effects.............................................................................58
7.3 Patent Trends....................................................................................................................................58
7.4.2 Acoustic Effects .......................................................................................................................61
7.4.3 Colour Effects...........................................................................................................................61
References..............................................................................................................................................64
8 Substrate Polymer Resins, Blends and Additives.............................................................. 66

8.1 Background......................................................................................................................................66
8.2.2 Acoustic Effects .......................................................................................................................67
8.2.4 Surface Improvement................................................................................................................67
8.3 Patent Trends....................................................................................................................................67
8.4.1 Three-dimensional, Tactile and Depth Effects ...........................................................................68
8.4.2 Acoustic Effects.......................................................................................................................70
References..............................................................................................................................................72
PART C: IN-MOULD PROCESSES

9 Coloration, Co-injection, Multilayer Moulding and Multiple Material Moulding.............. 75
9.1 Background......................................................................................................................................75
9.2.1 Colouring Processes.................................................................................................................76
9.2.2 Processing................................................................................................................................76
9.3 Patent Trends....................................................................................................................................77
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Contents

9.4.2 Colour Effects...........................................................................................................................79
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
10.4 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
11.4 Listed Patent Literature 2011-2103................................................................................................90
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
13.2.1 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
13.4.1 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
14.3 Patent Trends................................................................................................................................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
15.3 Patent Trends................................................................................................................................117
15.4.1 Definition, Detail and Contrast.................................................................................................118
15.4.2 Surface Quality Improvement .................................................................................................119
References............................................................................................................................................119
16 Embossing........................................................................................................................... 121
16.1 Background..................................................................................................................................121
16.3 Patent Trends................................................................................................................................121
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Contents

17 Flocking................................................................................................................................ 124
17.1 Background..................................................................................................................................124
17.3 Patent Trends................................................................................................................................125
17.4.1 Selective Coating Deposition...................................................................................................125
References............................................................................................................................................125
18 Foil Transfer Processes...................................................................................................... 126

18.1 Background..................................................................................................................................126
18.3 Patent Trends................................................................................................................................130
18.3.3 Principal Trends.......................................................................................................................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
19.2.1 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
19.4.5 Surface Quality Improvement .................................................................................................141
References............................................................................................................................................142
20 Labelling, Sleeving and Form Over Part............................................................................ 145

20.1 Background..................................................................................................................................145
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Contents
20.3 Patent Trends................................................................................................................................146

20.4.2 Interference Effects.................................................................................................................147
20.4.3 Metallic and Reflective Effects.................................................................................................147
References............................................................................................................................................148
21 Laser and Irradiative Marking, Engraving or Transfer..................................................... 149

21.1 Background..................................................................................................................................149
21.3 Patent Trends................................................................................................................................152
21.4.2 Colour Effects.........................................................................................................................153
21.4.6 Olfactory Effects.....................................................................................................................155
References............................................................................................................................................156
22 Liquid Coating Techniques ................................................................................................ 157

22.1 Background..................................................................................................................................157
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
22.4.2 Colour Effects.........................................................................................................................164
References............................................................................................................................................168
23 Pad Printing.......................................................................................................................... 170
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Contents
23.1 Background..................................................................................................................................170
23.3 Patent Trends................................................................................................................................171
23.4.2 Surface Improvement..............................................................................................................172
References............................................................................................................................................172
24 Pigment Orientation Techniques........................................................................................ 174

24.1 Background..................................................................................................................................174
24.3 Patent Trends................................................................................................................................174
24.4.2 Colour Effects.........................................................................................................................176
References............................................................................................................................................176
25 Plating, Electroplating and Chemical Deposition............................................................. 177

25.1 Background..................................................................................................................................177
25.3 Patent Trends................................................................................................................................180
25.4.2 Colour Effects..........................................................................................................................181
References............................................................................................................................................184
26 Powder or Particulate Coating........................................................................................... 185

26.1 Background..................................................................................................................................185
26.3 Patent Trends................................................................................................................................186
26.4.2 Metallic and Reflective Effects.................................................................................................186
References............................................................................................................................................187
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27 Screen Printing.................................................................................................................... 188

27.1 Background..................................................................................................................................188
27.2.1 Artwork and Screen-making ...................................................................................................190
27.2.2 Equipment for Moulded Substrates.........................................................................................190
27.2.3 Effects.....................................................................................................................................191
27.3 Patent Trends................................................................................................................................191
27.4.4 Olfactory Effects......................................................................................................................192
References............................................................................................................................................192
28 Sublimation Printing, and Dye Infusion............................................................................. 194

28.1 Background .................................................................................................................................194
28.3 Patent Trends................................................................................................................................195
28.4.2 Colour Effects..........................................................................................................................196
References............................................................................................................................................196
29 Vacuum Deposition............................................................................................................. 197

29.1 Background..................................................................................................................................197
29.2 Recent Commercial Developments in Decorative Deposition......................................................200
29.3 Patent Trends................................................................................................................................201
29.4.2 Colour Effects..........................................................................................................................203
29.4.4 Interference Effects..................................................................................................................204
References............................................................................................................................................206
30 Water Transfer Printing....................................................................................................... 208

30.1 Background..................................................................................................................................208
30.3 Patent Trends................................................................................................................................208
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Contents

References............................................................................................................................................210
Abbreviations.............................................................................................................................. 211
Index ............................................................................................................................................ 213
x
Preface
Preface
The subject of decoration and surface treatment of moulded thermoplastics covers a wide range of
processes and techniques intended to deposit thin films onto a polymer surface or induce a surface
change. Given the importance of the plastics industry, the third largest in the US for example, we should
perhaps not be surprised by the associated high level of innovation and the particularly demanding rate
of change, most notably in the automotive, consumer electronics and packaging industries.
The largest part of innovation (around two-thirds), mostly led by materials suppliers with headquarters
in Germany, Japan and the US, focuses on increased performance, whether through improvements
in process techniques or endurance properties such as adhesion, abrasion, chemical and weathering
resistance, anti-fingerprint, anti-microbial and anti-static properties, permeation barrier, and more recently
self-cleaning or healing.
But what of decorative effects themselves?
The primary purpose of this book is to compare different processes and the aesthetic effects they produce,
and above all to identify the key trends in innovation across the board. The book identifies over 20 classes
of process technology and 10 types of effect. This is an important and much needed treatment for a
subject that has yet to receive the level of focus it deserves.
Clients frequently ask for information on recent game-changing innovations in this field. A few items
always come quickly to mind. They might include digital printing, rapid-cycle in-line metallising and rapid
heat cycle moulding to improve surfaces. Then, after a little further thought, another wave of potentially
important subjects surfaces. These may include subjects such as ceramic deposition onto polymers
for hard gold-coloured effects, carbon dioxide snow cleaning in-line with spray coating, drum painting,
high-speed cold foiling in-line with flexographic printing, inkless printing using lasers, ion implantation to
control and improve gloss, on-mould printing, phase separation moulding for metallic effects, picosecond
lasers to reduce heating effects, and tactile hot foil stamping. Other subjects quickly follow, for example a
myriad of other methods to create three-dimensional or tactile surfaces or special colour effects. Before
long we arrive at the content of this book – over 1,000 new patent documents as well as hundreds of
examples of commercial exploitation … the devil is in the detail.
The analysis is based on a three-year sampling period, from 2011 to 2013. This is enough to highlight
the basic trends and the most active players who are likely to remain prominent for several years to
come. Although it would be difficult to systematically link patent applications with eventual practical
developments, this book also includes several hundred examples of the latter in order to reflect the
commercial world.
I would like to express my appreciation to Nicholas Thorne, PhD for his encouragement when the idea
for this project was first mooted three and a half years ago, as well as the many ex-colleagues at Alcan
Packaging Beauty (now Albéa), customers, and other parties who have since provided invaluable advice,
information and photos. I would also like to thank the team at Smithers Rapra for all their efforts in bringing
this book to fruition, especially Frances Gardiner, Elea Garmson, Claire Griffiths, and Helene Chavaroche.
Ed Crutchley
Tunbridge Wells, January 2014
xi
Preface
xii
Overview
PART A: OVERVIEW
1
Overview
2
Part A: Overview
1 Introduction
1.1 Scope
We use the term ‘decoration’ to refer to techniques such as printing that can produce images as well as
solid colour areas, and ‘surface treatment’ for those processes that non-selectively apply films of lacquers,
paints, or metallic coatings. Naturally the boundary between the two becomes less well-defined year-
by-year as innovation is directed towards making each increasingly versatile. What unites them is the
common challenge to address increasingly complicated shapes and types of polymer substrate, and to
do so reliably and at the lowest cost. Both have traditionally been carried out as separate operations after
moulding, often in specialist departments or companies. In recent decades, improvements in reliability have
allowed them to be increasingly run in-line with moulding at less cost, and more recently still, particularly
in the last 10-20 years, much focus has been placed on in-mould solutions (by ‘in-mould’ we refer to any
operation that occurs at the moulding machine). To illustrate this important, latest shift, new developments
in the relatively young generation of in-mould techniques cover almost 40% of the published process
innovation identified for this book. The horizon continues to shift; no doubt we will soon see a growing
presence of three-dimensional (3D) printing techniques take this phenomenon several levels further, and
live imaging surfaces applied, for example, using in-mould labelling (IML).
From a purely decorative point of view, market forces dictate that the resulting effect must be distinguishing.
The existence of an increasingly media-conscious world implies that dynamic visual effects such as flip-
flop or impression of depth be added to tactile effects, as well as anything else that provides a novel all-
encompassing experience to the final user. Quality levels have become extremely high and the demand
for originality in shape, appearance and functional performance relentless. The subject has come a long
way in 60 years.
1.2 Innovation and Patents
Innovation tracking and mapping are important tools for the identification of key trends and prediction
of new developments likely to appear in the near future. Patent applications and specifications provide
useful technical data. Although not everybody attempts to protect their innovative activities with intellectual
property rights, those who do provide us with an excellent database from which to obtain a reasonably
detailed understanding of the gamut of processes involved and their strengths and shortcomings, as well
allowing us to identify those subjected to the most focus.
Fortunately patent information remains secret for only 18 months. The challenge is that, once published,
it is so abundant that care must be taken to ensure that it is properly harvested. The task is considerable;
the World Intellectual Property Organization (WIPO) tells us that about 1.5 million new patent applications
are filed every year, i.e., over 4,000 per day. Through careful selection of a wide range of search phrases
and subject classification codes (see the next section), we have managed to identify over 1,061 patent
documents relevant to the purpose of this book over a three year period.
1.3 Prediction of Trends
By definition all patents are supposed to be unique. In reality they give rise to clusters of ideas centred
around a given principle found to be of interest, or being pushed for by a particular market at a particular
time, and clusters can be compared. The prediction of future trends in this book is based on the simple
premise that the more patents that point towards a given subject, the more the chance in the future
1
Part A: Overview
that new options will become available in that same area. In short, future trends will be influenced to
the largest extent by the level of innovation activity. This approach is not intended to deny the validity of
patents that find themselves on their own, or the possibility that significant exploitation will be made of
them. Such cases litter the section on individual technologies. However, less widespread attention by
innovators risks limiting chances of success in developing them into commercial ventures, and there is
an important tendency for innovation activity to congregate around the more promising ideas, particularly
those that end up offering different approaches for exploitation.
On a global scale, a review of all patents points towards the following five key trends in achieving decorative
effects on moulded plastics:
1. Increase in multiple and dynamic decorative effects, often acting on more than one of the senses
(e.g., colour change, tactile and sound effects).
2. Increase in the use of combined processes to avoid the costs and technical problems and risks
associated with off-line operations and rupture (e.g., in-mould decorative processes, in-line decoration
and in-line metallising).
3. Increased exploitation of digital controls to better control processes, enable more economical shorter
run lengths and improve uptime (e.g., servo-controlled printing heads and substrate holding devices,
and memorised set-up parameters).
4. Increase in the use of digitally controlled, non-contact deposition and surface change techniques
(e.g., inkjet devices, lasers and vacuum deposition).
5. Exploitation of the quality capability and versatility of web printing processes to decorate moulded
plastics (e.g., in-mould films, transfer foils and labels).
There exists conflict in all this to the extent that the future is never crystal clear. The common starting
point is the moulding operation itself (injection, extrusion-blow, thermoforming and so on). This typically
requires expensive tooling, which is barely conducive to the on-going trend towards shorter runs and
more frequent design changes. In-mould decorative operations only serve to aggravate these costs and
add complexity to managing the process.
A second issue relates to the nature of individual decorative processes themselves if they are instead
placed in-line; they are often economically optimised (from an investment point of view) at output rates
quite different, often much faster, than the moulding process. Most manufacturing processes involve well
over a hundred key set-up parameters; combining them adds to the permutations.
Only time will tell how designers/manufacturers come to terms with these conflicts.
1.4 Innovators
Innovating companies are mentioned where known. In each section the most frequently named innovating
companies (patent applicants or assignees) are listed. Across all patents the list is diverse - the average
number of relevant patents per company per year is only between one and two, but something close to
the 80:20 rule exists, which means there are key companies to watch out for more than others. These
are led by companies that include BASF, MERCK, DAI NIPPON PRINTING, LG HAUSYS and LG CHEM,
BYD, BAYER MATERIALSCIENCE, TORAY INDUSTRIES, EVONIK DEGUSSA and ROEHM, ASAHI GLASS
2
Part A: Overview
and NISSHA PRINTING, followed by other familiar names. In all, 41 innovators have been found to have
three or more patents (i.e., an average of one or more per year) mentioned in this book. Table 1.1 shows
their distribution by country of headquarters. Germany, Japan and the USA share 73% of the total.
Table 1.1
Ranking of countries according to number of patents (for innovators of three or more during 2011-2103)
Rank Country Number of company names Number of patents % share
1 Germany 6 79 31
2 Japan 13 76 29
3 USA 9 34 13
4 Korea 1 18 7
5 Taiwan 3 14 5
6 China 2 12 5
7 Switzerland 2 6 2
7 UK 2 6 2
7 Belgium 1 6 2
8 France 1 4 2
9 Italy 1 3 1
1.5 Comments on Presentation
1.5.1 Subject Classification
In such a complex and interrelated subject, there is inevitably a large degree of arbitrary classification.
For example, since many materials, or at least the innovative ideas behind them, can be employed in
quite different processes, the book is separated into sections covering materials (Part B) and processes
(Parts C and D). However, where there is a large element of process involved in the exploitation of certain
materials, these are consigned to the relevant process sections. For such reasons, sections should
never be read in isolation; this book should be treated as a whole. Equally, the variety it offers can only
be appreciated by reading the descriptions of patents listed in each section in Parts B, C, and D of this
book. These have been deliberately kept brief in order to facilitate this.
1.5.2 Year-to-year Analyses
Whereas the tables in each section indicate the year-to-year breakdown of specific subjects, this is for
indicative purposes only. Interpretations of variations over the relatively short period of this study should
be made cautiously. However, they do on occasion appear show up interesting surges or major trends,
and these are commented on in the accompanying text.
1.5.3 Text Formatting
Throughout the main text of this book the following formatting has been applied in order to ensure
consistency and clarity:
1. COMPANY NAMES are set in UPPERCASE (note: companies are not always mentioned in patent
documents).
3
Part A: Overview
2. Product names including those that are trademarked are set in italics.
3. Patent titles are in bold italics.
4. Patent documents are displayed in following manner: [Title] [Publication number] [Publication date]
[First named applicant as indicated on the patent document] [Summary description (this author)].
Original spelling has been preserved.
1.5.4 Definition of ‘Patents’
When we refer to the word ‘patent’ in this book, this may imply either that it has been a) applied for but
not yet granted, or b) it has been granted, or c) its application has no longer been pursued, or d) it has
been abandoned, i.e., the applicant had decided not to continue to support the annual costs for its
protection (usually for 20 years). To stress, we are interested in the ideas contained in patent documents
rather than the status of the claimed invention. Indeed, not all patent applications are granted. From our
observations, about one in four patent applications eventually becomes a specification, and this takes at
least 3-5 years. Since 2013, when the USA applied the America Invents Act, all countries grant patents
on a first to file basis (priority date) rather than first to invent. This can result in patents being granted for
decorative effects that have already been known for decades but neglected or dismissed as accidental
or unexploitable by others.
1.6 Disclaimers
There are always limitations to selective search methods and the reliability of databases used. This author
cannot claim to have captured all of the documents relevant to the subject area of concern during the
three year period examined. However, the choice of search terms, the extended period covered, and the
regular monthly samplings during that period, have collectively assured a wide enough sampling sufficient
to provide an accurate picture of the overall state-of-the-art and key innovative trends.
The interpretation of the key elements and purpose of a particular patent is not always easy, especially
when required to be condensed into only a few words and from limited translation. Although provided
in good faith, our observations should only be taken as broadly indicative, and the original document
referred to for more accurate reading in the case of specific interest. The importance of referring to original
documents cannot be over-stressed; 10 words can in no way fully describe a document of 10 pages.
Equally it should be stressed that our presentation of any claim related to a document does not imply
our endorsement of those claims.
4
Part A: Overview
2 Sources
2.1 Commercial Developments
Included in each section are exemplary commercial developments that have been publicised during
the selected three year period. These have been collected on a regular basis from hundreds of trade
magazines and websites, as well as supplier websites. Sources are indicated in the reference section at
the end of each section.
2.2 Patenting Authorities and Obtaining Copies of Patents
Copies of all patent documents, independent of issuing authority, can be freely searched and downloaded
from http://worldwide.espacenet.com. This useful website also provides all publishing details as well
as automatic translation for many languages. Patent documents presented here originate mostly from
Europe (EPO patent), China (SIPO), USA (USPTO) and the WIPO. Some other specific countries are also
represented when the occasion arises.
It is important to note that any citation here does not necessary imply a first ever publication. An appearance
in a former version may have occurred prior to the time period examined (2011-2013). Many applications
are initially filed under the Patent Cooperation Treaty (PCT) under WIPO and later extended to regional
patent authorities in the hope of being granted, i.e., pass from ‘application’ to ‘specification’ status. Close
to 150 countries participate in the PCT system. Across all subjects predominant countries filing PCT
are, in order, USA, Japan, Germany, China and Korea. Many patent applications end up being published
under several regional authorities, sometimes with minor variations even under the same authority, and
occasionally with changing titles between authorities. In order to avoid unnecessary repetition, we have
tried to not repeat mention of any of these variants. Therefore, if a particular reference is of interest to
the reader, its publishing history, status and variants should be investigated in more detail at the website
already mentioned.
2.3 Approaches to Patents
Some aspects and peculiarities of the patenting process merit briefly noting here:
1. Some larger companies in our field of concern, most notably German-speaking, appear to have a
policy of patenting as much as possible, undoubtedly in order to secure as much market share as
possible in the future.
2. A patent application may be modified in title, wording and/or claims in the course of examination and
in order to be granted.
3. An innovator’s priority may not be to obtain the exclusivity provided by a granted patent but instead to
publish simply to retain freedom to operate and exploit as well as prevent anyone else subsequently
claiming exclusivity.
4. Occasionally companies appear to apply stealth to their patent applications. Examples of this are a)
filing under a different name; b) applying no applicant name at all or using inventors as assignees;
and c) using wording in the title and abstract that tends to obscure the patent from any anticipated
keyword search.
5
Part A: Overview
2.4 Patent Coding
There exist several subject classification systems applied by patent examiners which help to locate
patents in any specific subject. Any individual patent may have one or several codes applied to it under
any given system. For our searches we have in part used the system of International Patent Classification
(IPC) codes mentioned in the patent documents, since it is the most universally employed by different
authorities. Codes selected were those that were found to appear in relative patents obtained from the
keyword searches. Further information on IPC codes can be found at http://www.wipo.int/classifications/
ipc/en. Most patents cited here refer to the 2006.01 version of the classification system.
2.5 How Patent Searches Were Carried Out
Two methods were carried out simultaneously (Part A, Sections 2.5.1 and 2.5.2).
2.5.1 Method 1
Variants of the following keywords found in abstracts: ‘aesthetic’, ‘cosmetic’, ‘decorative’ ‘visual’, ‘plastic’
or ‘polymer’, coupled with variants of the following words (note: the term ‘variants’ refers to varying word
endings, such as ‘decorative’, ‘decoration’ or ‘decorating’, or spelling, such as ‘in-mould’ or ‘inmold’
and so on): ‘Adhesion’, ‘barrier’, ‘cleaning’, ‘coating’, ‘decorating’, ‘defect’, ‘degreasing’, ‘deposition’,
‘dust’, ‘flaming’, ‘gloss’, ‘heat transfer’, ‘hot stamping’, ‘hydrophobic’, ‘injection moulding’, ‘inkjet’, ‘in-
mould’, ‘laser’, ‘metallising’, ‘packaging’, ‘pad’, ‘painting’, ‘permeability’, ‘physical deposition’, ‘physical
vapour’, ‘plasma’, ‘plating’, ‘polish’, ‘printing’, ‘physical vapour deposition (PVD)’, ‘scratch’, ‘screen
printing’, ‘smooth’, ‘spraying’, ‘sputtering’, ‘stamping’, ‘surface treating’, ‘topcoat’, ‘transferring’, ‘vacuum
metallising’, ‘wear’ and ‘vacuum’.
2.5.2 Method 2
Variants of the following keywords found in abstracts: ‘aesthetic’, ‘cosmetic’, ‘decorative’ ‘visual’, ‘plastic’
or ‘polymer’, as in Method 1, coupled with any of the following IPC codes:
B05B (Spraying Apparatus; Atomising Apparatus; Nozzles), B05D (Processes for Applying Liquids or Other
Fluent Materials to Surfaces, in General), B08B (Cleaning in General; Prevention of Fouling in General), B23K
(Soldering or Unsoldering; Welding; Cladding or Plating by Soldering or Welding; Cutting by Applying Heat
Locally, e.g., Flame Cutting; Working by Laser Beam), B29 (Working of Plastics; Working of Substances
in a Plastic State in General), B32b (Layered Products, i.e., Products Built-Up of Strata of Flat or Non-
Flat, e.g., Cellular or Honeycomb, Form), B41 (Printing; Lining Machines; Typewriters; Stamps), B44C
(Producing Decorative Effects), B65C (Labelling or Tagging Machines, Apparatus, or Processes), B65D
(Producing Decorative Effects), C09D (Dyes; Paints; Polishes; Natural Resins; Adhesives; Compositions
not Otherwise Provided for; Applications of Materials not Otherwise Provided for), C23 (Coating Metallic
Material; Coating Material with Metallic Material; Chemical Surface Treatment; Diffusion Treatment of
Metallic Material; Coating by Vacuum Evaporation, by Sputtering, by Ion Implantation or by Chemical
Vapour Deposition, In General; Inhibiting Corrosion Of Metallic Material or Incrustation in General) and
C25D (Processes for the Electrolytic or Electrophoretic Production of Coatings; Electroforming; Joining
Workpieces by Electrolysis; Apparatus Therefore).
6
Part A: Overview
2.5.3 Search Results
On average, these combined methods yielded about 1,500-2,500 newly published documents every
month, which, after a two-stage cull, yielded about 30 relevant patents which were retained for this book.
To maintain focus we have deliberately made choices. Items, for example, that were not included in our
final selection include:
1. Patent titles with the same or similar wording from the same applicant, or appearing at the same time,
unless a difference is obvious and substantial.
2. Patents where the description or innovative step is not clear.
3. Patents where there is no clear indication of applicability to polymer substrates.
4. Patents on specific moulded objects where there appears no evident generic interest.
5. Substrate materials other than basic moulded thermoplastic polymers unless there appears to be
potential interest for moulded thermoplastic substrates.
6. Standard polymer resin and pigment development unless deemed mentionable from an aesthetic
point of view.
7
Part A: Overview
3 Decorative Effects on Plastics

Innovation in plastics decoration and surface treatment strives towards providing an ever increasing
all-round sensory experience. Within the physical limits imposed by different processes (e.g., contact or
non-contact, point, linear, single side contact or full immersion) many diverse aesthetic effects, appealing
to any of the senses (visual, tactile, olfactory, taste, or auditory), can be produced or influenced in plastics
through one or more of the processes involved. Often several different technologies can be used to
produce the same effect to varying degrees of efficacy. Their sensory effects are described in descending
order of importance in Table 3.1, and refined into a list of 10 categories for describing the primary intent
of patents, presented in Table 3.2.
Table 3.1
Types of sensory effect
Type Description
1 Visual Colour, colour travel, contrast, depth, detail, gloss/matte, metallic and translucency
2 Tactile Cold touch, cushioned effects, haptic and slip
3 Olfactory Odour, scent and taste
4 Acoustic Music, noise, sounds and vocal
Table 3.2 primarily shows the increasing attention paid to surface quality improvement, as well as selective
coating deposition, and the decreasing attention to 3D, tactile and depth effects over the three year period
used for sampling. Whereas overall there is a heavy bias towards surface quality improvement, 3D, tactile
and depth effects, and metallic or reflective effects (between them representing the major focus of two-
thirds of all patents), five other categories still show a significant patent count. In Part A, Section 3.1
each of the 10 categories is described in turn.
Table 3.2
Table of effects ranked according to focus
Rank Category Number of mentions as principal patent focus
2011 2012 2013 TOTAL %
1 Surface quality improvement 76 103 127 306 29
2 3D, tactile and depth effects 100 90 74 264 25
3 Metallic or reflective effects 39 46 45 130 12
4 Colour effects 22 39 29 90 9
5 Definition, detail and contrast 23 25 32 80 8
6 Interference effects 23 21 19 63 6
7 Gloss and matte effects 19 16 18 53 5
8 Selective coating deposition 12 14 20 46 4
9 Olfactory effects 3 6 6 15 1
10 Acoustic effects 0 1 1 2 <1
The effects listed in Table 3.2 can be achieved at a number of stages in the manufacturing process,
from choice of resin, blend or additives through to moulding or post treatment operations. These are
summarised in Table 3.3, where it can be seen that the process of adding layers to a substrate provides
the greatest variety of effects. These, of course, can be layers of resin, film, coating, or just decoration,
whether applied in-mould or in a separate operation.
8
Part A: Overview
Table 3.3
Decorative capability chart
Polymer and Additives Shaping Surface treat Added layers
blends
Examples
Gloss Beads Blow Ion implant Coating
Softness Clarifiers Emboss Laser Decorating
Transparency Pigments Extrude Plasma IML (film)
Slip additive Inject Sand blast Multi-layer
Thermoform Sublimate Plating
Ultraviolet Sleeving
3D, tactile and depth effects
Acoustic effects
Colour effects
Definition, detail and contrast
Gloss and matte effects
Interference effects
Metallic or reflective effects
Olfactory effects
Selective coating
Surface quality improvement
Dark grey areas: mainstream applications
Light grey areas: limited applications
White areas: none or few applications
Table 3.4 ranks subject areas in this book according to patent count. A total of 45% patents focus on
materials’ development as opposed to processing. Overall, four subject areas out of 27 account for nearly
half of the patents. These are films, foils, labels, followed by inks, paints, coatings, then effect and other
special colour materials and finally in-mould film techniques.
Table 3.4
Ranking of patent count
Rank Subject Number of patents %
1 Films, foils and labels (Part B, Section 6) 145 14
2 Inks, paints and coatings (excluding colour change or effect materials) (Part 127
B, Section 7) 12
3 Effect and other special colour materials (Part B, Section 5) 106 10
4 In-mould film techniques (Part C, Section 11) 102 10
5 Colour or reflectivity change materials and additives (Part B, Section 4) 57 5
6 Liquid coating techniques (Part D, Section 22) 55 5
7 Inkjet and droplet printing (Part D, Section 19) 49 5
8 Plating, electroplating and chemical deposition (Part D, Section 25) 47 4
9 Substrate polymer resins, blends and additives (Part B, Section 8) 47 4
10 Vacuum deposition (Part D, Section 29) 42 4
11 Coloration, co-injection, multi-layer moulding and multiple material 40
moulding (Part C, Section 9) 4
12 In-mould surface improvement (Part C, Section 13) 36 3
13 Laser and irradiative marking and engraving or transfer (Part D, Section 21) 30 3
9
Part A: Overview
Table 3.4 Cont'd...

Rank Subject Number of patents %
14 In-mould coating and on-mould painting (Part C, Section 10) 22 2
15 In-mould printing, marking, or use of engraved cavities (Part C, Section 12) 22 2
16 Dry offset and flexographic printing (Part D, Section 15) 19 2
17 Foil transfer processes (Part D, Section 18) 17 2
18 Embossing (Part D, Section 16) 14 1
19 Labelling, sleeving and form over part (Part D, Section 20) 14 1
20 Pigment orientation techniques (Part D, Section 24) 14 1
21 Powder or particulate coating (Part D, Section 26) 11 1
22 Water transfer printing (Part D, Section 30) 11 1
23 Screen printing (Part D, Section 27) 7 1
24 Atmospheric plasma deposition or thermal spray (Part D, Section 14) 6 1
25 Sublimation printing (Part D, Section 28) 6 1
26 Pad printing (Part D, Section 23) 3 <1
27 Flocking (Part D, Section 17) 1 <1
3.1 Introduction to Decorative Effects
3.1.1 Three-dimensional, Tactile and Depth Effects
These popular effects can be visual and non-tactile, tactile only, or a combination of visual and tactile
effects. They constitute one of the most sought-after goals in plastics’ decoration and surface treatment,
and are displayed in Table 3.5.
Table 3.5
Types of 3D, tactile and depth effects
Effect Description
3D relief Tactile relief in a polymer surface or decoration
Cold touch Sense of heat dissipation when touched
Depth Impression of volume via optical effects, thick films and flake pigment orientation
Haptic Soft-touch resins and coatings, rough surfaces and slip
Transparency is a measure of the portion of unabsorbed light that passes through a material or coating.
Matte surfaces reduce clarity by introducing haze. Haze in a translucent material will reduce distinctness
of an image (DOI) seen through the material. Some polymer resins, inks and coatings are required to
be clear and transparent. ‘Water-whiteness’ is a term that is used to describe colourless transparency.
Polypropylene (PP) can be improved, for example, by adding clarifying additives. In decorative terms,
good transparency provides an impression of depth.
Visual 3D effects can be achieved by the simple assembly of components that are translucent and
optionally decorated. In the field of decoration and surface treatment, methods include depth effects
obtained by applying a thick translucent film over a decorated substrate, with optional decoration or
coating to enhance the effect, a gradated magnetic orientation of pigments in a coating, or the use of
lenticular or holographic effects via moulding, embossing, or printing. Table 3.6 shows some examples.
10
Part A: Overview
Table 3.6
Examples of methods for obtaining visual depth effect
Process Examples
Moulding and in-mould Film insertion processes, thick films and films with decorative effects (glass beads
and so on)
In-mould coating
Multi-layer moulding
Decoration Glass beads incorporated into inks
Lenticular printing
Magnetically oriented pigments
Coating (inkjet, spray and so on) Glass beads incorporated into coatings
Magnetically oriented pigments
Thick translucent coating
Tactile effects can be achieved with or without surface relief. Tactile relief effects can be produced by
suitably manipulating the surface of a mould. Effects can also be produced by laser etching, flocking,
or applying an embossed label, or sleeve with locally activated internal foaming agent. Coatings can
be made to crackle or foam, inks to swell, and certain deposition processes, notably inkjet and screen
printing, can be used to produce raised images (including Braille). Non-relief tactile effects include the
use of soft haptic materials for moulding or over-moulding a substrate, the use of soft touch coatings
on in-mould film or applied by spray coating. Methods for the evaluation of tactile perception are also
evolving and thereby the subject of innovation [1, 2]. Increasing the surface slip properties of a plastic
component, either through internal additives or coating, makes the object less tacky. Examples of these
effects are shown in Table 3.7.
Table 3.7
Examples of methods for obtaining relief and tactile effects
Process Examples
Moulding Additives Slip additives
Thermally conductive additives
Wood grain, leather masterbatches
Cavity surface Engraved cavity
Choice of resin Soft materials such as TPE
In-mould solutions Heat re-forming (blow-moulding)
In-mould coating and skinning
Multi-layer (outer soft touch)
Tactile films for in-mould application, flocked films and natural materials
Zones of blowing agent
Decoration Hot foil stamping Metallic die (embossing)
Inkjet, screen Cracking, wrinkling and foaming inks
Ink thickness (e.g., inkjet voxels)
Slip additives
Soft touch
Water droplet effect
Labels and sleeves Embossed labels
Tactile sleeves
11
Part A: Overview
Table 3.7 Cont'd...

Process Examples
Decoration Laser Selective etching and ablation
Water transfer Swelling or relief films
Coating Liquid coatings Cracking and wrinkling coatings
Granular pigments
Immiscible wet-on-wet application
Imprinting a coating before or after curing
Selective curing and washing away
Selectively pouring solvent over lacquer
Soft touch
Slip additives
Water droplet effects
Liquid coating/ Flocking
particulate Pouring granular material over wet lacquer before drying
TPE: Thermoplastic elastomers
Cold touch is often considered a desirable feature for consumers. It is achieved with thermally conductive
surfaces allowing a sufficient level of heat dissipation when touched. In the case of plastics decoration
it requires a metallic sheath, a sufficiently large appliqué or a deposited metallic film thickness of several
tens of microns. In electroplating of plastics, the thick copper layer, typically 10-20 μm, is effective. Metallic
films of less than 2-3 μm, or the use of conductive polymer blends, provide a less pronounced effect.
Table 3.8 compares different methods used to obtain 3D, tactile and depth effects. In-mould film techniques
as well as films, foils and labels are seen to lead.
Table 3.8
Ranking of 85% of methods to obtain 3D, tactile and depth effects in patent applications 2011-2013
Rank Method Number of mentions %
as principal patent
focus (2011-2013)
3 In-mould coating and on-mould painting (Part C, Section 10) 21 8
4 Substrate polymer resins and blends and additives (Part C, Section 8) 22 8
5 In-mould printing, marking, or use of engraved cavities (Part C, Section 12) 17 7
Inks, paints and coatings (excluding colour change or effect materials) 6
6 17
(Part B, Section 7)
7 Inkjet and digital printing (Part D, Section 19) 13 5
8 Pigment orientation techniques (Part D, Section 24) 13 5
Coloration, co-injection, multi-layer moulding and multiple material 5
9 12
moulding (Part C, Section 9)
10 Embossing (Part D, Section 16) 12 5
Recent innovations in 3D, tactile and depth effects have included a wide range of new embossed in-
mould films; the use of heat-expanding materials in films, inks and coatings to produce selective tactile
12
Part A: Overview
effects; tactile masterbatches; the use of in-mould coating to create tactile effects; the use of magnetic
and embossing techniques to create 3D effects with flake pigments; in-mould flock application; inkjet
and spray coating techniques for creating relief effects; and relief effects from water transfer printing.
3.1.2 Acoustic Effects
In packaging, a desired effect is often an audible noise when a container is opened or closed: a click, a
snap, or even a bolt action. Certain polymers, such as acrylonitrile-butadiene-styrene (ABS), produce a
more distinct metallic-like sound than softer polymers such as PP, and plating can be used to accentuate
this.
In more recent examples of audible effects, printed electronics using electrically conductive inks are
enabling labels which create sounds (speech, music) when touched, and these feature in developments
proposed by several companies mentioned in Part B, Section 6. The implications for the future are
evident.
The acoustic effect can sometimes be unwanted. Dry, non-lubricated plastic surfaces tend to squeak
when rubbed together, to the extent that new resin formulations have recently been proposed in order
to eliminate this annoying phenomenon encountered when parts are assembled next to each other, for
example in automobile manufacture.
3.1.3 Colour Effects
Colour effects are usually created by incorporating pigments or dyes into a substrate, ink or coating,
but other methods are included in Table 3.9. The precise colour is perceived according to the ambient
illumination, so measurement and matching have to be carried out under standard illumination conditions,
with care taken to avoid any objectionable metamerism (similar colours becoming dissimilar when
compared under alternative lighting). Colour measurement requires colorimeters (although measurement
of inks and coatings containing effect pigments presents a challenge [3, 4]). Methods for defining colours
include the L*, a*, b* (LAB) colour space (INTERNATIONAL COMMISSION ON ILLUMINATION (CIE) 1976)
or MUNSELL colour systems. Metallic effects can also be measured. Gold, for example, has a colour
measured by the LAB system of around L* = 84, a* (red-green) = 5; b* (yellow-blue) = 34, whereas more
neutral chrome may have a colour around L* = 96, and lower a* and b* values of -1, and 5 respectively.
For painted substrates of non-uniform surface texture special techniques may be required in order to
counter the spurious effect of surface variation on measurement [5]. Colour matching usually involves
using several components from a base scheme range of 15 or more mono-pigment concentrates in order
to achieve a target colour for a substrate, ink, or coating, and is nowadays largely assisted by computer-
aided colorimetry.
Covering power (opacity) and brightness are influenced by concentration. Colour saturation is influenced
by the choice of pigment or dye, or combination of pigments and dyes. Colours that are mixed together,
and are close to each other on the LAB or Munsell colour gamut or circle, produce a more saturated
hue. Multi-colour effects can be produced by multiple-layer or multi-shot moulding, or printing and
decorating in multiple colours and halftone.
13
Part A: Overview
Table 3.9
Examples of methods of obtaining colour effects
Method Examples
Additives Pigments or dyes incorporated into substrate, ink, or coating
Colour-change additives (e.g., laser-sensitive) in substrate, ink or coating
Coloured materials Metal alloys or ceramic finishes vacuum deposited onto a plastic substrate
Interferential effects Thin coatings that create colour via interference effects
Multi-colour process Multi-colour halftone or pixel printing
In printing and decorating, ink film thickness influences colour density and can be controlled to varying
degrees depending on process. Changes in lower film thicknesses produce the greatest effects, as the
thickness is increased the effect tails off. The same is true of laminating and co-extrusion processes.
Colours can also be created by coating with naturally coloured materials. Ceramic materials can be
blended into polymers or deposited onto plastic substrates using reactive sputtering or cathodic arc at
low pressure (vacuum). Effects range from blue, red and yellow (using metallic oxide targets), to metallic
gold and similar colours (using metal targets combining nitrogen and carbon), to black (silicon or titanium
and aluminium carbides) [6].
Colours can be generated by interferential effects, for example using nanometre scale transparent inorganic
films deposited in a vacuum, provided that deposition film thickness can be precisely controlled [7]. This
has now spread to an alternative solution for pigments. Scientists from the UNIVERSITY OF NAGOYA
and the UNIVERSITY OF OSAKA have developed non-fading and non-toxic sub-micron sized pigment
particles of silicon dioxide to create bright structural colours [8].
Colour obtained by surface plasmon resonance is the subject of a vacuum deposition patent mentioned
in Part D, Section 29.
Colour gradients can be created dynamically by varying pigment feed or layer thickness in moulding, by
variable printing techniques, or by spraying techniques using more than one colour and spray device at
the same time.
Colour effects can be made dynamic, i.e., changing in themselves. Phosphorescent or fluorescent additives
exhibit delayed reaction from sunlight or reinforcement of visible light emission by absorbing non-visible
wavelengths, respectively. Colour change can be induced by light, laser, humidity, temperature or even
leaching chemicals. Photochromic effects, for example, are used in so-called transition lenses used for
spectacles. The use of photochromic or thermochromic pigments or dyes is widely reported in the patent
documentation listed in Part B, Section 4.
Table 3.10
Examples of methods for obtaining colour gradients
Method Examples
Moulding Varying feed rate of colour layer
Printing Halftone decoration using process colours
Varied inkjet
Spray/coating Different overlapping feeds
Vacuum deposition Target positioning or masking
14
Part A: Overview
Electronic solutions permit image or colour alteration on the substrate itself, and this will surely have
significant applications in the future. A 2011 patent application, for example, talks of electronically-
controlled colour-change artificial fingernails [9] and a 2013 patent application talks of remotely sending
electronic signals in order to alter an image on a container [10].
Recent innovation in colour has included the development of solutions for inkless multi-colour printing
using lasers and additives incorporated into the substrate or coating; material blends that imitate surfaces
such as porcelain and stone; effect pigments of up to eight layers yielding increased colour intensity and
travel; and the manipulation of coloured layers during the extrusion phase for making bottles in order
to produce colour effects and gradients. Various methods for obtaining colour gradients in different
processes are shown in Table 3.10.
3.1.4 Definition, Detail and Contrast
A decorated image may constitute a wide area of solid colour, text, fine lines or pixels, or a halftone
photographic image. The final effect could also be a random or orderly decorative pattern. Imitation
finishes, such as wood or marble, have a combination of contrast, colour, and detail. Different decoration
processes are capable of varying degrees of detail, for example, in the production of fine halftone
dots barely discernible to the naked eye. Whereas screen printing is generally capable of only around
40 lines/cm, dry offset printing on moulded substrates such as tubes or tubs is capable of 50 lines/cm,
and flexography around 70 lines/cm. These have to be compared with the more controllable, faster and
cheaper processes of printing on web, such as digital, flexographic, gravure, or offset printing. Thus, the
rise in the use of pre-printed films in plastics decoration is explained.
An important feature of any printing or decoration process is its ability to accurately position an image on
a substrate and to register different colours to that position. Dry offset printing (Part D, Section 15) and
heat transfer of pre-printed foils directly onto a moulded substrate (Part D, Section 18) both have the
advantage that all the colours are usually transferred in one step; other processes such as flexographic
(Part D, Section 15), pad (Part D, Section 23), and screen printing (Part D, Section 27), rely on accurate
mechanical systems or servo controls to ensure constant plate and substrate positioning from one colour
station to the next between intermediate drying and curing stations.
The challenge for all processes is to accurately and repeatedly position the decoration on a 3D substrate.
Precise image positioning is somewhat precarious with some forms of sublimation printing (Part D,
Section 28) or water transfer printing (Part D, Section 30), where more than one face of a substrate is
enshrouded at once. With heat transfer (Part D, Section 18), where a single face is decorated at a time,
the foil itself can be accurately optically pre-positioned. Substrate control is often a further challenge; on
cylindrical shapes, a register feature moulded into the plastic is sometimes required to avoid, for example,
slippage around a mandrel, to ensure the same substrate orientation each time. The choice of process
and machine engineering concept, as well as proper validation of tailor-made holding devices, is a vast
and important subject learned by experience.
Examples of recent innovation include:
• The emergence of inkjet devices capable of finer pixilation,
• New additives for improving definition by laser marking,
• Improved mechanical and servo-driven techniques for controlling flexographic, screen and hot foil
printing heads and part holders,
15
Part A: Overview
• Improved tonal range in plate making for flexographic and dry offset printing, and
• The use of ultrasonic energy and finer meshes in order to increase screen printing detail.
The use of digitally controlled devices, such as inkjet heads or lasers, greatly facilitates image manipulation
on the fly. Digital control allows considerably wider potential than processes that rely on plates or screens.
Image manipulation can imply, for example, locally adjusting detail and contrast.
3.1.5 Gloss and Matte Effects
This section refers to gloss and matteness manipulation or any combination of either or both effects for
decorative purposes. Gloss is a measure of the level of specular reflectance from a surface, measured
using a gloss meter. It defines the degree of smoothness and is a measure vital for assuring the subsequent
visual quality of thin metallic films deposited by vacuum metallisation. Increase in gloss level presents
new challenges as small defects become more noticeable in glossy surfaces. The improvement in gloss
purely with the intent of improving surface quality is covered in Part A, Section 3.1.10.
Different incident and viewing angles are used according to the type of surface in order to obtain a
measurable differentiation between levels of gloss and matte. A matte surface, for example, is measured
at 85° between incident and reflected light and the perpendicular, a satin surface is measured at 60°,
and a high-gloss surface at 20°. A goniometer provides more detail by measuring gloss at all angles. On
curved surfaces, gloss measuring devices with small apertures are employed. It should also be mentioned
that a slight deformation in a flat surface can also give rise to lower gloss values when a larger aperture,
e.g., 10 × 10 mm, is used.
Examples of methods for increasing gloss are presented in Table 3.11. More recent innovation
refers to the use of ion implantation in order to control the level of substrate polymer gloss (Part D,
Section 29).
Table 3.11
Examples of methods for increasing gloss
Process Examples
Moulding Cavity heating, hold pressure and so on
Film insert moulding and so on
In-mould coating
Coating and decorating Coating (e.g., spray)
Film transfer
Plating and thick layer
A non-glossy surface is described as satin or matte. Examples of methods for increasing matteness are
presented in Table 3.12.
Sandblasting is little used today for creating finished polymer surfaces because of their resulting increased
sensitivity to scuffing; spray coating, as one alternative, gives a more resistant finish. Recent innovation
in gloss control has included the use of excimer UV curing in order to create matte effects through micro-
wrinkling of coating surfaces or the use of ion implantation.
16
Part A: Overview
Table 3.12
Examples of methods for increasing matteness
Process Examples
Moulding Cavity etching
In-mould coating
Matting agents incorporated into polymer
Surface treatment Plasma etching
Sandblasting
Coating and decorating Embossing
Excimer UV curing
Matting agents
UV: Ultraviolet
3.1.6 Interference Effects
Thin multiple-layer translucent materials, with film thicknesses in the order of wavelengths of light, can
cause interferential effects by employing different refractive indices and reflected light. Effects occur as
a result of phase differences between light rays re-emerging after being reflected from different layers.
Such conditions can theoretically be manipulated using vacuum deposition techniques onto plastics, but
this can be difficult to control on 3D substrates, and the technique is usually confined to substrates than
can be easily processed i.e., films or pigments. These are subsequently incorporated into or applied to
substrates for decorative effects.
Multi-layer coated pigment flakes incorporated into polymers, inks and coatings cause interference effects.
Special effect pigments can produce flop (colour travel, changing colour with viewing angle). This subject
constitutes an important area of on-going innovation (Part B, Section 5).
Moiré effects constitute a two-dimensional interference phenomenon. They are encountered particularly in
halftone printing as a result of visual patterns unintentionally appearing in superposed rows of organised
dots. Screen angles used for different halftone colours are carefully chosen to minimise the effect and
create instead small rosette patterns. The problem has resulted in a range of innovations designed to
randomise dot positioning, but the phenomenon has also been used in order to deliberately produce
visual effects or anti-counterfeit measures.
Coating a polymer substrate with a final thin film of high refractive index (RI) material, such as TiO2 or
ZnS (RI = >2.0), can produce interference effects and colours seen at certain angles. Vacuum deposition
techniques are used (Part D, Section 29), followed by spray coating of a protective translucent organic
topcoat. (The use of multiple layers of high and low refractive indices for anti-reflective (AR) coatings falls
outside the scope of this book).
A few patent documents refer to the effects achieved using polarised light and are also included here.
3.1.7 Metallic or Reflective Effects
Paradoxically but understandably, metallic effects constitute the third most sought after decorative effect
on plastics. With polymer substrates, a metallic effect is mostly achieved by one of the following methods:
17
Part A: Overview
1. Adding metallic flake pigments to the resin,
2. In-mould applying a pre-metallised film or separately applying a hot stamping foil,
3. Applying pigmented inks or coatings, and
4. Coating with metal either through PVD under vacuum, plating, or by silver reduction process.
Vacuum metallising and plating are the most widely used processes for a high quality metallic finish. In-
mould metallising using die-slide technology was proposed in a 2004 Japanese patent [11].
Table 3.13
Examples of common methods for obtaining bright metallic effects
DOI Colour range Selective Shape
Process
possible metallisation versatility
Vacuum metallising processes ●●●● Excellent Limited Excellent
Electroplating ●●●● Limited Good Excellent
Silver reduction by spray ●●●● Good Limited Good
Hot foil stamping or heat transfer ●●● Excellent Excellent Limited
In-mould decorating ●●● Excellent Excellent Limited
Buff and lacquered or anodised metallic sheath ●●● Excellent Limited Limited
In-mould film processes, form over part ●●● Excellent Excellent Limited
Printing or spraying second surface ●●● Excellent Excellent Limited
Spray coating (metallic pigments) ●● Excellent Limited Excellent
Printing (metallic pigments) ●● Excellent Excellent Limited
Drum coating (metallic pigments) ● Excellent Limited Good
Substrate pigmentation ● Excellent Good (multi-shot) Excellent
● Low DOI (distinctness of image), i.e., high scattering of reflected light
● ● Moderate DOI
● ● ● Good DOI
● ● ● ● Excellent DOI, minimum scattering, mirror-like quality
A bright metallic surface can be described as having a high DOI. A mirror, or a vacuum metallised surface
over a high gloss and smooth basecoat, exhibits a high DOI. If, however, the surface is matte, or if the
metallic effect had been produced with pigments as opposed to vacuum deposition, DOI is inevitably
much lower by virtue of the non-smoothness or lack of homogeneity of the reflective layer. Table 3.13
ranks DOI according to type of manufacturing process.
Pigmented solutions do not produce as bright an effect as continuous media, except when second-
surface applied as paint or ink to a glossy translucent polymer such as polycarbonate (PC) or
polymethylmethacrylate (PMMA). In this case, the substrate forms the visible surface of the film, and
its smoothness optimises the metallic effect by encouraging flake pigments to lay flat. As a first surface
decoration, the effect produced by pigments can be improved by using a vacuum metallising process
to create an exceptionally flat pigment to be incorporated into the ink or coating (e.g., Metalure® from
ECKART). Optimising pigment lay by spraying several (very dilute) layers, or printing a very thin layer,
further improves the result. In this respect, solventless UV-curable inks do not provide as good a result
as solvent-borne systems.
18
Part A: Overview
Table 3.14 ranks 80% of methods to obtain metallic effects from patent documents recovered over the
three year period. These are led by effect and other special colour materials followed by films, foils, labels
and vacuum deposition, accounting for 60% of all methods.
Table 3.14
Ranking of 80% of methods to obtain metallic effects in patents 2011-2013
Rank Method Number of mentions as %
principal patent focus
(2011-2013)
1 Effect and other special colour materials (Part B, Section 5) 42 32
3 Vacuum deposition (Part D, Section 29) 15 12
5 Plating, electroplating and chemical deposition (Part D, Section 25) 9 7
The best metallic effects on moulded polymer surfaces are obtained by either plating a thick metal film
of about 20-30 μm that includes a levelling copper layer or by vacuum metallising or by silver reduction.
The latter two processes are carried out over a high gloss surface and, more usually, a pre-applied glossy
organic basecoat. Thin film vacuum deposition requires the use of a protective translucent topcoat. This
usually consists of 5-10 μm of an organic topcoat and leads to an optical phenomenon that must be
taken into account when choosing and optimising the substrate layer. Small degradations in the surface
gloss of the substrate layer have a multiplying effect in the brightness of the top-coated metallised film
[12]. It is therefore important that this under-layer is as glossy as possible, and the traditional means for
achieving this is to spray 10-20 μm of a high-gloss organic basecoat.
In the patent documents listed in the following sections, newer methods are proposed to provide metallic
effects include self-stratification during moulding (Part C, Section 9), plasma deposition (Part D, Sections
14 and 29), and inkjetting of nanoparticles or pigment flakes in the diameter range of around 1 μm (Part D,
Section 19). Other recent innovations in metallic effects have included a number of in-mould films; silver
reduction (with more benign chemistry); an increased range of metallic colours obtainable by electroplating;
use of a cathodic arc to produce ceramic finishes sufficiently hard to not to require topcoats.
3.1.8 Olfactory Effects
Scents and flavours can be deliberately incorporated into a polymer, ink or coating using micro-
encapsulation to delay their dissipation. This is exemplified by the appearance of Scratch and Sniff printing
in the late 1960s. Some objects are intended for oral use and masterbatches have been developed in
order to provide them with an attractive taste.
From an opposite point of view, many uses of coatings and inks require the absence of odour, and this
has given rise to much development aimed at eliminating culpable ingredients or trace materials and
facilitating more benign processing conditions. A new book has recently been published on the subject
of odours in plastics [13].
19
Part A: Overview
3.1.9 Selective Coating Deposition
Compared to printing processes, coating processes are usually designed to apply the same finish to
an entire exterior surface. Any selective nature of such finishes (such as the use of masking, avoiding
interior areas or rims and so on) is the object of a part print that defines areas to treat or not treat. Ideally,
prints should also define where and how the substrate will be held for surface treatment. Increasing the
potential for selectivity continues to be subject to innovation in order to broaden their potential. The prime
example of innovation in this area is the emerging use of inkjet deposition to coat a substrate, with the
added advantage of this technique being able to locally vary deposition thickness. Table 3.15 covers
examples in the field of metallic effects.
Table 3.15
Examples of methods for achieving selective metallisation
Process Examples
In-mould In-mould decorating
In-mould film with selective metallisation
Decorating Heat transfer foil with selective metallisation
Hot foil stamping
Electroplating Laser direct structuring prior to plating
Laser etching after plating
Multi-shot moulding of plateable and non-plateable polymers
Overprinting metallic finishes with opaque inks
Pre-printing (special refusal ink) prior to plating
Vacuum deposition Laser etching the finished result
Masking
Overprinting metallic finishes with opaque inks
Selective bright metallisation, whereby metallic images or zones are created on a substrate, is a subject
of wide interest. This is readily possible in electroplating, for example by co-injecting plateable and non-
plateable resins (Part D, Section 25) or by the use of lasers. A new technique that exploits the phenomenon
that metal is not deposited where there are traces of oil on the substrate surface has been proposed
for vacuum metallisation (Part D, Section 29), and once again the use of inkjet technology with metallic
nanoparticles or micronised flakes may also provide practical future solutions (Part B, Section 5).
3.1.10 Surface Quality Improvement
In the most important subject category according to the number of patents, surface quality improvement
often refers to improvement in gloss and smoothness. Common methods to improve surface quality of
moulded polymers are shown in Table 3.16. Some polymers are naturally glossier than others. Polybutylene
terephthalate, PC, poly(cyclohexylene dimethylene terephthalate) acid, PMMA, and styrene-acrylonitrile,
for example, are usually glossier than ABS, polyamide or PP. The latter group can in part be improved by
choosing more fluid grades (lower molecular weight (MW)), as well as heating the injection mould cavity.
Accelerated heating (and cooling) leads to the technique of rapid heat cycle moulding (RHCM) which
has received so much attention in recent years as a means for improving part surface quality (Part C,
Section 13). RHCM techniques are designed to obtain class A finishes without penalising cycle time by
also accelerating the cooling process. These and other techniques can be used in order to eliminate weld
lines and sinks, and a claim often made is that the resulting substrate surface no longer requires painting.
Cooling time and hold pressure have to be manipulated in order to improve results. Gloss is also affected,
20
Part A: Overview
of course, by the level of mould cavity polishing, and this is also covered in Part C, Section 13. In blow
moulding of bottles, several patent applications refer to the use of product filling during the blowing cycle
in order to shape and improve the surface of the container.
Table 3.16
Common methods for improving surface quality
Process Examples
Moulding Cavity heating
Glossy polymers (PC, PMMA and so on)
High-melt flow resins (low MW)
In-mould coating
Polished cavities
Product filling during the blowing phase (blow moulding)
Coating Basecoat before decoration or surface treatment
Glossy coating resins
Plating
Spray, curtain and flow coating
Decorating Foil transfer processes
Glossy ink resins
In decoration processes which rely on liquid or powdered raw materials, refusal or poor flow-out can
result in visual defects such as orange peel, or even incidents of cratering (a surface tension phenomenon
also referred to as fisheyes, pinholing, cissing, reticulation and so on [14, 15]). Edge effects can result in
excessive build-up on corners and constitute a target for innovation particularly in curtain and dip coating.
Common methods to improve surface quality of inks and coatings are shown in Table 3.17.
Table 3.17
Examples of methods for improving surface quality in printing, decorating and coating
Technique Examples
Contamination control Cleaning techniques (flame, plasma, brushing, degreasing, deionising and so on)
Environmental control (clean room, humidity control, pressurisation and so on)
In-line processing
Pinning techniques (e.g., to stop cratering)
Flow-out Additives (solvents and surface active additives)
Increased film thickness
Increased time/temperature before drying/curing
Infrared heat before drying/curing
Slower solvents
Specific techniques for reducing edge or electrostatic Faraday effects
Substrate plasma treatment (inkjet)
Rheology control Lower viscosity (via formulation, application method and conditions)
Lower yield-value
21
Part A: Overview
A common feature of decoration processes is the creation of a decorated overlap when treating the
sides of cylindrical and similarly shaped substrates (dry offset, flexography, screen and so on), or when
the decorating device is smaller than the surface to be treated (large format inkjet printing and so on).
Overlaps constitute a very specific problem and can be unsightly, and are, therefore, the focus of attention
in innovation. In IML the film should not overlap as it will not stick to itself; a butt join is aimed for, but
inevitably tolerance requirements mean that some gap will occur, albeit flush with the film surface. The
choice of substrate colour may therefore be important. In hot foil stamping some films do not stick to
themselves when overlapped. A method proposed in the past to blend overlaps in processes involving
transfer foils or inks has been to employ a halftone blending technique. Similar solutions have been
proposed in ink processes. In screen printing, the ink film is sufficiently thick that a radiant heat-assisted
delay between printing and curing can allow the ink to flow out. In spray coating, for example, the overlap
is disguised by rotating the substrate at least 2-3 times.
Table 3.18 shows that inks, paints, coatings, followed by films, foils and labels, account for half the
methods used to improve surface quality.
Table 3.18
Ranking of 87% of methods to obtain surface quality improvement in patent applications 2011-2013
Rank Method Number of mentions as %
principal patent focus
(2011-2013)
1 Inks, paints, coatings (excluding colour change or effect materials) 86 28
(Part B, Section 7)
2 Films, foils, labels (Part B, Section 6) 64 21
3 In-mould surface improvement (Part C, Section 13) 36 12
6 Substrate polymer resins, blends and additives (Part B, Section 8) 20 7
Recent innovation in surface quality improvement has focused on: improved in-mould films formulated
to maintain good surface quality after deeper draws; the growing use of in-mould coating; innovations
related to RHCM to improve substrate surface gloss and quality; the use of vibration and particle size
distribution to reduce orange peel effects in powder coatings; the use of ion implantation to improve
polymer substrate gloss; the use of filled product pressure to improve surface quality during blow
moulding; improved spray coating devices and controls; the use of pinning techniques in order to stop
cratering in liquid coatings.
3.2 Functional Properties of Inks, Coatings, Films and Substrate Materials
Although not constituting the prime consideration for this book, it is clear that a number of functional
properties will be required of decorative effects on plastics in order to ensure their long-term durability
and intended performance. They therefore merit a passing mention. Mainstream properties are presented
in Table 3.19. For more on advanced functional coatings, refer to reference [16].
22
Part A: Overview
Table 3.19
Common functional properties required of inks, coatings, films or substrate polymers
Properties Examples and comments
1 Abrasion and chemical resistance Degree of crosslinking. Inclusion of additives (e.g., silica nanoparticles)
2 Adhesion Resin choice, pretreatment (flame, plasma and so on) and primer
3 Anti-counterfeit and identification Taggants, special decoration techniques, oriented pigments and so on
4 Anti-fingerprint and easy-to-clean Typically obtained using fluorine chemistry to obtain low surface energy
5 Anti-fouling and stain resistance Tied with chemical resistance, hydrophobicity and oleophobicity
6 Anti-frost and anti-fog Typically obtained by ensuring high surface energy for improved
wetting
7 Anti-glare and anti-reflective Typically multiple coats of alternating high and low refractive indices
8 Anti-microbial Additives or coatings, e.g., containing silver ions or other biocide
9 Anti-static Humidity absorbing materials, conductive polymers, carbon nanotubes
and so on
10 Barrier to permeation Resin choice, multi-layer, inorganic deposition, barrier label and oxygen
scavengers
11 Conductivity Carbon nanotubes, carbon and metallic fillers
12 Discoloration resistance Non-yellowing through UV or heat resistance. Absence of residual
volatiles
13 Low misting Methods to reduce misting in high speed inkjet and dry offset
processes
14 Low outgassing Absence of volatiles that outgas during moulding or vacuum processes
15 Recoatability Coating ability to be re-covered, e.g., via under-curing, absence of slip
additive
16 Recyclable and removable Removable labels or coatings
17 Safety and toxicity Absence of toxic materials, residual solvents, initiators or catalysts and
so on
18 Self-cleaning Typically a TiO2 additive or coating, which becomes reactive in sunlight
19 Self-healing Typically microencapsulation of liquid healing agents
20 Stress crack resistance Stress relieving, reducing molecular weight spread and so on
Many decoration processes claim advantages for specific properties. For example, in-mould film application
or spray coating can be used to improve abrasion, chemical and weathering resistance properties of
substrates; ceramic deposition using reactive sputtering or arc deposition can also be used to improve
resistance; plasma enhanced chemical vapour deposition or atmospheric plasma deposition can be used
to apply a barrier or abrasion-resistant coats, or anti-fingerprint finishes and so on. An analysis of recent
patents in this area shows that current innovation focuses principally on:
1. Barrier properties against migration of oxygen and other gases, aromas, moisture or solvents, followed
by
2. Improvements in abrasion and chemical resistance, and
3. Adhesion promoting materials and processes.
In specialised fields, for example medical applications, good wetting and lubrication, as well as low
toxicity, are important objectives.
23
Part A: Overview
References
1. R. Fagiani, F. Massi, E. Chatelet, Y. Berthier and A. Akay, Tribology International, 2011, 44, 10,
1110.
2. F. De Boissieu and B. Guilhamat, inventors; Commissariat à l’Energie Atomique et Aux Energies,

assignee; US20120118080A1, 2012.
3. J. Alspach and A.B.J. Rodrigues in Measurement and Specification of Gonioapparent Color and
Appearance, Presentation made at BYKE User Meeting, 2011.
http://byke.com {Accessed June 2014}
4. W.R. Cramer, European Coatings Journal, 2011, Issue 04, 32.
5. A. Chauvey, inventor; Peugeot Citroen Automobiles SA, assignee; FR20090051631, 2010.
6. M.C. Colton, CERAC Coatings Materials News, 1998, 8, 1.

http://www.materion.com {Accessed June 2014}
7. S. Franssila in Introduction to Microfabrication - Thin-film Materials and Processes, 1st Edition,

Wiley, New York, NY, USA, 2004.
8. Colourful Sand Avoids Toxic or Fading Pigmentations.

http://www.european-coatings.com {Accessed May 2014}
9. T. Schneider and D. Chaney, inventors; Kent Displays Inc., assignee; US20110061670A1, 2011.
10. M. Pivaudran, inventor; Société Lotoise d’Evaporation (Solev), assignee; US20130122817A1,

2013.
11. U. Takao and I. Shiyu, inventors; Oshima Denki Seisakusho, assignee, JP20044338328, 2004.
12. D.W. Hoffman and R.A. Dickie, Polymer Engineering and Science, 1977, 17, 12, 865.
13. G. Wypych in, Handbook of Odors in Plastic Materials, ChemTech Publishing, Ontario, Canada,
2013.
14. E.B. Crutchley in Proceedings of the SPE EUROTEC 2013 Conference, Lyon, France, 2013, Paper
No.1666164.
15. E.B. Crutchley. Keeping Contamination at Bay, Plastics Decorating Magazine, Topeka, KS, USA.
http://www.plasticsdecorating.com {Accessed May 2014}
16. V. Stenzel and N. Rehfeld in, Functional Coatings, Vincentz Network, Hanover, Germany, 2011.
24
Part B: Materials
PART B: MATERIALS
3
Part B: Materials
4 Materials and Additives for Colour or Reflectivity Changes
4.1 Background
Table 4.1 Shows that innovation in colour effects predominates over additives designed to improve
definition, detail or contrast, and this is particularly due to an apparent surge in 2012. Colour change
(chromogenic) materials, as well as those that change reflectivity, fit in perfectly with the growing trend
to provide more variety and dynamic aesthetic effects in plastics. This area of innovation is dominated
by the use of laser initiation for colour change. Additives are incorporated either into substrates, inks
or coatings, or labels or films applied to the substrate. Non-laser applications often focus on functional
purposes (e.g., colour changes for food packaging [1], temperature warnings and so on). One of the best
known applications is for spectacle lenses (known as Transitions) which reversibly darken in sunlight.
Included in this section and relative to decorative effects are additives that improve sensitivity and contrast
when using laser marking techniques. Laser marking additives improve the efficiency of converting laser
energy into heat in order to effect a colour change in selected materials.
Table 4.1
Primary focus of patents listed in Section 4.4
Rank Subject 2011 2012 2013 TOTAL
1 Colour effects 9 17 9 35
2 Definition, detail and contrast 6 7 5 18
3 Metallic or reflective effects 1 3 0 4
Thermochromic materials consist of either microencapsulated liquid crystals that undergo a permanent
or reversible change of crystal structure according to temperature or more commonly (and easier to
manufacture and employ), leuco dyes, which change their molecular form.
4.2 Recent Commercial Developments
4.2.1 Colour Change Materials
PakSense labels monitor temperature [2]; the UNIVERSITY OF STRATHCLYDE has developed labels that
change colour when food is about to go stale [3]; Coors has employed a two-stage thermochromic ink system
to monitor canned beer temperature [4]; PHANTOM PLASTICS has marketed its ThermoShift colour change
injection mouldable polymer [5]; Chameleon EVA (ethylene vinyl acetate) and Chameleon LLPE (low linear
polyethylene) are reversible thermochromic masterbatches from LCR HALLCREST for common moulding
materials. Various colour changes are available, including from a translucent state [6]; the UNIVERSITY OF
WARWICK is developing methods to produce three-dimensional (3D) electroluminescent surfaces in an
in-mould process [7]; researchers at the INSTITUT CATALÀ DE NANOCIÈNCIA I NANOTECNOLOGIA have
developed a new fast-response photochromic film by encapsulating the photochromic component in the
polymer matrix [8]; and INSIGNIA TECNOLOGIES has developed colour-change inks and pigments in order
to provide labels with automatic timers once a package has been opened [9].
4.2.2 General Subjects
A EUROPEAN UNION project has resulted in an online database for active and intelligent packaging
at http://activepackaging.eu [10]; the Spanish AITIIP technology centre will be launching a European
25
Part B: Materials
project on smart and multifunctional packaging. Partners include GTI, INNOVIA FILMS, VITO, SOGAMA,
AVANZARE INNOVACION TECNOLOGIA SL and NUTRECO [11].
4.2.3 Laser Additives
LaserSafe is a new heavy metal-free laser marking additive from ECKART (Figure 4.1) [12].
Figure 4.1
LaserSafe environmental-friendly laser marking pigment from ECKART.
Reproduced with permission from ECKART GmbH, Hartenstein, Germany. ©2014, ECKART GmbH
4.3 Patent Trends
4.3.1 Subjects, Ranking and Innovators
Table 4.2
Principal themes of patents listed in Section 4.4
Colour effects Colour change with chemicals • Colour change with humidity • Colour change with
laser treatment • Fluorescent materials • Laser markable materials • Light emitting
materials • Luminescent materials • Photochromic materials • Temperature-time
indicators • Thermochromic materials
Definition, detail and contrast Laser marking additives • Laser marking polymer blends • Laser marking coatings •
Optimised laser parameters for marking
Metallic or reflective effects Humidity-dependent metallic effect • Humidity-dependent reflectivity • Temperature-
dependent reflectivity
Types of colour or reflectivity change covered here are summarised in Table 4.2; many of these solutions
have been devised primarily for labels and film materials. They include colour change induced by chemicals,
heat, humidity, laser, and normal daylight. Table 4.3 shows that the majority of development is focused
on laser initiated solutions, either in the form of additives that improve marking, contrast, definition and
26
Part B: Materials
sensitivity, or new colour-change additives or coatings. The potential of inkless printing using lasers is
also covered by patent applications from PROCTER & GAMBLE, and DATALASE LTD, where a process
is described in Part D, Section 21 on laser marking.
Table 4.3
Principal patent subject trends
Rank Trend Number of patents %
1 Laser additives and laser-sensitive materials 24 42
2 Thermochromic solutions 12 21
3 Photochromic and photoluminescent materials 11 19
4 Chemical initiation 4 7
5 Humidity 3 5
6 Time-temperature indication 3 5
Several patents propose new additives for enhancing laser marking and are listed in Table 4.4.
Table 4.4
Patent applications for laser additives to improve marking (Section 4.4.2)
Patent no. Publication date Applicant Additive description
WO2011050934A2 5th May 2011 DSM Bismuth-containing compound
WO2011085779A1 21st July 2011 MERCK White core platelet of zirconium oxide, silicon
dioxide, barium sulfate (barite), kaolin or talc
with carbon coating
WO2011115879A2 22nd September 2011 BASF Graphite nanoplatelets
US20120010345A1 12th January 2012 None given Finely divided metal pigment
US20120129090A1 24th May 2012 BASF Tungsten oxide
WO2012072173A1 7th June 2012 MERCK Doped tin dioxide coated plate shaped laser
sensitive pigments
WO2012104006A1 9th August 2012 MERCK Tungsten or phosphorus doped tin oxide
US8318262 27th November 2012 ECKART Spherical metallic particles
WO2013112264A1 1st August 2013 JAGDIP THAKER Coated metallic oxides
CN101851350B 6th November 2013 SHANGHAI KINGFA Tin oxide
The most frequently innovating companies and applicants are listed in Table 4.5.
Table 4.5
Ranking of top innovating applicants (3 or more patents)
Rank Applicant Number of patents %
1 BASF, BASE (sic) 5 9
2 JAGDIP THAKER 4 7
3 MERCK 3 5
4 TEMPTIME CORPORATION 3 5
27
Part B: Materials
4.3.2 Items of Particular Interest
Humidity dependant reflectivity or metallic effects; inkless printing; photochromic resin mixtures;
photoluminescent resin mixtures and temperature dependent reflectivity.
4.3.3 Principal Trends
Laser marking additives and thermochromic materials.
4.4 Listed Patent Literature 2011-2103 (for A toy integrates the use of pre-printed or hand-applied
search phrases see Part A, Section 2) thermochromic inks.
Method for the manufacture of a decorative

4.4.1 Colour Effects coating, a decorative paint for implementation
of this method, decorative coatings and articles
Transparent bottle with illuminant for obtained with the use thereof (embodiments).
beverage. WO2011126399A1 Oct 13th 2011.
JP2011031968A Feb 17th 2011. SHCHERBAKOVA, ELMIRA MURATBEKOVNA
FRP KK A decorative effect achieved by applying luminophore-
A plastic bottle is equipped with capsules each containing paints visible under ultraviolet light.
containing ingredients for a chemical light emitting
solution. When the boundary between the capsules is Color changing fishing lure.
broken, the bottle is illuminated. CA2705087A1 Nov 25th 2011.
GRAVELLE, GERALD D
Thermoplastic material comprising A coloured plastic object designed to change colour at
polychromic substances. different temperatures has at least one sprayed coating
US7897320B2 Mar 1st 2011. containing thermochromic pigment.
PROCTER & GAMBLE
An inkless printing solution whereby diacetylene Doneness indicator for heat-in packaging and
additives are added to polymers for injection for method of making same.
subsequent laser activation. GB2481569A Dec 28th 2011.
GEN MILLS INC
Intelligent pigments and plastics. A thermochromic ink, such as ThermaSOLV from SUN
WO2011045572A1 Apr 21st 2011. CHEMICAL encapsulated in polymer, is used to indicate
UNIVERSITY OF STRATHCLYDE that appropriate cooking temperature has been reached
Calorimetric indicators that include reactive dyes can for the required length of time as opposed to simply
be used for detecting types of gases, such as CO2, indicating temperature reached.
O2, and NH3, for example those found in packaging
containing spoiled food. Laser fusible coating compositions used for
laser marking systems and methods.
Photochromic molding compositions and WO2011162814A2 Dec 29th 2011.
articles produced therefrom. THAKER, JAGDIP
US7993755 Aug 9th 2011. A range of colour-change pigment coating formulations
EMS-PATENT AG that can be used to adhere to a polymer substrate using
A reversible photochromic polyamide resin mixture, a CO2 or other type of laser irradiating at a wavelength
e.g., for ophthalmic lenses, is proposed. of between 700 and 11,000 nm via a foil transfer, spray,
or printing process.
Thermochromatic inks, printing methods and
kits. Luminous printing.
US20110212421A1 Sep 1st 2011. WO2011109349A3 Jan 19th 2012.
NUCOAT INC ADAMS
28
Part B: Materials
A method for decorating a substrate with an image WORLD WIDE LINES INC
divided into multiple layers of which one luminesces An article is spray or dip coated with a resin containing
under ultraviolet black light. an encapsulated thermochromic pigment such as
Dynacolor from CTI, SAKURA Color TC from SAKURA,
Coating compositions for marking substrates. or NC Base Ink from MATSUI.
US8101544 Jan 24th 2012.
DATALASE LTD Photoluminescent resin composition and
An economical transparent to translucent coating for decorative sheet.
polymers that is laser-markable. WO2012053545A1 Apr 26th 2012.
MITSUBISHI CHEMICAL CORPORATION
Thermosensitive decolorable ink composition. A photoluminescent effect that can be incorporated into
EP2412762A1 Feb 1st 2012. polycarbonate using metal oxide or metal coated non-
MITSUBISHI PENCIL COMPANY LIMITED metallic inorganic or metal photoluminescent particles.
A non-reversible writing ink based on leuco dyes that
changes colour under heat caused by friction without Reaction-based laser marking compositions,
using microcapsules. system and methods.
WO2012015480A3 May 10th 2012.
Reaction-based laser marking compositions, THAKER, JAGDIP
systems and methods. A resistant coating or ink formulation for 800-11,000 nm
US20120027958A1 Feb 2nd 2012. laser marking based on a resin and infrared absorbing
THAKER, JAGDIP metal oxide and oxidising or reducing agent.
A marking ink or coating that binds to the substrate
after exposure to laser. The coating can be applied by Color changing polymer-based article.
printing or spraying onto a polymer surface. US20120119170A1 May 17th 2012.
SKYRAD LTD
Process for preparing an indicator A low-cost photochromic injection moulding additive
composition. based on spiropyranes, spiroxazines or naphthopyrans
US20120045837A1 Feb 23rd 2012. reacting to ultraviolet light.
TEMPTIME CORPORATION
Inks based on polyacetylenic indicators for time- Method for manufacturing packaging material
temperature indication, e.g., for smart labels. capable of sensing food freshness.
WO2012062015A1 May 18th 2012.
Waterproof self-luminescent spray-painted film. JIANGSU UNIVERSITY
US20120058322A1 Mar 8th 2012. A method for rendering a package capable of displaying
DALIAN LUMINGLIGHT CO LTD the presence of migrating gases using an array of
An improved self-luminescent film applied by inkjet. odour-sensitive materials applied by inkjet.
Active and intelligent additive, polymer and Indicator, application thereof and related
article. products.
WO2012034198A1 Mar 22nd 2012. US20120142527A1 June 7th 2012.
BRASKEM SA An oxygen, water, or chemically-sensitive thiazine,
Additives for plastics which allow for various properties oxazine, azine, triphenylemethane, indophenol, indigo,
including indicating food decomposition. or viologen indicator dye, for example for perishable
goods, that does not leach out of inks and is insensitive
Water detecting label. to ultraviolet-curing.
US20120067270A1 Mar 22nd 2012.
AVERY DENNISON CORPORATION Laser-markable compositions.
A label or sheet that changes colour when exposed to US20120147120A1 Jun 14th 2012.
water, e.g., for incorporating into an electronic device. The use of infrared absorbing colour changing
multivalent octamolybdate for creating 800-1,500 nm
Thermochromatic pigment covered article and laser-markable inks which can be ultraviolet-curable.
method of making the same.
US20120088094A1 Apr 12th 2012.
29
Part B: Materials
Thermochromic coatings with resin vehicle. Thermochromic plastic infant feeding bottle.
WO2012112729A1 Aug 23rd 2012. GB2498515A Sep 24th 2013.
CHROMATIC TECHNOLOGIES INC EBEJER, CHRISTOPHER
An abrasion-resistant heat or ultraviolet-curable A thermochromic pigment is incorporated into
thermochromic ink, containing encapsulated dye, such the wall of a plastic feed bottle in order to denote
as a leuco dye, suitable for beer cans. temperature.
Tunable fluorescent UV curable gel inks Photochromic swim goggles structure and
containing fluorescent monomers for food method of manufacturing the same.
packaging applications. WO2013149338A1 Oct 10th 2013.
US8334026B2 Dec 18th 2012. Photochromic swimming goggles determine exposure
XEROX to sunlight.
Fluorescent ink for inkjet application.
Molded nanoparticle phosphor for light
Thermochromic compositions from emitting applications.
trisubstituted pyridine leuco dyes. WO2013108125A3 Oct 24th 2013.
WO2013049229A1 Apr 4th 2013. NANOCO TECHNOLOGIES LTD
CHROMATIC TECHNOLOGIES INC A moulding incorporates a nanoparticle phosphor for
Reversible encapsulatable thermochromic leuco dyes light-emitting diode applications.
for inks, sensitive within the range of -5 to 110 oC.
Thermochromatic earplug and method for

manufacturing the same.
US20130123657A1 May 16th 2013. Laser-marking additive.
An earplug that changes colour according to the WO2011050934A2 May 5th 2011.
wearer’s body temperature. DSM IP ASSETS BV
A laser marking additive which comprises a bismuth-
Thermochromic systems with controlled containing compound with lower amounts of antimony,
hysteresis. no halogen, and no tendency to discolour during
US20130193386A1 Aug 1st 2013. processing.
Thermochromic microencapsulated dye systems with
reduced sensitivity to ultraviolet light and showing less Transparent, laser-inscribable polyurethane.
hysteresis provoked by thermal history. US20110165381A1 Jul 7th 2011.
BASE SE
Photochromic curable composition. A transparent injection-mouldable thermoplastic
EP2554624A4 Aug 7th 2013. polyurethane contains bismuth oxide and is laser-
TOKUYAMA CORP inscribable, producing high-contrast images.
A curable photochromic coating.
Laser additive.
Process for preparing an indicator WO2011085779A1 Jul 21st 2011.
composition and indicator compositions. MERCK PATENT GMBH
US8529682 Sep 10th 2013. Small platelet particles for polymers, coatings or inks
TEMPTIME CORPORATION consisting of a white core and black coating have been
Inks for time-temperature indicators and indication of found to provide high-contrast after laser marking with
deterioration. CO2, Nd:YAG and various other types of laser.
Robust, ultraviolet-protected ambient Method for marking polymer compositions

condition history indicator and method of containing graphite nanoplatelets.
making same. WO2011115879A2 Sep 22nd 2011.
US20130239874A1 Sep 19th 2013. BASF SE
TEMPTIME CORPORATION Graphite nanoplatelets are found to improve laser
A time-temperature dependant colour-change label that marking efficiency.
is resistant to ultraviolet light.
30
Part B: Materials
Laser etching of an acrylic and polyvinyl Laser markable and weldable polymers which give a
chloride composition, and laser etched article. high-contrast white image, typically using 0.1 to 1%
WO2011133840A1 Oct 27th 2011. of a tungsten or phosphorous doped tin oxide, or 3 to
ECHELON LASER SYSTEMS LP 10% dispersed in a coating applied to an unmodified
Laser etching of fine detail on large surfaces or multiple polymer.
parts worked together has not hitherto been practical.
It has been found that substrates in acrylic/polyvinyl Use of spherical metal particles as laser-
chloride Kydex can be rapidly marked. marking or laser-weldability agents, and laser-
markable and/or laser-weldable plastic.
Coating composition for marking substrates. US8318262 Nov 27th 2012.
US20110274893A1 Nov 10th 2011. ECKART GMBH
BASF SE A laser marking or welding additive for plastics
A laser markable coating containing a char forming incorporating spherical metallic particles.
compound, a latent activator, and colour former that has
improved sensitivity to laser light and higher contrast. Chemical coating composition for forming a
laser-markable material and a laser-markable
Pigment for laser marking. material.
US20120010345A1 Jan 12th 2012. US20130183620A1 Jul 18th 2013.
A heavy-metal free laser-sensitive finely divided metal A stable coating that provides improved contrast after
pigment for plastic substrates or coatings providing a laser marking.
colour-change of high contrast and sharp image.
Chemical coating composition for forming a
Aqueous laser-sensitive composition for laser-markable material and a laser-markable
marking substrates. material.
US20120045624A1 Feb 23rd 2012. WO2013109268A1 Jul 25th 2013.
BASF SE FUJIFILM HUNT CHEMICALS USA INC
A coating consisting of non-encapsulated fluoran An improved coating with longer storage life for laser
dye with improved colour-change sensitivity for laser marking containers.
marking.
Doped oxide powders in laser markings and
Heat absorbing additives. methods of use.
US20120129090A1 May 24th 2012. WO2013112264A1 Aug 1st 2013.
BASF SE THAKER, JAGDIP
Tungsten/tungsten oxide laser-sensitive additives. A combination of coated metallic oxides incorporated
into a substrate polymer that improves contrast after
Pigments. laser marking.
WO2012072173A1 Jun 7th 2012.
MERCK PATENT GMBH Laser absorbing compounds.
Doped tin dioxide coated plate-shaped laser sensitive WO2013131064A1 Sep 6th 2013.
pigments. FERRO CORPORATION
Molybdenum and tungsten metal complexes for
Laser marking method and urea resin product. improving marking contrast or bonding.
WO2012073091A1 Jun 7th 2012.
PANASONIC CORPORATION Laser mark auxiliary agent for plastic and
Urea resin turns white when marked with a long-wave preparation method thereof.
laser such as CO2. If the article is already white, the CN101851350B Nov 6th 2013.
mark is not sufficiently discernible. This invention SHANGHAI KINGFA SCI & TECH CO
provides a solution to the problem using a pulse width A tin oxide blend for improving laser markability of
of less than 20 ns. acrylonitrile-butadiene-styrene.
Laser-markable and laser-weldable polymers.

WO2012104006A1 Aug 9th 2012.
MERCK PATENT GMBH
31
Part B: Materials
4.4.3 Metallic or Reflective Effects Hydration controlled variable reflectivity

coatings.
Films having switchable reflectivity. US20120225282A1 Sep 6th 2012.
EMPIRE TECHNOLOGY DEVELOPMENT LLC
WO2011129524A1 Oct 20th 2011.
KOREA UNIVERSITY RESEARCH AND BUSINESS FOUNDATION
A coating that changes reflectivity according to the level
A film that has switchable reflectivity according to of moisture present.
temperature by incorporating a hydrogel that moves
from a dehydrated (reflective) to hydrated state (anti- Temperature controlled variable reflectivity
reflective). coatings.
US20120225281A1 Sep 6th 2012.
EMPIRE TECHNOLOGY DEVELOPMENT LLC
Color-change laminate.
US8147959 Apr 3rd 2012. A coating containing microcapsules of ionic liquid and/
THE PILOT INK CO LTD
or surfactant that increases in reflectivity from 20-80%
A laminate that takes on a metallic look when wetted. when ambient temperature increases.
References
1. L. Feliciano in Color Changing Plastics for Food Packaging, Ohio State University, Columbus, OH,
USA, 2009.
2. New PakSense Temperature Monitoring Labels, Web Packaging.

http://www.webpackaging.com {Accessed May 2014}
3. Smart and Affordable Packaging that Indicates Food is about to Get Stale, Omnexus.
http://www.omnexus.com {Accessed May 2014}
4. Can of Coors Light to Feature New Cold Indicator, Can Tech International.
http://www.cantechonline.com {Accessed May 2014}
5. Smart Plastic Dishwasher Door, Phantom Plastics.

http://phantomplastics.com/case-studies/smart-plastic-dishwasher-door/ {Accessed June 2014}
6. How the Masterbatch Changed its Colour, LCR Hallcrest.

http://lcrhallcrest.com/chameleonplastics/news.php {Accessed June 2014}
7. B. Middleton and V. Goodship, Polymer Engineering and Science, 2012, 53, 7, 1554.
8. Spanish Scientists’ Find Could Transform Photochromic Response, European Coatings.

9. Insignia Technologies Develops Opportunities in Food Packaging Sensor Market, Printed Electronics
Now.
http://www.printedelectronicsnow.com {Accessed May 2014}
10. Packaging Materials Database is Now Online, European Coatings.

http://www.european-coatings.com/Raw-Materials-Technologies/Applications/Decorative/
Packaging-materials-database-is-now-online. {Accessed June 2014}
11. C. Eyre, European Plastics News, 2013, 40, 2, 7.
12. Heavy Metal-Free Laser Marking Products, Dr Gupta Verlag.

http://www.gupta-verlag.com {Accessed May 2014}
32
Part B: Materials
5 Materials for Effects and Other Special Colours
Table 5.1
1 Interference effects 17 18 17 52
4 Surface quality improvement 0 1 3 4
5 3D, tactile and depth effects 1 1 0 2
5.1 Background
This section covers interference, metallic, or special colour pigments or dyes for incorporation into
polymers, inks and coatings, as well as the material blends in which they are used. The majority of
pigments involved are flake shaped.
For interference (gonioapparent, goniochromatic) pigments, use of natural mica remains predominant
over traditional high refractive index translucent alternatives such as lead carbonate (toxicity concern) and
bismuth oxychloride, as well as other newer substrates. Platelet substrates now also include synthetic
mica, alumina, silica and borosilicate glass. To obtain various interference effects from internal reflection,
translucent flakes are coated with controlled thin layers of translucent metal oxides of alternately high and
low refractive indices using materials such as iron oxide, titanium dioxide, silica, and chromium oxide.
Precision physical vapour deposition (PVD) is used to produce Fabry-Pérot structures which are typically
five-layer pigments. By virtue of interference effects, the superposed layers produce colour effects that
vary according to viewing angle (colour travel), and the more layers there are, the higher the colour intensity
produced [1]. Table 5.1 shows that interference pigments account for the majority of patent documents
covering the three year period examined. The platelet structure for these and metallic effect pigments is
important as it provides the reflective surface to give lustre. A typical platelet may be in the order of 25 μm
× 1 μm thick, i.e., its large dimension is comparable to, or greater than, the average thickness of a coating
film in which it is dispersed. The appearance of effect pigments is therefore understandably influenced by
their lay (orientation) in the ink or coating film or polymer substrate. Processing and application conditions
can be used to influence this orientation (see Part D, Section 24, covering pigment orientation techniques).
Metallic effects from pigments can be achieved by either coating mica flakes with metal, physical vapour
coating a polymer film with metal and then stripping and flaking the metal, or using metal flakes developed
from milling techniques. Common metallic flake forms are referred to as cornflake, silver dollar, or vacuum
metallised (PVD), depending on their manufacturing process and resulting degree of flatness [2]. Table 5.1
shows that this subject constitutes the second most frequent subject of innovation in patents.
Metallic Jetfluid® inks for inkjet have been developed by ECKART [3] (Figure 5.1); ECKART’s RotoStar
UV Flexo Shrink Silver ink is claimed to maintain its high brilliance after sleeve shrinking [4]. SpectraFlair®
Plus 25, is an economic effect pigment from JDSU [5]; BASF has developed a new effect pigment called
Firemist® Velvet Pearl which creates a patina effect [6]; and researchers at the CAVENDISH LABORATORY,
33
Part B: Materials
Cambridge, UK, have developed a synthetic nacre coating [7]. BASF’s new Glacier™ effect pigments
are mica flakes coated with TiO2 and are claimed to be the whitest effect pigments currently on the
market [8]. ECKART presented its non-toxic and inert chromium oxide Metalure® Liquid Black pigment
that produces a dark reflective effect [9] at a recent ‘European Coatings Show’. MERCK has offered a
new range of highly brilliant pigments for coatings called Meoxal® [10]. SHEPHERD COLOR’s StarLight™
FX silver-coated glass flakes were claimed to provide good sparkle and glitter effects for both coatings
and plastics [11]. MERCK’s new Iriodin® 506 Sunset Orange was said to provide strong body colour and
good coverage in plastics [12] and a new type of aluminium pigment has appeared from SUN CHEMICAL
with a nanostructured surface to provide an interesting gold to blue colour travel effect [13]. A unique
sparkle with BASF’s XSpark® effect pigment is based on glass particles [14]. New effect pigments and
functions can be created using tailor-made nanostructures [15]. New effects are claimed using solid glass
microspheres such as ENGELHARD’s Prizmalite® incorporated into inks, coatings, and polymers [16].
ADDMIX has developed special effect masterbatch tablets for moulding processes [17].
Figure 5.1
Jetfluid metallic inkjet ink from ECKART.
Reproduced with permission from ECKART GmbH, Hartenstein, Germany. ©2014, ECKART GmbH
34
Part B: Materials
5.3 Patent Trends
Table 5.2
3D, tactile and depth effects Magnetically orientable pigments for inks and coatings
Colour effects Flaky black pigments • Imitation porcelain • Imitation stone • Nanoparticulate
pigments for sharp colour
Interference effects Anti-counterfeit effect pigment • Colour travel with multiple layers of inks containing
interference pigments • Conchoidal pearl effects • Effect coatings • Interference effect
pigments with or without colour travel • Pearlescent effects from siloxane • Pleochromic
effects • Mesogenic compounds and polymerisable liquid crystal mixtures • Mother of
pearl • Multi-colour flip-flop with cholesteric pigments • Snowflake
Metallic or reflective effects Coloured metallic coatings • Crushed glass addition • Diffusively light reflecting paint
• Glitter • High flop metallic paint • Imitation agates • Imitation metal • Interferential
metallic effects • Metallic effect pigments and blends • Metallic coatings • Metallic
inks for inkjet printing • Micronised and nanoparticulate metallic pigments • Non-
marking metallic coatings
Surface quality improvement Low bubbling TiO2 pigment • Metallised glass bubbles to reduce surface defects •
Pigment modification to improve dispersion
Table 5.2 shows a wide range of colour, interference, metallic, and surface improvement effects from this
class of materials. From Table 5.1 it is clear that interference effects are the most sought after, followed
by metallic effects. Patents related to the former mention up to six to eight layer effect pigments, and it
is interesting to note that half of the patents do not specify the choice of flake substrate. Combined with
metallic pigments, these pigments constitute a development rate of about two per month. Table 5.1 also
shows that year-to-year activity in both has remained stable.
The use of small particulates to produce metallic effects is receiving attention, e.g., the use of colloidal silver
in inkjet inks (US20120105559A1, 3rd May 2012, CABOT CORP.); a chrome effect paint from micronised
aluminium (WO2012079136A1, 21st June 2012, COLORTEC TINTAS E VERNIZES); the use of metallic
nanoparticles to create a metallic coating (WO2012114180A2, 30th August 2012, TOYOTA JIDOSHA
KABUSHIKI KAISHA); a coating containing a metal nanopowder that claims to resemble electroplating
(CN101974268B, 24th October 2012, JIANGSU UNIVERSITY OF SCIENCE AND TECHNOLOGY); and
a metallic finish consisting of a basecoat, a layer of metallic nanoparticles, and a protective topcoat
(US7891799, 22nd February 2011, ELECTRONICS FOR IMAGING, INC).
Table 5.3 lists the top innovating applicants, dominated by MERCK and BASF.
Table 5.3
1 MERCK 19 17
2 BASF 14 13
3 ECKART 5 5
4 TOYO ALUMINIUM 5 5
5 NIPPON SHEET GLASS 4 4
6 SILBERLINE 3 3
35
Part B: Materials
Conchoidal pearl effects; flaky black pigments; metallic inkjet inks; nanoparticulate pigments for sharp
colour; optically diffractive magnetic pigments; pearlescence from siloxane fluid in polymers; pleochromic
effects; eight-layer effect pigments; porcelain-plastics blends; and the use of pearlescent or interference
pigments or cholesteric liquid crystal compositions in colour process printing.
Interference pigments and metallic pigments.
5.4 Listed Patent Literature 2011-2103 (for Black bright pigment, and cosmetic, coating
search phrases see Part A, Section 2) composition, resin composition and ink
composition comprising the same.
EP1666541B1 Dec 21st 2011.
5.4.1 Three-dimensional, Tactile and Depth NIPPON SHEET GLASS CO LTD
Effects A bright flaky black pigment with improved brightness,
hiding power, and smoothness consisting of a C-glass
Alignable diffractive pigment flakes. base and a metal oxide layer based on Fe or Ti.
EP1537182B1 Nov 30th 2011.
JDS UNIPHASE CORPORATION Decorative and durable coatings having
Pigments with optically diffractive structure that can be a homogeneous hue, methods for their
magnetically orientated. preparation, and articles coated therewith.
CA2637708C Mar 20th 2012.
Multi-colored lustrous pearlescent pigments PPG IND OHIO INC
and process for making. A solution for dry blending powders in order to obtain
US8211224 Jul 3rd 2012. a homogeneous colour involves using polymer coated
SUN CHEMICAL CORP nanoparticles of each colour.
A magnetically sensitive iron oxide coated black
pearlescent pigment. Black effect pigment.
WO2012125789A2 Sep 20th 2012.
BASF CORPORATION
5.4.2 Colour Effects A black effect pigment with improved darkness.
Injection molding method of stone-based Porcelain plastic and preparation method and
composite material. application thereof.
US20110156298A1 Jun 30th 2011. CN101993603B Jan 2nd 2013.
NINGBO HAITIAN BEIHUA SCIENCE AND TECHNOLOGY CO DONGGUAN TIANJIA PLASTIC HARDWARE PRODUCTS CO
LTD LTD
A method is proposed for injection moulding a material A high gloss porcelain-plastic blend containing 30 to
consisting of a mixture of stone, unsaturated polyester, 70 parts of porcelain.
fibre glass and additives.
Use of nanoparticulate organic pigments in 5.4.3 Interference and Refraction Effects

paints and coatings.
US8026299 Sep 27th 2011. Patents for pigments exhibiting colour
PPG INDUSTRIES OHIO INC interference effects (Base flake material, where
Nanoparticulate pigments have the distinct advantage indicated: (1) Various; (2) Glass; (3) BiOCl; (4)
of relatively sharp absorption bands are used in order Mica; (5) SiO2; (6) Perlite; and (7) Alumina):
create base colours for colour matching for powder US7875112, Jan 25th 2011.
coatings. Colour matching is simplified and made MERCK
more versatile. Dispersibility, lustre (1).
36
Part B: Materials
US7887849, Feb 15th 2011. US8114211, Feb 14th 2012.

MERCK MERCK
Glittering, brightness, hiding power, processability (2 Non-cracking – brightness maintained (1).
and 3).
WO2012055507A1, May 3rd 2012.
WO2011051122A1, May 5th 2011. MERCK
BASF 8-layers. Coverage (1).
Sparkle (4).
CN101565563B, Jul 5th 2012.
US20110113984A1, May 19th 2011.
SHANTOU LONGHUA
BASF CATALYSTS
Angle dependant colour change (1).
Lustre, chromaticity and/or hiding power (1).
CA2545789C, Aug 7th 2012.
US20110129674A1, Jun 2nd 2011.
ENGELHARD
MERCK
Spherical to aid masterbatch use (1).
Non-toxic glass flake (2).
CN101565565B, Sep 5th 2012.
US7959727, Jun 14th 2011.
JIAYUE SUN
BASF
Low cost angle dependency (4).
Colour strength and purity (5).
CN101278015B, Sep 5th 2012.
WO2011085780A1, Jul 21st 2011.
DAINICHISEIKA COLOR
MERCK
Uniform photoluminescence (7).
Glossy black or grey, no goniochromaticity. Processability
(1). EP1940971B1, Sep 12th 2012.
ENGELHARD
WO2011095326A1, Aug 11th 2011.
Lustre, chromaticity, hiding power. Not obeying quarter-
MERCK
stack approach (1).
Fading resistance (4).
US8268069, Sep 18th 2012.
WO2011103713A1, Sep 1st 2011.
MERCK
SHANTOU LONGHUA
Chemical and mechanical stability (2).
Flip-flop (4).
WO2012124855A1, Sep 20th 2012.
US20110265690A1, Nov 3rd 2011.
CQV
Lustre, chroma, flop (1).
Brightness, chroma, gloss, multi-colour (1).
US20110265689A1, Nov 3rd 2011.
US20120240823A1, Sep 27th 2012.
Lustre, chroma, flop (1).
For coating transparent substrates (2).
US20110269845A1, Nov 3rd 2011.
US8287636, Oct 16th 2012.
BASF
KOREA RESEARCH INST
Compatibility, colour strength, sparkle and/or colour
Gloss, tinting strength due to higher aspect ratios (7).
purity (6).
US20120308667A1, Dec 6th 2012.
US20110301273A1, Dec 8th 2011.
MERCK
MERCK PATENT
Processing and weathering resistance (4).
Wettability (1).
US8337611, Dec 25th 2012.
US20110306678A1, Dec 15th 2011.
MERCK
Colour saturation and angle dependence (1).
Non-yellowing (4).
US20110319498A1, Dec 29th 2011.
CN101434759B, Jan 2nd 2013.
BASF
UNIV WENZHOU
Lustre, chromaticity and/or hiding power (1).
Gloss, brightness, chemical and weathering resistance
US20120010300A1, Jan 12th 2012. (2).
Processability, application (2).
US20130040057A1, Feb 14th 2013.
WO2012013663A2, Feb 2nd 2012. SILBERLINE
BASF Blackness, hiding power (1).
Simulated patina or antique appearance (6).
37
Part B: Materials
EP2058374B1, Mar 27th 2013. obtained when two films containing different cholesteric
NIPPON SHEET GLASS pigments are overlapped. This patent application
High flop with weathering and water resistance (1). exploits this effect to create multi-colour effects.
US20130131246A1, May 23rd 2013.
BASF Waterborne effect base coats having improved
Flow and processing conditions (1). optical properties.
EP2430120A1 Mar 21st 2012.
US20130149363A1, Jun 13th 2013. BASF COATINGS GMBH
MERCK Effect basecoats with additives that improve optical
Improved colour and application. 5-layers (1). properties.
US20130164529A1, Jun 27th 2013.
SILBERLINE Polyurethane special-effect paint as well as
Superior bright colour effect and low solvent bleeding (1). preparation method and use method thereof.
CN102020918B Jul 25th 2012.
US20130164356A1, Jun 27th 2013.
SHENZHEN GUANGTIAN ENVIRONMENTAL FRIENDLY
MERCK
COATING CO LTD
Colour saturation and hiding power and application.
A heat-curing polyurethane paint with a bright pearl
Round flakes (1).
conchoidal effect.
US20130172473A1, Jul 4th 2013.
MERCK Coating film and method for producing same.
Dispersibility, angle-dependant glitter (2). WO2012127608A1 Sep 27th 2012.
FUJITSU LIMITED
CN102443285B, Jul 24th 2013.
A tactile anti-fingerprint non-slip ultraviolet-cured film
FUZHOU KUNCAI FINE CHEM
with a mother-of-pearl or crystal appearance.
Prussian blue, colour depth, brightness (1).
US8500901, Aug 6th 2013. Reactive mesogenic compounds and
MERCK mixtures.
Gloss, colour intensity (1). US8455563 Jun 4th 2013.
US20130216597A1, Aug 22nd 2013. MERCK PATENT GMBH
MERCK Mesogenic compounds and polymerisable liquid crystal

8-layer effect pigments (1). mixtures that can be used for decorative or security
marking.
Method of producing an iridescent printed
polychromatic transparent image. Ultraviolet light cured silk screen snowflake
WO2011114056A2 Sep 29th 2011. printing ink and preparation method thereof.
FASVER CN102643576B Jul 3rd 2013.
A low-cost multi-colour superimposable translucent WUHAN HONGZHICAI PACKAGING PRINTING CO LTD
iridescent image (for example for security or decorative A ultraviolet-curable snowflake effect ink for screen
purposes) that changes with viewing angle under printing.
visible light that avoids the need for a hologram.
The process consists of printing successive layers Colored resin composition exhibiting
of translucent monochromatic ink incorporating pleochroism, and molded plastics
interference pigments. manufactured using same.
WO2013115443A1 Aug 8th 2013.
Method for producing multi-coloured CHEIL INDUSTRIES INC
coatings. A translucent resin and dye composition that includes 5
WO2011120620A1 Oct 6th 2011. dyes and shows different colours at different substrate
MERCK PATENT GMBH thicknesses.
Normal subtractive colour effects achieved by CMYK
process colours in printing or coating are replaced by Pearl gloss paint having entirely or partially
additive colour mixing when pearlescent or interference parabolic path of refraction, and method for
pigments or cholesteric liquid crystal compositions are manufacturing same.
concerned. In the retained latter case, flip-flop effects are WO2013137608A1 Sep 19th 2013.
noted according to viewing angle, and a third colour is A pearl paint with higher gloss levels.
38
Part B: Materials
Multi-layer flake with high level of coding. US8283397, Oct 9th 2012.
US20130256415A1 Oct 3rd 2013. TOYO ALUMINIUM
SICPA HOLDING SA Resin coated metal pigment for aqueous coatings.
An anti-counterfeit pigment.
WO2013011772A1, Jan 24th 2013.
TOYO ALUMINIUM
Pearlescent container. Aluminium pigment for inkjet.
US20130307198A1 Nov 21st 2013.
THE PROCTOR & GAMBLE COMPANY EP2554608A1, Feb 6th 2013.
An immiscible siloxane fluid creates a pearlescent effect ASAHI KASEI CHEMICALS CORP
in polyethylene terephthalate. Metallic pigment for water-based formulations with
improved storage, performance, photoluminescence,
concealment, flip-flop.
EP2011836B1, Mar 6th 2013.
Patents for pigments exhibiting metallic effects; NIPPON SHEET GLASS
Bright gold tone.
US20110008399A1, Jan 13th 2011. EP2009066B8, May 1st 2013.
BASF NIPPON SHEET GLASS
Angular colour effect. Narrow particle size range. High lustre without filter
WO2011024407A1, Mar 3rd 2011. clogging.
OIKE EP2436738A4, Jun 26th 2013.
For non-clogging in inkjet. TOYO ALUMINIUM
WO2011040905A1, Apr 7th 2011. Coated metallic pigment for aqueous coatings for
POLYONE CORP storage stability and humidity resistance.
Metallic or pearlescent polyester. US20130192789A1, Aug 1st 2013.
US20110091691A1, Apr 21st 2011. ECKART AMERICA
VACUMET Embossed metallic flakes for brightness and colour
Holographic metallic flakes. intensity.
WO2011068596A2, Jun 9th 2011. CN102391687B, Aug 28th 2013.
SILBERLINE FUZHOU KUNCAI FINE CHEMICALS
Polymer coating for dispersion. A metallic effect pigment based on glass flake.
US20110179971A1, Jul 28th 2011. WO2013127874A1, Sep 6th 2013.
Copper-containing for reverse printing (second surface) BASF
inks. Shear-stable aluminium flakes produced by vacuum
US7998266, Aug 16th 2011. metallising have an inner aluminium oxide material.
TOYO ALUMINIUM
Light and weather resistance, hue, hiding power and Acrylic polymers, coating compositions and
appearance. methods of preparing.
WO2011009228A1 Jan 27th 2011.
WO2011155399A1, Dec 15th 2011.
EVONIK
ASAHI KASEI CHEMICALS
Water-based heat-curable coating for use with metallic
Storage stability, adhesiveness, chemical resistance,
pigments.
colour in aqueous formulations.
US20120029121A1, Feb 2nd 2012. Coated articles and multi-layer coatings.
BASF SE US7981505 Jun 19th 2011.
Al flake for rainbow effect, purity and contrast in PPG INDUSTRIES OHIO INC
holograms. Colour-imparting non-hiding coatings for example over
WO2012130680A1, Oct 4th 2012. a metallic finish have traditionally employed dyes in
ECKART order to obtain translucent colour. Dyes do not have
Coated copper effect pigments for chemical stability. good stability and can include toxic metals. A solution
is proposed whereby such a coating contains colour
imparting particles having a maximum haze of about
39
Part B: Materials
10%. Such a coating is applied between the basecoat Metallic pigment composition, and UV-metallic
and a translucent protective topcoat. ink composition or UV-metallic coating
composition using the same.
Pulverulent composition for the manufacture EP1739137B1 May 23rd 2012.
of articles with a metallic appearance, which TOYO ALUMINIUM KABUSHIKI KAISHA
is stable over time and shows improved A pigment composition that avoids gelation of
resistance to metal marking. ultraviolet-curable metallic ink.
US2011236698A1 Sep 29th 2011.
ARKEMA FRANCE Process for producing chrome-effect paint
A metallic powder coating that does not leave marks and system for applying said paint.
when rubbed against another surface (‘metal marking’). WO2012079136A1 Jun 21st 2012.
COLORTEC - TINTAS E VERNIZES CESARIO LANGE LTDA
Polyester molding compound with imitative A micronised aluminium powder pigment in organic
agate decorative patterns and preparation dispersion is used to obtain a metallic effect. The
method thereof. basecoat is black or grey. Application is by spray or dip.
CN101845119B Oct 19th 2011.
NINGBO HUAYUAN FRP ELECTRICAL APPLIANCE Decorative coating.
MANUFACTURE CO LTD WO2012114180A2 Aug 30th 2012.
A moulding compound that contains imitation natural TOYOTA JIDOSHA KABUSHIKI KAISHA
agates (agate is a microcrystalline variety of silica). A method for applying a metallic coating containing
coated metallic nanoparticles to a plastic surface. The
Imitation metal engineering plastic composite coating does not cause magnetic interference.
material and preparation method of the same.
US20120059100A1 Mar 8th 2012. A method of forming metallic tone glitter paint
XIAMEN RUNNER INDUSTRIAL CORPORATION films and the painted objects.
An injectable imitation metal with improved surface EP1817119B1 Oct 3rd 2012.
quality suitable for electroplating, physical vapour BASF COATINGS JAPAN LTD
deposition, or spraying, based on polyamide or A metallic paint effect with improved glitter and metallic
polybutylene terephathalate, with a density of 1.8 to tone consists of two aluminium pigments in a basecoat,
4.2 gcm-3. A metal powder such as iron, stainless a glitter coat, and a protective topcoat.
steel, copper, nickel, or zinc can be used. See also:
US20130062805A1 Mar 14th 2013. Emulated electroplated coating and
application thereof.
Structural or decoration element and CN101974268B Oct 24th 2012.
manufacturing method thereof. UNIV JIANGSU SCIENCE & TECH
US20120065050A1 Mar 15th 2012. A coating containing metal nanopowder that claims to
SUOMEN LASINJALOSTUS OY resemble electroplating.
Crushed glass is used in a plastic casting resin in order
to improve mechanical properties and optical effect Ink jetprinting ink containing thin aluminium
from an embedded light-emitting diode source. effect pigments and method.
US20120274714A2 Nov 1st 2012.
Dope for plastic decorative cover of automotive ECKART GMBH
wheel and preparation method thereof. Inkjet inks containing 2-6 micron aluminium pigment
CN101613553B Mar 21st 2012. that does not agglomerate.
TIELING YONGXIN COATING CO LTD
A resistant metallic paint for plastic hubcaps. Metal powder, ultraviolet ray curable ink jet
composition and recorded object.
Metallic dispersions for inkjet printing. US20120295082A1 Nov 22nd 2012.
US20120105559A1 May 3rd 2012. SEIKO EPSON CORPORATION
CABOT CORPORATION A resistant and stable ultraviolet-curable metallic ink,
Silver-based inks dispersed in a colloidal dispersion consisting of fine flakes, for inkjet decoration. (See also
for inkjet printing. US20120295076A1 Nov 22nd 2012) .
40
Part B: Materials
Metallic paint, method for the production Aqueous coating composition having
thereof, and uses thereof. stabilized color pigments.
US8361217 Jan 29th 2013. WO2013170007A1 Nov 14th 2013.
ECKART GMBH US COATINGS IP CO LLC
A pronounced metallic effect paint with high gloss that A stable heat-cure and water-based metallic paint.
does not require the use of physical vapour deposition
pigments.
Diffusively light reflective paint composition,
method for making paint composition, and Titanium dioxide pigments, process for the
diffusively light reflective articles. production thereof, and resin compositions
US20130069023A1 Mar 21st 2013. containing the pigments.
Teather EP1760116A4 Apr 11th 2012.
A diffusively light-reflecting paint that contains ISHIHARA SANGYO KAISHA
microspheres micro-porous polymeric particles. The An improved TiO2 pigment for plastic resins coated
paint can be applied in several manners, including using with hydrous silica in order to produce lower lacing
in-mould techniques. (bubbling) tendency.
Polymer composition for producing articles Method of surface treatment of micro/

having a metallic appearance. nanoparticles by chemical means and its
WO2013049541A1 Apr 4th 2013. application to obtaining a pigment composition
TICONA LLC. intended for the field of cosmetics, paint or inks.
A polyacetal, or polyoxymethaline, material with 5-15% WO2013050560A1 Apr 11th 2013.
a pigment with high metallic brilliance. SIKEMIA
A method for improving the dispersion of inorganic
Pigment preparation and ink jet printing ink. pigments through chemical grafting.
US20130088553A1 Apr 11th 2013.
ECKART GMBH Glass bubble, master batch including the
A non-agglomerating metallic inkjet printing ink. same, and resin particle with metal film
formed on surface thereof.
Paint composition. WO2013154291A1 Oct 17th 2013.
SAMSUNG ELECTRONICS CO LTD
US8450392 May 28th 2013.
QINETIQ LIMITED
Metallised glass bubbles for providing a metallic
An electromagnetic field shielding paint with a non- masterbatch that reduces surface defects.
metallic finish and improved resistance.
Pigment preparations.
A liquid metal composition. US8613800 Dec 24th 2013.
MERCK PATENT GMBH
WO2013098654A1 Jul 4th 2013.
BASF COATINGS GMBH
Improved dispersibility of effect pigments primarily in
A silver colour paint with high flop index, i.e., high degree polymer masterbatches is achieved without heating
of physical vapour depositionproduced aluminium flake effects using wax and antioxidant.
orientation. The effect is described as one of liquid metal.
Plastic profiled bar decorative layer

combination material with metal-like natural
texture, preparation method and application
thereof.
CN101717554B Sep 25th 2013.
GUANGDONG SHENGHENGCHANG CHEMI
A material for co-extruding metallic-effect profiles.
41
Part B: Materials
References
1. G. Pfaff in Special Effect Pigments, Vincentz Network GmbH & Co. KG., Hannover, Germany, 2008.
2. P. Wißling in Metallic Effect Pigments, Vincentz Network GmbH & Co. KG., Hannover, Germany,
2006.
3. Brilliance by ECKART, Packaging Europe.

http://www.packagingeurope.com {Accessed May 2014}
4. Metallic UV Flexo Ink, Package Design.

http://www.packagedesignmag.com {Accessed May 2014}
5. JDSU Introduces a High Performance and Cost Effective Pigment, Coatings World.
http://www.coatingsworld.com {Accessed May 2014}
6. Effect Pigment Creates Surfaces with Patina Effect, European Coatings.

7. ‘Nature’s Cookbook’ Used for Synthesis of Nacre, University of Cambridge.

8. Good-Looking Coatings, BASF.

http://www.basf.com {Accessed May 2014}
9. Dark Night Reflective Effects, European Coatings Show Daily 2013 – Daily 2 – page 16.
http://blueworldpartners.com/EC_2013_Daily_2.pdf {Accessed June 2014}
10. Merck Launches with Meoxal® a New Generation of Effect Pigments, European Coatings.
http://www.europeancoatings.com {Accessed May 2014}
11. Additives for Polymers, 2013, 8, 4.
12. Merck Adds Sunset Orange to its Range of Effect Pigments, Additives for Polymers, 2013, 6, 3.
13. J. Doll and J. Louis, European Coatings Journal, 2013, 9, 38.
14. New BASF XSpark® Coating Makes Cars Sparkle, BASF.

http://www.basf.com {Accessed May 2014}
15. Zigzag Structured Nanomaterials, Automotive Circle International.

http://www.european-coatings.com/Raw-Materials-Technologies/Technologies/Nanotechnology/
Zigzag-structured-nanomaterials {Accessed May 2014}
16. New Functional Enhancement Pigments Based on Solid Glass Microspheres: Improving Visibility
at Night, Deepening Color Intensity, Omnexus.
17. Addmix Announces Availability of Special Effect Masterbatch Tablets, European Plastics News.
http://www.europeanplasticsnews.com {Accessed May 2014}
42
Part B: Materials
6 Films, Foils and Labels
Table 6.1
5 Gloss and matte effects 3 1 2 6
6 Olfactory effects 1 1 3 5
6.1 Background
This section covers all types of film materials, whether for in-mould or off-line applications, as integral
films (including labels) or transfer films (in-mould, hot foil or heat transfer and so on). The primary purpose
of any patent here may be a distinctive decorative or sensual effect, or it may be aimed towards ease of
manufacturing. In the latter case the category ‘surface quality improvement’ refers to where the principle
focus of the patent is to improve performance during and after processing to make the final object, i.e.,
optimising the balance between ease of processing, deeper drawing (in the case of in-mould films), and
the abrasion, chemical and visual performance of the result. Table 6.1 shows that this is by far the most
important category, followed by three-dimensional (3D), tactile and depth effects (for an example of the
latter, see Figure 6.1).
Figure 6.1
Sample of in-mould micro engraved decoration foil.
Reproduced with permission from Leonhard Kurz Stiftung & Co. KG, Fuerth, Germany.
©2014, Leonhard Kurz Stiftung & Co. KG
43
Part B: Materials
These films are almost always multilayer by virtue of the co-extrusion, lamination, decoration or coating
processes employed in their manufacture. Depending on the application, films typically have a base resin
layer (or carrier); a release layer if any separation is to occur; a separate adhesion layer for adhering to
a polymer substrate if transfer is involved; a decoration layer which may be vacuum metallised and/or
printed in sheet or web form (typically using digital printing, flexography, gravure, offset, or screen or
combinations of either); topcoating, often with an ultraviolet (UV) cured organic coating to protect and
provide scratch resistance and final surface finish. Some films also have an additional temporary protective
layer, which is removed after any thermoforming or in-mould operation, either to protect gloss and avoid
scratching during the forming process, or to preserve a relief pattern. The demand for abrasion-resistant
topcoats implies the need for a hard (and therefore brittle) surface, adding to the challenge when the
film has to be deformed. For this reason a commonly used technique in in-mould applications requiring
significant degrees of deformation is to use films with dual-cure protective coatings and carry out a final
UV hardening cure after forming. If the film is used for a transfer process, clean release properties and
subsequent good adhesion of the transferred portion are required. If the film is to be adhered to the
substrate polymer, choice of suitably compatible material for adhesion is important. Most such films for
film insert moulding are manufactured in polycarbonate (PC)/polybutylene terephthalate-blend films,
polymethyl methacrylate or polyethylene terephthalate (PET) [1]. A compatibility chart with moulded
materials can be found in reference [2].
The products for which these films are destined are, of course, restricted by their shape. The technical
challenge in each case is to provide a wrinkle-free finish without visible cracking, whitening, or delamination
occurring during processing. While stretching of 200% or more may be possible with high pressure
thermoforming processes, this may be significantly restricted when decoration or metallisation is present.
Whilst in decorative processes on plastics the trend is towards process integration in favour of value
adding for the moulder and better process control, there is the supply chain issue in the case of films.
The ability of tailor-made film production to face the challenge of fast turnover and shorter run length is
put to the test. The processes in which these films are employed and the challenges they are subjected
to are described in later sections. Films can often be considered to be finished products in themselves
and their variety of combinations of relief, haptic and visual effects render each solution unique.
Not captured in the patent literature, since it falls outside the scope of this book, but an important emerging
feature mentioned in commercial developments, is the arrival of printed electronics that allow additional
features for labels such as making sounds or varying visual effects (see Part B, Section 6.2.3).
The vast majority of patent documents here can be located by using any of the International Patent
Classification search codes B29C (Shaping or joining of plastics; shaping of substances in a plastic state,
in general; after treatment of the shaped products, e.g., repairing), B32B (Layered products, i.e., products
built-up of strata of flat or non-flat, e.g., cellular or honeycomb form), B44C (Producing decorative effects)
or B41M (Printing, duplicating, marking, or copying processes; colour printing).
6.2.1 In-mould Films
Picasus® film from TORAY INDUSTRIES is a conductive metallic lustre film with lamellar layers made without
metal, designed for replacing plating and PVD and suitable for in-mould decoration (IMD) [3]; PROELL
INC., developed its Noriphan® XWR 2K ink that resists film deformation during in-mould applications
[4]; INKWORKS PRINTING talked of the use of high-speed digital printing (LANDA’s Nanography™) for
44
Part B: Materials
IMD films [5]; MARABU announced its new Ultramould UVPC screen inks for IMD [6]; MACDERMID
AUTOFLEX has added Autoflex® EB embossable UV-coated hard coated film for in-mould applications
[7]; MACDERMID AUTOTYPE has demonstrated its new Autoflex® XtraForm [8]; CYTEC announced its
flexible urethane acrylate Ebecryl® 4858 coating for protecting in-mould films [9]; AKZO-NOBEL SOLIANT
publicised its Fluorex® metallised film for in-mould applications [10]; TORAY INDUSTRIES developed a
multilayer metallised PET film called Lumirror® FA6 [11]; MACDERMID AUTOTYPE has developed Autotex®
Steel hard-coated PET film which has a brushed stainless steel appearance and hides fingerprints [12]; EFI
has developed thermoformable inks suitable for deep draw for their VUTEk GS3250 Pro-TF and GS2000
Pro-TF printers UV light-emitting diode (LED) curing inkjet printers [13]; Norilux® DC - abrasion resistant
dual-cure screen printing lacquer from PROELL INC., is designed for PC and poly(m-methylstyrene) films
for in-mould applications. Final curing after thermoforming is by UV [14]. MACDERMID AUTOTYPE has
developed Autotex® Softouch polyester film for in-mould applications [15]. TEIJIN has developed a PC
resin blend for thinner-wall IMD with improved surface quality [16].
6.2.2 Labels and Sleeves
SUN CHEMICAL and POPIMS have co-developed an alternative to lenticular printing for labels using
single-pass flexographic printing [17]; LIBO COSMETICS CO. LTD., has used embroidered fabric to
decorate cosmetics compacts [18]; AVERY DENNISON introduced its Prime Film Portfolio, Shrink PS,
TurnLock™ Laminating System, Wash-Off, MultiCycle™, Z338 Adhesive, and Bottle-to-Bottle portfolios
[19]; SLEEVER has developed more than 26 tactile effects for their films [20]; AVERY DENNISON has
launched a new website that provides advice and experience for label design [21]; DOW has developed
the VISIQUE™ stretch sleeve label for highly contoured bottles [22]; SLEEVER offer a new range of sleeve
effects for lipstick packaging [23]; AVERY DENNISON has developed for labels a PET iridescent film
called Fasson® Diamond [24]; SYSTEMS LABELLING LTD., exposed its R-IML® in-mould label that can
be removed for recycling [25]; SEALED AIR’s new Cryovac® LT-1 shrink sleeve label has a density lower
than the 1 g/cm3 PET recycling standard [26]; VERSTRAETE has developed transparent barrier labels for
in-mould labelling [27]; an in-mould label that is printed on both sides in order to provide more information
[28]; and peelable in-mould labels designed for containing more information [29]. AVERY DENNISON
announced its Curve Appeal™ label range for wrapping around complex shapes [30]; BRICKSTIX have
applied for a patent for reusable decals for plastic toys [31]; and ACCUDIAL PHARMACEUTICAL have
applied for a patent for a multiple-layer label system in which the top label can be moved over the base
label and may have a window [32].
6.2.3 Smart Labels (see also Part B, Section 4)
Printed electronics solutions for labels are available from NOVALIA [33]; integrated printed electronic
functionality on INNOVIA FILMS (BOPP) label substrate has been made available by PRAGMATIC PRINTING
[34]; WIPAK has developed and won an award for talking packaging [35]; APPLE INC., has filed for a patent
for active packaging [36]; THINK4D® has developed electronic solutions for packaging [37]; NOVALIA has
created a poster that plays music clips printed with conductive inks [38]; PRINTECHNOLOGICS GmbH
has received an award for their Touchcode, an invisible electronic data tag that prompts a mobile device
to display information [39]; BEMIS and THIN FILM ELECTRONICS ASA have joined forces to use printed
electronics technology to manufacture and launch intelligent labels [40]; SAY IT CORP., has developed
an electronic device that is activated when a can is opened [41]. FRESHPOINT HOLDINGS SA have
applied for a patent for a time-temperature indicator for a label capable of providing a summary of the
time and temperature history [42].
45
Part B: Materials
6.2.4 Transfer Foils
New holographic and depth effect foils from LEONHARD KURZ STIFTUNG & CO. KG include SB
Aquadrops and Diffractive Lens [43, 44]; and LEONHARD KURZ STIFTUNG & CO. KG has developed
3D tactile films for hot stamping and IMD [45].
6.3 Patent Trends
Table 6.2
3D, tactile and depth effects Anti-slip skin • Cushioned labels • Grain effects • Holographic in-mould film • Imitation
tactile materials for in-mould application (wood, leather) • Infrared absorbing inks for
producing embossed effects • Lenticular labels and films • Lenticular moiré effect
• Relief and depth effects in, in-mould films and labels • Soft touch • Tactile films •
Tactile sleeves • Textured films
Definition, detail and Avoiding unintended transfer • Film for smear-free decoration • Film with improved
contrast transferability • Stable transfer film • Transfer foil with improved edge definition
Gloss and matte effects Anti-glare in-mould film • Anti-reflective film coating • Fingerprint resistant matte film •
High and low gloss areas • Matte films
Interference effects Film with colour travel • Interference effects with films • Polarising effects
Metallic or reflective effects Aluminium complex label • Bright metallic coated labels and films • Coloured metallic
films and effects • Highly reflective films • In-mould film with improved ink-metal
adhesion • Metallic in-mould films • Radio frequency transmitting metallic films
Olfactory effects Low odour in-mould film • Ozone taste removal • Scented labels and IMD films
Surface quality Anti-fingerprint in-mould film • Blow moulding resistant stretchable label • Hard-coats
improvement cured after forming • Hard-coats for in-mould films • Improved in-mould decorating
transfer foils • In-mould films and labels with improved surface after deformation or deep
draw • Labels with reduced shrink force • Non-cracking basecoat for decorated films
Table 6.2 shows that this subject offers an impressive array of decorative options. These are backed up
by a large number of innovating companies, around 80 different names, as seen in Part B, Section 6.4.
Most of the innovation is focused on surface quality improvement, in particular for in-mould films with
larger draw ratios and their final aesthetic and functional performance. The substrate film materials
used vary, with about 40% of cases focusing on coatings choices and providing for a variety of film
resin options. Protective coatings applied to films are typically UV or electron beam (EB) cured. A lot of
attention is also directed towards tactile and visual depth effects as well as metallic finishes. The most
frequent applicants are listed in Table 6.3.
Table 6.3
Ranking of top innovating applicants (three or more patents)
1 DAI NIPPON PRINTING 15 10
2 LG HAUSYS and LG CHEMICAL 11 8
3 TORAY INDUSTRIES 9 6
4 KANEKA CORPORATION 5 3
5 SIPIX CHEMICAL INC. 5 3
6 ETANSI INC. 4 3
7 TEIJIN 4 3
46
Part B: Materials
Infrared absorbing inks selectively printed to influence film deformation; labels with a cushioned layer;
leather and wood effects; metallic effect in-mould films; relief hot stamping and IMD foils.
In-mould films offering surface and processing improvements and 3D effects or tactile surfaces in films
and labels.
6.4 Listed Patent Literature 2011-2103 (for Skin material and compound molding with
search phrases see Part A, Section 2) improved tactile feeling using the same.
JP2011073148A Apr 14th 2011.
TOYO BOSEKI
6.4.1 Three-dimensional, Tactile and Depth A moulded skin with improved tactile properties is
Effects obtained using a urethane (meth)acrylate composition
on one face of a base material in-mould film.
Multi-layer body.
WO2011000485A1 Jan 6th 2011.
KURZ
Method of manufacturing decorative film, and
A relief film for in-mould roller applications. method of manufacturing decorative molded
body.
JP2011079273A Apr 21st 2011.
Decorative film for plastic surfaces.
SHINETSU POLYMER CO
CN101954829 Jan 26th 2011.
An in-mould film with a 3D tactile surface that is not
KUNSHAN DINGSHUO ELECTRONIC SCIENCE AND
deteriorated during the moulding process.
TECHNOLOGY CO LTD
An imitation leather thermoplastic polyurethane film for
plastic surfaces. Multi-layer film, injection molded article
decorated therewith and process for the
production of the decorated injection molded
Embossed decorative sheet for skin material,
laminate of embossed decorative sheet article.
US7976931 Jun 12th 2011.
and adhesive layer, and integral molding of
LEONHARD KURZ STIFTUNG & CO KG
embossed decorative sheet using embossed
A film with ultraviolet-cured replication layers
decorative sheet.
resists temperatures encountered during injection
JP2011025610A Feb 10th 2011.
KANEKA CORP
moulding in order to preserve its optical or functional
An in-mould film with which embossing and non- properties.
whitening is maintained despite injection gate pressures
during the moulding process. Decorated device and method of fabricating
the same.
Multi-layer decorative element for use during US2011159409A1 Jun 30th 2011.
SIPIX CHEMICAL INC
production of lining- or trim part of motor
vehicle, has plastic foil provided with multiple An in-mould method for making a holographic image
projections, where refractive indices of plastic using a film.
foil and intermediate layer deviate from each
other. Decorative resin molded article for
DE102010034879A1 Feb 24th 2011. automobile, and method of manufacturing the
BURG DESIGN GMBH same.
A 3D finely textured decorative film suitable for insert JP2011156774A Aug 18th 2011.
moulding. KOJIMA PRESS KOGYO KK
The surface of an in-mould film is coated with a pattern
that hides the minute 3D surface features of the film
during processing.
47
Part B: Materials
Decorative sheet for thermoforming, and Infrared absorption or reflection inks are selectively
method of manufacturing decorative molded printed on a heat-shrinkable plastic sheet so that,
body. when it is placed on a support and exposed to infrared
JP2011189556A Sep 29th 2011. heat, different areas are heated differently according to
DAINIPPON INK & CHEMICALS the position of the ink. This creates a 3D surface on a
A method for creating a 3D tactile surface in substrate without the need to resort to topcoating for
thermoforming involves using infrared absorbing protection.
or reflecting inks in order to create an embossed
surface. Adhesive backed skins and grips for handheld
devices.
Wood-like decorative sheet and method for US8124216 Feb 28th 2012.
manufacturing the same, and wood-like resin A thin anti-slip skin for handheld devices.
molding and method for manufacturing the
same. Decorative sheet.
JP2011201238A Oct 13th 2011. US20120064310A1
WAVELOCK ADVANCED TECHNOLOGY CO LTD Mar 15th 2012
An in-mould film with a wood grain effect. A decorative sheet with 3D effect for moulded objects
uses white as opposed to metallic layers.
Labeling device for container, and related
manufacturing method. Decorative resin sheet, and molded resin
US20110272316A1 Nov 10th 2011. article and process for production thereof.
EOS WO2012046531A1 Apr 12th 2012.
An impact-resistant elastic sleeve, e.g., in thermoplastic KANEKA CORPORATION
elastomers, not requiring adhesive. An embossable sheet for in-mould application.
Layered image display applications and Decoration film and decorated molded device.
methods. US20120196065A1 Aug 2nd 2012.
US8056929 Nov 15th 2011. ETANSI INC
TRAVEL TAGS INC A soft-feel decorated film for in-mould roller application.
An improved lenticular Moiré method for obtaining a
3D visual effect. Decorative lamination structure, outer housing
structure and method for manufacturing outer
Transfer sheet having excellent cubic effect. housing structure.
CN101687423B Nov 16th 2011. US20120282420A1 Nov 8th 2012.
LG HAUSYS LTD COMPAL ELECTRONICS INC
A 3D effect sheet to be used in in-mould decoration. A laminate for in-mould application consists of a soft
touch polymer with 3D texture surface and a removable
Three-dimensional visual effect sticker and transfer layer.
manufacturing method thereof.
KR20110134065A Dec 14th 2011. Plastic moulded body and method for the
KIM BYUNG KI production thereof.
A plastic 3D-effect label or appliqué. WO2012163323A3 Jan 24th 2013.
A lenticular sheet formed by thermoforming and
Decoration film, decoration device, and decorated and coated on the rear face in order to be
method for manufacturing decoration device. suitable for food contact.
US20120003433A1 Jan 5th 2012.
SIPIX CHEMICAL INC Plastic part having tridimensional decoration
An in-mould decoration transfer film having a tactile and method for molding the same.
effect and perception of 3D. TW201304975A Feb 1st 2013.
HON HAI PREC IND CO LTD
Method for manufacturing decorated molding. An in-mould film with wear-resistant relief pattern.
US20120006480A1 Jan 12th 2012.
DIC CORPORATION
48
Part B: Materials
Decorated film for film insert molding and Decorative packaging element.
method for producing same. WO2013139600A1 Sep 26th 2013.
WO2013031456A1 Mar 7th 2013. KRAFT FOODS R & D INC
SHARP KABUSHIKI KAISHA A deformable lenticular sheet.
A film with 3D tactile relief for film insert moulding.
Decoration film, method of fabricating a
Embossed thermoplastic label. decoration film, and method of fabricating a
US20130071589A1 Mar 21st 2013. decoration device.
AVERY DENNISON CORPORATION US20130248095A1 Sep 26th 2013.
An embossed thermoplastic label. ETANSI INC
An in-mould decoration film providing a 3D relief
Decorative sheet and decorative resin molded surface.
article obtained using same.
WO2013046752A1 Apr 4th 2013. Textured heat transfer label.
DAI NIPPON PRINTING CO LTD US20130251922A1 Sep 26th 2013.
A tactile decorated film for in-mould application. ILLINOIS TOOL WORKS INC
A textured heat transfer label which can include metallic
Squeezable and conformable oriented portions.
polypropylene label.
WO2013055461A1 Apr 18th 2013. Multi-layer decorative film structure.
EXXONMOBIL OIL CORPORATION US20130288011A1 Oct 31st 2013.
A PP flexible self-adhesive label with a cushion layer. WANG SHUI-MU
A relief in-mould film.
Decorating sheet, decorated molded article
and in-mold decorating injection molding. Coating composition with excellent tactile
EP1669191B1 May 22nd 2013. characteristics, preparation method thereof,
DAI NIPPON PRINTING CO LTD and transfer sheet using same.
A sheet for in-mould application that gives a visual WO2013168871A1 Nov 14th 2013.
3D effect. LG HAUSYS LTD
A transfer film with tactile effect.
Transfer film for in-mold injection showing 3D
pattern, and preparation method thereof.
WO2013081384A1 Jun 6th 2013. 6.4.2 Definition, Detail and Contrast
LG HAUSYS LTD
An in-mould film for creating a 3D tactile effect. Thermal transfer sheet.
US20130135417A1 May 30th 2013.
In-mold transfer film having an elastic texture, DAI NIPPON PRINTING CO LTD
and method for manufacturing same. A thermal transfer sheet for sublimation which provides
WO2013118964A1 Aug 15th 2013. high transferability.
LG HAUSYS LTD
A soft-touch in-mould film. Thermal transfer sheet.
US20130142969A1 Jun 6th 2013.
Decorative sheet with different beads in YAMASHITA
different layers. A thermal transfer sheet for sublimation which has
US20130216754A1 Aug 22nd 2013. improved stability during storage and provides high
3M INNOVATIVE PROPERTIES COMPANY transferability.
An in-mould film that provides a frost and embossed
pattern, for example a wood-like appearance. Process for production of transfer sheets
excellent in the resistance to burr generation
Low-gloss soft-touch thermoformable paint and transfer sheets.
film laminate. EP2221175B1 Oct 23rd 2013.
WO2013120922A1 Aug 22nd 2013. NISSHA PRINTING CO LTD
AKZO NOBEL COATINGS INTERNATIONAL BV A heat transfer film that provides sharp edges to
A soft-touch in-mould film. images.
49
Part B: Materials
System and method for transferring images 6.4.4 Interference Effects

onto substrates.
WO2013159922A1 Oct 31st 2013.
Film for decorating in mold.
A transfer printing substrate that avoids unintended CN101982311A Mar 2nd 2011.
transfer of a coating from the substrate itself during SUZHOU DARFON ELECTRONIC CORP
the application of heat and pressure. An in-mould film contains coloured particles that
change colour according to viewing angle.
Decorative membrane and in-mold decorative
molding process.
Antireflective film, method of production
CN102039770A May 4th 2011.
thereof, and UV-curable resin material
ENTIRE TECHNOLOGY CO LTD
composition coating liquid.
An in-mould film has layers of material consisting
US20110164322A1, Jun 7th 2011.
of different refractive indices in order to produce an
SONY CORPORATION
interferential optical effect.
A low refractive index ultraviolet-cured coating is
proposed for anti-reflective properties.
Decoration film for insert molding, insert
molded article, method for producing
Transfer film.
decoration film for insert molding.
EP1871620B1. Aug 3rd 2011.
WO2011077738A1 Jun 30th 2011.
OVD KINEGRAM AG
ULVAC INC
A finely textured surface hot stamping film is proposed,
An interferential in-mould film in which colour and
e.g., for anti-reflection or dirt repellence.
brilliance vary according to viewing angle.
Decorative film, method for manufacturing Decorative film and in mode decoration/
thereof, and decorative molding article. forming process.
US20110223389A1 Sep 15th 2011. US20110171440A1 Jul 14th 2011.
A fingerprint resistant matte film for in-mould decoration ENTIRE TECHNOLOGY CO LTD
film. Colour-shift effects at different angles due to refraction
are achieved by film insert moulding a multi-layer
Decorative sheet, process for producing film in at least two different materials which have
decorative resin molded product, and been stretched during lamination in order to create
decorative resin molded product. differences in refractive index.
EP2298526A4 Oct 31st 2012.
DAINIPPON PRINTING CO LTD Decorative casing and manufacturing method
A laminated acrylonitrile-butadiene-styrene decorative thereof.
sheet with high and low-gloss areas for in-mould US8153270 Mar 10th 2012.
application with high abrasion and scratch resistance FUJITSU COMPONENT LIMITED
and low cracking during thermoforming. The decorative effect of a polarising film bonded to a
casing is enhanced by attaching it using an adhesive
Anti-reflective coating composition providing containing special effect material.
improved scratch resistance, anti-reflective film
using same, and production method therefor. Flicker boxes.
WO2013048205A3 May 23rd 2013. US8240479 Aug 14th 2012.
LG CHEM LTD XEROX CORPORATION
A scratch-resistant anti-reflective coating. A visual effect is obtained by using differently polarising
portions that interact when opening or closing a
Anti-glare hardened film for in-mold container with portions that slide over each other.
decoration.
CN101825729B Jun 26th 2013. Shallow fringe transparent hard coating film
CHINA LUCKY FILM GROUP CORP for in-mold decoration.
An improved in-mould decorating film with anti-glare CN101885255B Dec 26th 2012.
properties. CHINA LUCKY FILM GROUP CORP
50
Part B: Materials
A hardcoated interference film for film insert Self-adhesive label.

moulding. WO2013043083A1 Mar 28th 2013.
IMAGENCY PRINT LTD
A flexible aluminium-polymer complex label.
Decorative article and device housing using
Metallic in-mould films: the decorative article.
JP2011068081A, Apr 7th 2011. TOPPAN PRINTING; US20130302621A1 Nov 14th 2013.
JP2011079178A, Apr 21st 2011. NICHIBAN; WU
JP2011093296, May 12th 2011. DAINIPPON PRINTING; A decorated metallic in-mould label film with improved
CN201833636, May 18th 2011. GOLDENKEN adhesion between the metal and ink.
ELECTRONICS; JP2011167969A, Sep 1st 2011.
NISSHA PRINTING; WO2011128973A1, Oct 20th 2011.
Moulded article and label therefor.
WAVELOCK ADV TECH; JP2011218776A, Nov 4th
US20130344268A1 Dec 26th 2013.
2011. HAKUICHI; WO2012057072A1, May 3rd 2012.
An in-mould label has a metallised layer for oxygen
TOYO BOSEKI; WO2012133234A1, Oct 4th 2012. DAI
barrier.
NIPPON PRINTING; US8354171, Jan 15th 2013. TORAY;
US20130034693A1, Feb 7th 2013. MAZDA MOTOR.
Metallic in-mould films – radio wave
transmitting (non-conductive):
Scented Label.
US20120003489A1, Jan 5th 2012. SIPIX CHEMICAL;
US20110155606A1 Jun 30th 2011.
EP2409832A1, Jan 25th 2012. SHIN-ETSU POLYMER;
SANCOA INTERNATIONAL COMPANY LP
WO2012096512A2, Jul 19th 2012. LG HAUSYS;
A label with incorporated scent.
EP2372387A4, Aug 8th 2012. TOYOTA MOTOR;
CN102099203B, Jan 2nd 2013. NISSHA PRINTING.
Decoration film, decoration device, and
Thermoformable 3D retroreflective article and method for manufacturing decoration device.
method of manufacture. US20120003441A1 Jan 5th 2012.
EP2390688A1 Nov 30th 2011. SIPIX CHEMICAL INC
AVERY DENNISON CORPORATION An in-mould decorating film with encapsulated aroma.
A high reflectivity 3D object of at least 200 lux is
obtained by thermoforming and the use of variable In-mold transfer film which changes its color
diameter micro-beads. according to a temperature and which has
a scent-emitting function and method for
Method for decorating e.g., bottle containing manufacturing same.
fluid product in perfumery field, involves WO2013048064A2 Apr 4th 2013.
applying translucent material layer to part of LG HAUSYS LTD
sheet to view metallized layer through material A thermochromic and scent-producing in-mould film.
layer to confer color shade on metallized layer.
FR2962068A1 Jan 6th 2012. Decorated sheet for insert molding.
AIRLESSYSTEMS CN101351333B Jul 10th 2013.
A method for personalising the colour of a metallic film DAI NIPPON PRINTING CO LTD
or sheet, for example hot foil stamping, by overcoating An acrylonitrile-butadiene-styrene decorated sheet for
with a translucent colour coating. in-mould decoration that avoids odour issues during
moulding.
Metallized films, pressure-sensitive label
structures, and methods of making same. Films and articles with good taste and/or odor
US2013059119A1 Mar 7th 2013. performance.
A polymeric metallised pressure-sensitive label material US8568894 Oct 29th 2013.
where the metallisation brightness is not subdued as a DOW GLOBAL TECHNOLOGIES LLC
result of protective layers. A multi-layer film, e.g., for bottles, which removes the
taste of ozone used for sterilising.
51
Part B: Materials
6.4.7 Surface Quality Improvement 3rd 2013. TORAY; TW201304931A, Feb 1st 2013.
JNC; WO2013027547A1, Feb 28th 2013. TORAY;
WO2013083967A2, Jun 13th 013. WORLDMARK
Non-metallic in-mould films. Substrates
INTERNATIONAL; EP2617758A1, Sep 24th 2013.
include materials such as ABS, acrylics,
TORAY; WO2013141551A1, Sep 26th 2013. LG
ionomers, PA, PC, PET, PGA, PMMA, PP.
HAUSYS; EP2248846B1, Oct 23rd 2013. TECHNO
US20110045284A1, Feb 24th 2011. DAI NIPPON
POLYMER; WO2013169375A1, Nov 11th 2013. TORAY
PRINTING; WO2011021720A1, Feb 24th 2011.
PLASTICS (AMERICA); US20130341826A1, Dec 26th
TEIJIN LIMITED; JP2011068086A, Apr 7th 2011;
2013. ETANSI.
NISSHA PRINTING; JP2011073384A, Apr 14th 2011.
DAINIPPON PRINTING; JP2011079156A, Apr 21st
Label film for deep-drawing processes.
2011. KANSAI PAINT; US20110094664A1, Apr 28th
MX2011007533A Aug 12th 2011.
2011. SOLIANT; TW201114580A, May 1st 2011. TENYI
TREOFAN GERMANY GMBH & CO KG
TECHNOLOGY; JP2011088421A, May 6th 2011.
A 5 or more layer in-mould label material where gloss
DAINIPPON PRINTING; US20110183120A1, Jul 28th
is maintained after stretching.
2011. SABIC; US8043691, Oct 25th 2011. EVONIK
ROEHM; US20110272841A1, Nov 10th 2011. ENTIRE
Decoration device and method for fabricating
TECHNOLOGY; US20110274894A1, Nov 10th 2011.
decoration device.
AVERY DENNISON; EP1731285B1, Nov 30th 2011.
US20120003426A1 Jan 5th 2012.
DAI NIPPON PRINTING; WO2012018099A, Feb 9th
SIPIX CHEMICAL INC
2012. TEIJIN CHEMICALS; US8119235, Feb 21st 2012.
An in-mould decoration film with anti-fingerprint
E I DUPONT DE DEMOURS; US20120052314A1,
properties.
Mar 1st 2012. SABIC; TW201208903A, Mar 1st 2012.
WANG MING-CONG; WO2012035955A1, Mar 22nd
2012. TORAY; SG178436A1, Mar 29th 2012. TEIJIN;
Multi-layer decorative film.
WO2012065966A1 May 24th 2012.
WO2012043748A1, Apr 5th 2012. DAI NIPPON
BAYER MATERIALSCIENCE AG
PRINTING; US20120094116A1, Apr 19th 2012.
A multi-layer decorative film for vacuum thermoforming.
EVONIK DEGUSSA; WO2012060311A1, May 10th
2012. KANEKA CORPORATION; US20120148847A1,
Jun 14th 2012. TEIJIN; US20120168074A1, July Label for in-mold forming and resin container
5th 2012. LG HAUSYS; WO2012090767A1, Jul 5th with the label.
2012. KANEKA; US20120237702A1, Sep 20th 2012. US20120288652A1 Nov 15th 2012.
PANASONIC; WO2012133235A1, Oct 4th 2012. DAI YUPO CORPORATION
NIPPON PRINTING; EP1967358B1, Oct 31st 2012. DAI An antistatic label that adheres to blow-moulded PP
NIPPON PRINTING; CN101831239B, Nov 7th 2012. and resists hot filling.
CHINA LUCKY FILM GROUP; US20130008600A1, Jan
10th 2013; US20130049267A1, Feb 28th 2013 FUJIFILM; Process to mold a plastic optical article with
WO2013039119A1, Mar 21st 2013. MITSUBISHI integrated hard coating.
RAYON; WO2013051239A1, Apr 11th 2013. KANEKA US8342682 Jan 1st 2013.
CORPORATION; US20130168011A1, Jul 4th 2013. INSIGHT EQUITY APX LP
TORAY; EP2623319A1, Aug 7th 2013. DAI NIPPON A hardcoat is partially cured on a film which in turn is
PRINTING; WO2013114964A1, Aug 8th 2013. TORAY; applied in-mould to the injected article and then post-
US20130269872A1, Oct 17th 2013. LG HAUSYS; cured following ejection.
WO2013154877A2, Oct 17th 2013. ARKEMA FRANCE;
WO2013183489A1 Dec 12th 2013. TORAY INDUSTRIES In-mould labelling.
INC; US20130344299A1 Dec 26th 2013. SABIC WO2013024259A1 Feb 21st 2013.
INNOVATIVE PLASTICS IP BV. INNOVIA FILMS LIMITED
An in-mould label with reduced shrink force.
Non-metallic in-mould transfer foils:
WO2011136068A1, Nov 3rd 2011. DIC; Decorative sheet and in-mold forming method.
WO2012002504A1, Jan 5th 2012. DAI NIPPON EP2561969A2 Feb 27th 2013.
PRINTING; US8192837, Jun 5th 2012. ETANSI; FUJIFILM CORPORATION
WO2012096437A1, Jul 19th 2012. LG HAUSYS; A decorated sheet for in-mould forming with the
US20120251755A1, Oct 4th 2012; CN102837522A, facilitated possibility of short decoration runs.
Dec 26th 2012. SONY; WO2013002065A1, Jan
52
Part B: Materials
Label film for deep drawing methods. Decorative sheet, method for producing
US20130134625A1 May 30th 2013. decorative sheet, in-mold injection molding
TREOFAN GERMANY GMBH & CO KG method, and resin molded product.
A label suitable for deep drawing while maintaining US20130344306A1 Dec 26th 2013.
adhesion. FUJIFILM CORPORATION
A film printed with an ultraviolet curable inkjet ink
Gas-barrier shrink films and their use in deep- suitable for in-mould decoration contains polymer
drawing applications. particles in order to enable stretchability and heat
EP1825998B1 Sep 4th 2013. resistance.
CRYOVAC INC
A 40-160 micron heat shrinkable barrier film capable
of deep draw.
References
1. N. Bolding, Driving the Development of Film Insert Molding, Screen Web.
http://www.screenweb.com {Accessed May 2014}
2. J.C. Love and V. Goodship in In-Mould Decoration of Plastics, Rapra Review Report No.146, Rapra
Technology Ltd., Shawbury, Shropshire, UK, 2002, p.12.
3. S. Moore, Metal-free Film Exhibits Chrome Effect, Plastics Today.

http://www.plasticstoday.com {Accessed May 2014}
4. Noriphan® XWR - Wash-Out Resistant IMD Screen Printing Ink Marabu, Proell.
http://www.proell.de {Accessed May 2014}
5. B. Travis in Exploring the Value Proposition of Digitally Printed In-Mould Decoration, Plastics
Decorating, 2012, October/November, 14.
6. The IMD Process Using UV-Curable Screen Printing Ink.

http://www.marabu-inks.com/fileadmin/content_druckfarben/Applications/Screen_Printing/
IMD_Process_ENG_Final.pdf {Accessed June 2014}
7. Data Sheet: MacDermid Autoflex EB has UV-Cured Hard Surface, The Engineer Supplier Network.
http://source.theengineer.co.uk {Accessed May 2014}
8. MacDermid Autotype’s Autoflex Xtraform Film is Targeted at Vehicle Dashboard Designers, The
Engineer Supplier Network.
http://source.theengineer.co.uk {Accessed May 2014}
9. EBECRYL 4858 Aliphatic Urethane Acrylate for UV/EB Cured Films and Plastics, Cytec.
http://www.european-coatings.com {Accessed March 2011}
10. AkzoNobel Soliant Fluorex® Bright Film Shines with Three Major Awards, Plastics Decorating,
2011, April/May, 31.
11. Super-Smooth Multi-layered PET Film for In-Mold Decorating Applications, Omnexus.
12. MacDermid Autotype Turns Plastic into Steel, MacDermid Autotype.

http://www.macdermidautotype.com {Accessed May 2014}
13. Thermoformable Inkjet Inks, Industrial & Speciality Printing.

http://www.industrial-printing.net {Accessed May 2014}
53
Part B: Materials
14. Norilux® DC - Abrasion Resistant Dual-Cure Screen Printing Lacquer, Proell.

http://www.proell.de {Accessed May 2014}
15. Gaining a Competitive Edge with Autotex Softouch, MacDermid Autotype.

http://www.macdermidautotype.com {Accessed May 2014}
16. Teijin Develops Polycarbonate Resin for In-mold Decorations, Teijin.

http://www.teijin.com {Accessed May 2014}
17. 3D Printing Technology, Popims.

http://popims.com {Accessed June 2014}
18. Libo’s New Embroidered Cosmetic Packaging, Web Packaging.

http://www.webpackaging.com {Accessed May 2014}
19. Avery Dennison Introduces Groundbreaking Labeling Technologies at Labelexpo Americas 2012,
Avery Dennison.
http://news.averydennison.com {Accessed May 2014}
20. Sleever Develops New Tactile Finish, Beauty Packaging, 2011, 16, 1, 62.
21. Avery Dennison Launches Online Designer Showcase Featuring Tips and Advice from Leading
Design Firms, Designer Showcase.
http://designershowcase.averydennison.com {Accessed May 2014}
22. Dow and PetroplastVinora Introduce Visique™ Stretch Sleeve Label, Dow.
http://www.dow.com {Accessed May 2014}
23. La Solution Sleever Make Up Lipstick, Sleever.

http://www.sleever.com {Accessed May 2014}
24. Iridescent Film, Package Design.

http://www.packagedesignmag.com {Accessed May 2014}
25. R-IML® Could Enable the Production of Food Grade Polypropylene, Americk Systems Labelling.
http://www.systemslabelling.com {Accessed May 2014}
26. H. Caliendo, New Shrink Labels Suitable for the Recycling Stream, Plastics Today.
http://www.plasticstoday.com {Accessed May 2014}
27. Barrier IML Labels, Verstraete In Mould Labels.

http://www.verstraete-iml.com {Accessed May 2014}
28. DoubleSided IML, Verstraete In Mould Labels.

29. Peelable IML, Verstraete In Mould Labels.

30. Avery Dennison Curve Appeal System Gives Wraparound Look for Complex Curved Containers,
Web Packaging. http://www.webpackaging.com {Accessed May 2014}
31. A.R. Maclean and G.A. Maclean, inventors; Brickstix LLC, assignee; GB2491531, 2013.
32. S.M. Key, inventor; Accudial Pharmaceutical Inc., assignee; WO2013019907A1, 2013.
54
Part B: Materials
33. IDTechEx Printed Electronics USA 2010 Award Winners, Novalia.

http://www.novalia.co.uk/html/Images/IDTechEx%20Printed%20Electronics%20USA%202010%20
Award%20Winners(2).pdf {Accessed June 2014}
34. BOPP Labels with Interactive Printed Electronics Function Light Up Bottles, Omnexus.
35. WorldStar and President’s Gold Award: Wipak Group Double Winner, Wipak.
http://www.wipak.com/wipak_news/articles/en_GB/PresidentAward {Accessed June 2014}
36. E. Fischer, Pack to the Future: Next-Gen Packaging Materials, Packaging Gateway.
http://www.packaging-gateway.com {Accessed May 2014}
37. Pack to the Future: Next-Gen Packaging Materials, Packaging Gateway.

http://www.packaging-gateway.com {Accessed March 2012}
38. Playing Pop Music Via Paper Posters with Conductive Ink, BBC News Technology.
http://www.bbc.co.uk/news/technology-17339512 {Accessed June 2014}
39. Printechnologics Excels at Printed Electronics Europe 2012, Printed Electronics Now. {Accessed
May 2014}
40. Bemis Company Signs Joint Development Agreement With Thin Film Electronics Bemis.
http://www.bemis.com/news/press/article/id/356/ {Accessed June 2014}
41. M. Greenberg, M. Illouz, R. Talor, N. Talor and D. McIntire, inventors; Say It Corporation, assignee;
WO2012102759A1, 2012.
42. H. Salman, inventor; Freshpoint Holdings SA, assignee; WO2013186782A1, 2013.
43. Hot Stamping Foils: Kurz Launches New Designs, Premium Beauty News.
http://www.premiumbeautynews.com {Accessed May 2014}
44. Hot Stamping Foil, Package Design.

http://www.packagedesignmag.com/content/product-focus-special-effects {Accessed June 2014}
45. Designs You Can Touch Tactile Surfaces are on the Up for Automotive Interiors, K Show.
http://www.k-tradefair.com {Accessed May 2014}
55
Part B: Materials
7 Inks, Paints, Coatings (Excluding Colour Change or Effect Materials)
7.1 Background
Development of inks and coatings to be applied to polymer substrates provides the second most
important area of innovation covered in this book after films, foils and labels (see Part B, Sections 4
and 5 for colour change and effect materials). As with dry film products, most innovation comes from
chemical companies active in the field of plastics decoration and surface treatment processes. Inks
and coatings may be radiation or heat curable or simply air dried; be formulated for food packaging
applications (no leachable materials - low migration, e.g., from AGFA GRAPHICS, MARABU, RUCO,
SUN CHEMICAL, and others); have anti-static and anti-fingerprint properties; or have varying degrees
of hardness and chemical resistance. In coating formulations, nanotechnology has improved their
performance in abrasion resistance. More recent innovations have included anti-microbial, self-cleaning
and self-healing properties. Table 7.1 shows that the predominant trend is attention to surface quality
improvement, and this refers mostly to different types of hard coat applied to polymer substrates e.g.,
by curtain coating, dipping, flow-coating, roller or spray. Whereas constant efforts are being made to
improve substrate resin surface quality through formulation (Part B, Section 8), or moulding conditions
(Part C, Section 13), a coating operation still remains a viable solution for improving surface quality
and ensuring resistance properties. Coating in-line with moulding facilitates the use of formulations
that do not require solvents (Part D, Section 22).
Table 7.1
5 Acoustic effects 0 1 0 1
7 Definition, detail, contrast 0 0 1 1
An important historical event related to plastics processing was the arrival of ultraviolet (UV) curing for
inks and coatings in the 1970s. The ability to obtain higher gloss, abrasion and chemical resistance in
inks and coatings, not to mention the benefit of rapid curing at low temperatures, represented the biggest
revolution the industry had seen since its inception.
Innovations in adhesion improvement have introduced new choices for coating resins, substrate resins
and additives for either of these. There also continues to be development in adhesion primers, where
most recent innovation has been directed towards halogen and solvent-free solutions. Pre-treatment
processes for adhesion include those that simply clean the substrate, those that remove the surface
layer of the substrate and, most commonly, those that raise the surface energy of the substrate, typically
through oxidation (i.e., flame, corona and plasma treatment). Most current innovation in this area focuses
on atmospheric and low-pressure (vacuum) plasma treatment methods. Table 7.2 presents common
atmospheric pressure surface treatment processes.
56
Part B: Materials
Table 7.2
Common atmospheric pre-treatment processes prior to applying inks or coatings to polymer substrates
Primary Process Comments
purpose
Adhesion Chemical etching Limited use outside plating operations where it is used, for example, for
preparing acrylonitrile-butadiene-styrene. Can discolour substrate
Adhesion Corona discharge Widely used on polyethylene (PE) and polypropylene (PP) bottles to oxidise
surfaces. A high tension corona is grounded, often through the substrate.
Electrodes have to be close to the substrate, and therefore the process is
suitable for flat or cylindrical shapes
Adhesion Flame treatment Very widely used on 3D objects in PE or PP to oxidise surfaces. Treatment
levels can be high, and longer flames facilitate the treatment of shaped surfaces
Adhesion Laser direct A process used to render polymer surfaces suitable for plating by activating an
structuring internal additive. See Section 25. Used primarily for electronics applications
Adhesion Photografting Adhesion improvement by photo-chemically grafting onto a polymer surface.
Limited use
Adhesion Primer coat When applied by dip or spray, addresses the challenge of shapes. Also useful
for masking pollutants on the substrate surface. Widely used in conjunction
with spray coating of PE, PP, and other materials where exudation and other
effects cause defects in liquid inks and coatings. Traditionally adhesion primers
have been rapid-drying solvent-borne chlorinated polyolefins
Adhesion Plasma treatment Adhesion improved by oxidation, chemical modification or deposition. Best
and deposition suited to simple shapes because the substrate distance is usually less than
10 mm (low pressure processes do not have this restriction). Limited cleaning
unless used in etch mode (extended time, higher energy). Plasma enhanced
chemical deposition is sometimes used to deposit adhesion-assisting coatings
such as silicon dioxide (SiO2)
Adhesion and Sandblasting Used to improve adhesion - limited use
cleaning
Cleaning Brushing and Dry or wet contact processes used in conjunction with deionisation to remove
wiping pollutants. The contact media has to be constantly cleaned; brushing is
accompanied by extraction of dust
Cleaning Degreasing Various forms of aqueous, solvent, or CO2 snow processes are used prior to
coating processes such as spray coating. CO2 cleaning has the advantage of
not requiring any rinsing, drying, or chemicals, and is increasingly used in-line to
prepare parts for spray coating, in particular for the automotive industry
Cleaning Deionisation and Used for dust removal. Deionisation also prevents re-attraction of dust to the
blowing substrate. Commonly used on all types of decoration and surface treatment
lines
Cleaning Steam treatment Used for cleaning - limited use
UV light-emitting diode (LED) curing is making important inroads in applications for flat or cylindrical
substrates, e.g., for flexographic, inkjet, offset and screen printing. Power levels of 8 W/cm2 are possible
without the need for water cooling. Some of the suppliers using this process are: AIR MOTION SYSTEMS;
HERAEUS NOBLELIGHT [1]; INTEGRATION TECHNOLOGY; IST METZ; LUMEN DYNAMICS [2]; and
PHOSEON TECHNOLOGY [3]. Lamps with outputs up to 16 W/cm2 and negligible loss of power over
100 mm are claimed, but emissions are monochromatic, requiring special ink and coating formulation.
Other curing developments include the use of low-temperature near-infrared to replace UV curing [4];
the use of a single lamp to achieve cure on 3D objects (from IST) [5]. Energy Sciences talked of the
advantage of electron beam curing over UV curing for eliminating residual monomers, applying thicker
films and 3D effects with lower energy and without the need for photoinitiators [6]. In conventional UV
curing, DR. HÖNLE AG have announced use of power levels up to 8 W/cm2 [7].
57
Part B: Materials
RH SOLUTIONS INC., has developed a range of 18 different tactile and 3D effects in screen inks [8]; UV
light has been used to induce microcellular foaming in inks [9]; Tego® Rad 2010 and Tego® Rad 2011
crosslinking multifunctional slip additives for UV cured inks and coatings have been developed by EVONIK
INDUSTRIES AG [10]; and DOW CORNING CORP., has developed its 2634 slip coating which dries in
minutes after spraying [11].
PEPSI has patented the use of coatings with encapsulated aromas for their packaging [12].
A new crosslinking additive for UV curable coatings called Taicros® is providing new levels of performance
[13]; a new solvent-free acrylate high solids waterborne hard coat for plastics from ALLNEX requires a
flash-off time of 5 min at 50 °C [14]; MOMENTIVE has developed SilFORT* UVHC7800 hard coat for
plastics with improved scratch resistance and less cure shrinkage [15]; Nanomyte® SR-100EC is an easy-
to-clean, water-based, hard coat from NEI CORPORATION, that can be applied by dipping, spraying,
roller, or flow coating [16]; EVONIK TEGO CHEMIE GMBH has introduced a new universal substrate
wetting additive for water or solvent-borne inks and coatings, including UV coatings [17]; and ALLNEX
has introduced a nine-functional EBECRYL™ 8602 and a 10-functional EBECRYL™ 8415 urethane acrylate
resins for UV hard coats. The lower functionality version is suitable for in-mould decoration of films. Both
show advantages over traditional six functional products [18].
7.3 Patent Trends
Table 7.3
3D, tactile and depth effects Crack effects • Depth effects • Depth effect under UV • Elastomeric coating •
Heat expanding microspheres • Low friction coatings • Non-tacking tactile ink •
Slip via self-stratification • Soft touch • Tactile inks and coatings
Acoustic effects Anti-squeak
Colour effects Imitation ceramic effect
Definition, detail and contrast Non-spreading inkjet ink
Gloss and matte effects Anti-glare coatings • Anti-reflective coatings • Diffuse reflectance • Frost effects
• Low gloss and matte
Olfactory effects Odour control inks • Scented inks and coatings
Surface quality improvement Abrasion and scratch resistance • Antistatic coatings • Easy-to-clean coatings •
Hiding scratches • Liquid coatings • Powder coatings • Reduced defects • Self-
cleaning coatings • Self-healing coatings
Table 7.3 illustrates the range of effects offered by inks and coatings listed in Part B, Section 7.4.
58
Part B: Materials
The largest amount of development has focused on liquid coatings to improve the appearance of
polymer surfaces, primarily through spray coating, in order to hide substrate defects, improve gloss
level, and to variously add functional properties such as abrasion and chemical resistance, easy-to-clean
and anti-static properties. Most of these are UV-curable and any easy-to-clean properties imparted
by fluorine chemistry.
Table 7.4 lists the principal patent trends in inks and coatings used for surface improvement, and Table 7.5
for 3D, tactile and depth effects.
Table 7.4
Repartition of principal patent subject trends, liquid gloss coatings for surface improvement
1 Coatings 53 62
2 Coatings with anti-fingerprint properties 23 27
3 Coatings with anti-static/conductive properties 8 10
Table 7.5
Repartition of principal patent trends, 3D, tactile and depth effects
1 Tactile and soft touch effect coatings 8 47
2 Crackle and relief effect coatings 3 18
3 Depth effect coatings 3 18
4 Slip and low friction effect coatings 3 18
The most frequently innovating companies are listed in Table 7.6.
Table 7.6
1 BASF 8 6
2 LG CHEMICAL 7 6
3 ASAHI GLASS 6 5
4 BAYER MATERIALSCIENCE 6 5
5 EVONIK DEGUSSA and ROEHM 6 5
6 PPG INDUSTRIES 4 3
7 ARKEMA 3 2
Anti-fingerprint and easy-to-clean coatings; coatings containing heat-expandable microspheres selectively

heat activated; crackle coatings; imitation ceramic; self-healing scratch-resistant coatings; and soft touch
coatings.
59
Part B: Materials
Liquid gloss coatings for surface improvement.
7.4 Listed Patent Literature 2011-2103 (for Resin-coated material and process for
search phrases see Part A, Section 2) manufacturing same.
US20120015162A1 Jan 19th 2012.
SOCIETE D’ENDUCTION ET DE FLOCKAGE
7.4.1 Three-dimensional, Tactile and Depth A coating contains heat-expandable microspheres
Effects which are activated by selective heating with a hot die
or laser in order to produce an embossed effect.
Coating material composition and use thereof.
WO2011006476A3 Jan 20th 2011. Hand-feeling coating and preparation method
MANKIEWICZ GEBR & CO GMBH & CO KG thereof.
A soft touch coating. CN101619184B Feb 1st 2012.
CHINA PAINT MFG SHENZHEN CO
Elastomeric surface coatings for plastic A waterborne tactile coating.
articles.
US20110059277A1 Mar 10th 2011. Self-structuring surfaces through PDMS phase
An elastomeric coating for polyethylene terephthalate. separations in hard polymer coatings.
WO2012020068A2 Feb 16th 2012.
Polyolefin-based composite resin spherical UNIVERSITAET PADERBORN
particles, coating composition and coated A solution for reducing friction involves phase
object. separation of the paint film.
WO2011027818A1 Mar 10th 2011.
SUMITOMO SEIKA CHEMICALS CO LTD A tack free decorative ink composition
Polyolefin spherical particles enable a matte finish with comprising an aziridine derivative and a
soft feel. polyethylene/paraffin wax mixture, process
and use thereof.
Crackle lacquer, preparing method thereof WO2012063157A1 May 18th 2012.
and spraying method for the same. PRIMUS RAIN SL
CN101210129B Apr 6th 2011. A non-tacking tactile ink that can be applied, for
BYD CO LTD example, by inkjet printing.
A heat-curing acrylic crackle lacquer requiring a primer
coat. Soft touch coating composition.
WO2012089827A1 Jul 5th 2012.
Luminous printing. BECKERS HIGH PERFORMANCE COATINGS (TIANJIN) LTD
WO2011109349A2 Sep 9th 2011. A polyurethane soft-touch coating with improved
ADAMS chemical resistance.
Prints having a depth effect under ultraviolet black light
conditions. Multi-phase self-stratifying coating exhibiting
gradient behavior.
Coated articles and multi-layer coatings. US20120201965A1 Aug 9th 2012.
US20110236673A1 Sep 29th 2011. Self-stratifying coatings with slip properties that
PPG INDUSTRIES OHIO INC optimise required properties at substrate and
A semi-translucent coloured layer consisting of air interfaces and avoid the need for multiple
colour-imparting particles admixed with unsaturated applications.
monomers in aqueous solution and incorporated into
a coating which is subsequently topcoated with a clear Coating material, coating material layer, and
layer in order to provide a depth effect. laminated structure.
WO2012108414A1 Aug 16th 2012.
F CONSULTANT CO LTD
A translucent water-based coating giving depth effect.
60
Part B: Materials
Coating material composition and its use. 7.4.5 Gloss and Matte Effects
DE112010002951A5 Sep 13th 2012.
MANKIEWICZ GEBR & CO
A water-based soft-touch coating that avoids the use method for making paint composition, and
of N-methylpyrrolidone co-solvent to assist adhesion. diffusively light reflective articles.
US20110064939A1 Mar 17th 2011.
Waterborne polyisocyanate composition that Diffuse reflectance values up to 98% are achieved.
provides a low friction coating. One paint application technique described here is in-
US20120302471A1 Nov 29th 2012. mould, whereby the paint composition is cured during
A low friction waterborne coating for plastics. the moulding process.
Energy cured coating composition and Transparent textured coating surfaces from
process of applying same to substrate. water evaporation.
WO2013049002A1 Apr 4th 2013. WO2011034600A1 Mar 24th 2011.
ARMSTRONG WORLD INDUSTRIES INC
SUN CHEMICAL CORPORATION
A method for avoiding viscosity build-up of a tactile Fast drying water-based ultraviolet-curable coatings
coating applied by roller coating uses a ultraviolet- solve the issues related to using solvents and alternative
cured coating. methods to get varied frost effects for products in
contact with food.
Ultraviolet curable resin composition and
aesthetic coating. Device having reduced friction properties.
WO2013145497A1 Oct 3rd 2013.
WO2011047840A3 April 28th 2011.
ORIGIN ELECTRIC COMPANY LIMITED
SCHOTT AG
A cracking ultraviolet coating that produces a mesh
A low-friction smooth anti-reflective coating for glass
design.
or plastic that reduces fingerprinting.
7.4.2 Acoustic Effects A resin for use in a coating composition.

WO2011097478A1 Aug 11th 2011.
BASF COATINGS GMBH
Polymer mixture.
US8314179 Nov 20th 2012.
A low-gloss (preferably less than 10% at an angle of
BENECKE-KALIKO AG
20o) heat-cured coating that reduces problems of cost
A durable aqueous coating for automobile interiors of higher levels of matting agents, pigment settling,
which also retains anti-squeak properties. coagulation, and cured film durability.
Low gloss radiation-curable compositions.

7.4.3 Colour Effects WO2011146123A2 Nov 24th 2011.
BAYER MATERIALSCIENCE LLC
Paint coating material for producing an A solution for producing scratch resistant matte ultraviolet-
imitation ceramic effect and its application curable high-solids coatings without excessive viscosity.
method thereof.
US20130183449A1 Jul 18th 2013. Anti-reflection/anti-fog coatings.
A 4-coat paint system, including topcoat, which creates US20110318567A1 Dec 29th 2011.
an imitation ceramic effect. BAYER MATERIALSCIENCE AG
Improved low-temperature curing anti-reflection
coatings for plastics have been achieved using silica
nanoparticles.
Ink for active energy ray-curable inkjet Process for scratch- and abrasion-resistant
recording. coating and physical matting of plastics
WO2013062090A1 May 2nd 2013. substrates, more particularly polymethyl
DIC CORPORATION
methacrylate, with nanocomposite coating
An inkjet ink for printing fine detail avoiding reticulation material.
or spreading. WO2012013364A1 Feb 2nd 2012.
61
Part B: Materials
EVONIK ROEHM GMBH LG CHEM LTD

A solution for protecting polymethyl methacrylate which An anti-reflection film applied as a single wet coat which
entails post-curing a coating using excimer ultraviolet subsequently undergoes phase separation.
in order to assure adhesion of the matte coat.
Method for producing coatings having anti-
UV-curable antireflective coating composition, reflection properties.
antireflective coating film using the same, and US20130068137A2 Mar 21st 2013.
its manufacturing method. An anti-reflection coating for temperature-sensitive
US8110249 Feb 7th 2012. substrates.
LG CHEM LTD
A ultraviolet-curable metal fluoride containing coating
that avoids vacuum coating solutions for anti-
reflectance.
A composition for a scented paint.
WO2011100510A1 Aug 18th 2011.
Antireflective coating composition, antireflective
DIAMOND MARKETING AGENCY LLC
film, and preparation method thereof.
A paint containing microencapsulated scented oil.
WO2011126303A3 Mar 8th 2012.
LG CHEM LTD
A coating with a higher level of matte.
Releasable entrapment of aroma using a
polymeric matrix.
WO2012006328A1 Jan 12th 2012.
PEPSICO INC
method for making paint composition, and
A coating that encapsulates an aroma in a container
diffusively light reflective articles.
closure.
EP2431428A1 Mar 21st 2012.
WHITEOPTICS LLC
Patterned application of activated carbon ink.
A coating that can be applied in-mould that provides
AU2005322555B2 Aug 2nd 2012.
diffuse light reflection.
KIMBERLY CLARK CO
An odour control decorative ink that incorporates
Anti-glare coating composition and anti-
activated carbon.
glare coating film having superior abrasion
resistance and contamination resistance.
Scented thermochromic ink.
WO2012008757A3 May 31st 2012.
US20120315412A1 Dec 13th 2012.
LG CHEM LTD
A thermochromic ink contains scented microcapsules.
A ultraviolet-curable easy-to-clean anti-glare coating.
System and method for applying aroma

Novel matting agent for UV varnishes.
releasing material to product packaging.
US20120202914A1 Aug 9th 2012.
US20130105066A1 May 2nd 2013.
EVONIK DEGUSSA GMBH
A coating that releases aroma after being manipulated.
An improved surface-treated silicon dioxide matting
agent for ultraviolet curable coatings.
Scented preparation comprising scented
compound.
Polyolefin-based composite resin spherical WO2013104826A1 Jul 18th 2013.
particles, coating composition, and coated KA AROMA MARKETING OY
object. A scented composition for screen printing inks.
US20120208926A1 Aug 16th 2012.
SUMITOMO SEIKA CHEMICALS CO LTD
A matting agent that provides excellent scratch 7.4.7 Surface Quality Improvement
resistance and a soft-feel.
Liquid coatings or inks for polymer substrates:
Antireflective coating composition, US20110014477, Jan 20th 2011, FUJIKURA
antireflective film, and preparation method KASEI; WO2011011363A2, Jan 27th 2011. PPG;
thereof. US20110059251A1, Mar 10th 2011. BASF;
EP2557130A2 Feb 13th 2013. EP2053101B1, Apr 27th 2011. AGFA; US20110151218A1,
62
Part B: Materials
Jun 23rd 2011. BAYER MATERIALSCIENCE; US7981506, INTERNAT; WO2012087661A2, Jun 28th 2012. 3M;
July 19th 2011. SEIKO EPSON; US20110177350A1, US20120189843A1, Jul 26th 2012; US20120214893A1,
Jul 21st 2011. EVONIK DEGUSSA; WO2011095186A1, Aug 23rd 2012. CYTONIX; WO2012133443A1, Oct
Aug 11th 2011. BASF COATINGS; US7999026, Aug 4th 2012. KANEKA; US20120251706A1, Oct 4th
16th 2011. NISSAN CHEMICAL; WO2011105382A1, 2012; WO2013008645A1, Jan 17th 2013. TORAY;
Sep 1st 2011. ASAHI GLASS; EP2371871A1, Oct WO2013015600A2, Jan 31st 2013. SAMSUNG
5th 2011. TOAGOSEI; WO2011131463A1, Oct 27th ELECTRONICS; WO2013014546A2, Jan 31st 2013.
2011. BASF COATINGS; US8053486, Nov 18th 2011. KIMBERLY-CLARK; WO2013012252A3, Apr 4th 2013.
ETERNAL CHEMICAL; EP1950262B1, Nov 23rd LG CHEM; EP2589615A2, May 8th 2013. SHIN-ETSU
2011. NISSAN MOTOR; WO2011145196A1, Nov CHEMICAL; EP2604668A1, Jun 19th 2013. ASAHI
24th 2011. RIKEN TECHNOS; EP2058343, Dec 21st GLASS; WO2013105429A1, Jul 18th 2013. TORAY.
2011. ARKEMA; WO2011119272A3, Jan 5th 2012.
HENKEL; WO2011099766A3, Jan 5th 2012. LG
Liquid coatings with antistatic/conductive
HAUSYS; US20120040120A1, Feb 16th 2012. BASF;
properties for polymer substrates:
US20110248223A1, Oct 13th 2011 ESSILOR;
WO2012024402A1, Feb 23rd 2012. E I DU PONT
US20120010316A1, Jan 12th 2012. BAYER
DE NEMOURS; US20120065322A1, Mar 15th 2012.
MATERIALSCIENCE; US20120015179A1, Jan 19th 2012.
EVONIK ROEHM; EP1944344B1, Mar 28th 2012.
ESSILOR; US20120097897A1, Apr 26th 2012. HERAEUS
SHOWA DENKO; EP2433991A1, Mar 28th 2012.
PREC. METALS; WO2012093995A1, Jul 12th 2012.
TOKUYAMA CORPORATION; US20120076994A1,
ESSILOR; EP2487213A1, Aug 15th 2012. MITSUBISHI
Mar 29th 2012. SUN CHEMICAL; WO2012046784A1,
MATERIALS; US20120256139A1, Oct 11th 2012. BAYER
Apr 12th 2012. ASAHI GLASS; US20120121910A1,
MATERIALSCIENCE; WO2013084847A1, Jun 13th 2013.
May 17th 2012. PPG; WO2012099125A1, Jul 26th
KAO.
2012. ASAHI GLASS; US20120202911A1, Aug 9th
2012. TOAGOSEI; EP2261289B1, Aug 15th 2012. UV curable coating composition having self-
FUJIKURA KASEI; EP2489510A1, Aug 22nd 2012. healing capabilities, coating film and method
ORIGIN ELECTRIC; US20120219788A1, Aug 30th for preparing coating film.
2012. BAYER MATERIALSCIENCE; EP2508579A1, WO2012111947A2 Aug 23rd 2012.
Oct 10th 2012. SHIN-ETSU CHEMICAL; US8303704, LG CHEM LTD
Nov 6th 2012. LG CHEM LTD; CN101848950B, Nov A self-healing scratch-resistant coating.
7th 2012. ARKEMA; US20120288706A1, Nov 15th
2012. EVONIK ROEHM; EP2527047A1, Nov 28th 2012.
Coating compositions providing improved mar
ASAHI GLASS COMPANY; WO2012160894A1, Nov
and scratch resistance and methods of using
29th 2012. DAICEL; EP1948748B1, Dec 12th 2012.
the same.
AKZO NOBEL COATINGS; US20130034735A1, Feb 7th
US8258225 Sep 4th 2012.
2013, TOYOTA; EP1489148B1, Feb 27th 2013. BASF
PPG INDUSTRIES OHIO INC
JAPAN; WO2013035263A1, Mar 14th 2013. TOYOTA;
A powder coating with improved scratch and mar
WO2013079478A1, Jun 6th 2013. BAYER; EP2213697B1,
resistance.
Sep 4th 2013. DIC CORPORATION; WO2013129531A1,
Sep 6th 2013. HOYA CORPORATION; US8536274, Sep
Ultraviolet light curing coating modified by
17th 2013. BASF COATINGS JAPAN; EP2639272A1,
fluorine-containing polymer nanoparticle and
Sep 18th 2013. CYTEC SURFACE SPECIALTIES;
preparation method thereof.
CN101747818B, Oct 30th 2013. GUANGZHOU KINTE.
CN102120914B Oct 3rd 2012.
Liquid coatings with anti-fingerprint or easy- GUANGZHOU CHEMISTRY CO LTD CHINESE ACADEMY OF
to-clean properties for polymer substrates: SCIENCES FOSHAN FUNCTIONAL POLYMER MATERIALS AND
WO2011002668A1, Jan 6th2011. 3M; EP2215171A4, FINE CHEMICALS PROFESSIONAL CT
May 4th 2011; US20110200826A1, Aug 18th 2011. E I A ultraviolet-curable superhydrophobic and self-
DU PONT DE NEMOURS; US8071195, Dec 6th 2011. cleaning coating.
TDK; WO2011157657A1, Dec 22nd 2011. SOLVAY
SOLEXIS; WO2012003004A2, Jan 5th 2012. UNIV OF Reactive mixture for coating molded objects
PITTSBURGH; WO2012008970A1, Jan 19th 2012. by means of reaction injection molding and
BRIGHAM YOUNG UNIV; WO2012018160A1, Feb coated molded object.
9th 2012. DNF; US20120107581A1, May 3rd 2012; US20130001825A1 Jan 3rd 2013.
WO2012030945A3, May 31st 2012. HONEYWELL EVONIK ROEHM GMBH
63
Part B: Materials
An in-mould scratch-resistant coating which can be Spray powder having improved morphology
cured rapidly. for producing plastic molded skins.
WO2013150112A1 Oct 10th 2013.
Solventborne clearcoat coating composition, RESITECH GERMANY GMBH
process for producing it and use thereof. A powder for plastic moulded skins that creates fewer
WO2013076208A1 May 30th 2013. defects and reduces overspray.
BASF COATINGS GMBH
A thermally curing clearcoat formulation with good Low-viscosity varnish composition for
stability in recirculating systems and application quality. substrate printed by inkjet.
WO2013160385A1 Oct 31st 2013.
Coating for coating plastic surfaces which MGI FRANCE
have grooves. A ultraviolet-curable low viscosity varnish for inkjet
WO2013139824A1 Sep 26th 2013. application. (See also WO2013160384A1)
PROFINE GMBH
A coating for hiding scratches on polyvinyl chloride Resin substrate provided with hardcoat
surfaces. coating, and method for producing same.
EP2666629A1 Nov 27th 2013.
ASAHI GLASS COMPANY LIMITED
A humidity and weather-resistant primer and hardcoat
top layer for a polymer substrate.
References
1. NobleCure® - the Standard UV LED Solution for Curing Applications Heraeus-Noblelight.
http://www.heraeus-noblelight.com/en/products_1/optoelektronik_1/noblecure.aspx {Accessed
June 2014}
2. Lumen Dynamics Reveals Its Revolutionary Excelerate® Air-Cooled UV LED Technology Which
Boasts Highest Irradiance for Rapid Printing Speeds, Lumen Dynamics.
http://www.ldgi.com {Accessed June 2014}
3. Phoseon Technology Launches FirePower Family of Products, Coatings World.

http://www.coatingsworld.com {Accessed June 2014}
4. B. Strehmel, European Coatings Journal, 2012, Issue 9, 20.
5. Increasing Process Efficiency – Curing of Three Dimensional Subjects with Only One UV Lamp,
Radtech Europe.
http://www.radtech-europe.com/knowledge-center/articles/equipment-and-process-control/
increasing-process-efficiency-curing-three {Accessed June 2014}}
6. U.V. Läuppi in Proceedings of the Radtech Europe, The Hague, The Netherlands, 2011.
7. JetCURE LED, Honle UV Technology.

http://www.hoenle.de/en/product/led-units/jetCURE_LED {Accessed June 2014}
8. UV Special-Effects Inks, Package Design.

http://www.packagedesignmag.com {Accessed June 2014}
9. S. Schlögl, M. Reischl, V. Ribitsch and W. Kem, Progress in Organic Coatings, 2012, 73, 1, 54.
10. Radiation-Curing Multifunctional Additives, Evonik Industries.

http://www.tego.de/product/tego/en/products/additives/radiation-curing-additives/pages/default.
aspx {Accessed June 2014}
64
Part B: Materials
11. Dow Corning Announces Advances in Spray Coating Technology for Easy-to-Clean Touch Screens
and Displays, AZoM.
http://www.azom.com {Accessed June 2014}
12. Pepsi Looking to Add Aroma to its Packaging, Plastics & Rubber Weekly.
http://www.prw.com {Accessed June 2014}
13. Automotive Industry Sees a Very Clear Light in the Development Tunnel, European Coatings.
http://www.european-coatings.com {Accessed June 2014}
14. P. De Groote, M. Tielemans, J. Zhang and M. Hutchins, European Coatings Journal, 2013, 10, 20.
15. SilFORT* UVHC7800, Momentive.

http://www.momentive.com {Accessed June 2014}
16. NEI Coating Provides Scratch Resistance, Enhanced Lubricity, Products Finishing.
http://www.pfonline.com {Accessed June 2014}
17. TEGO® Twin 4200 - The New Universal Wetting and Anti-Cratering Additive, Evonik Industries AG.
http://corporate.evonik.com {Accessed June 2014}
18. Allnex Unveils UV Curable Urethane Acrylates, EBECRYL 8602 and EBECRYL 8415 for Hardcoats,
Coatings World.
http://www.coatingsworld.com {Accessed June 2014}
65
Part B: Materials
8 Substrate Polymer Resins, Blends and Additives
Table 8.1
5 Acoustic effects 0 0 1 1
8.1 Background
This section focuses on innovation in thermoplastic substrate resins, blends and additives relating to
gains in a wide range of aesthetic properties other than colour. Table 8.1 shows the predominant trends
towards three-dimensional (3D), tactile and depth effects followed closely by surface quality improvement.
The latter shows increased focus year-to-year. Polymer blends designed for selective plating using laser
direct structuring are covered in Part D, Section 25.
An innovation may entail new polymer engineering in order to obtain the desired properties such as
surface appearance, compatibility with decorative materials, processability, tactile effects, or transparency.
Many solutions, however, involve polymer blends and/or the incorporation of additives, and so the choice
of mixing and dispersion technique and process conditions are important. This is especially true of
nanocomposites, which have higher surface area to mass ratios, and therefore, often require little addition.
The relative compatibility of any additive with the polymer and its potential diffusivity are significant factors;
an efficient anti-static or slip additive must migrate to the surface, and therefore both properties need to
be low and high, respectively, whereas a clarifying additive should remain well-dispersed throughout the
bulk of the polymer. A tendency for any additive to show visible signs of chalking, bleeding or blooming
must be low. As with any additive or pigment, addition levels, dispersion, and choice of any carrier, must
be sufficiently controlled so as not to yield weaknesses at weld lines or harm the stress crack resistance
of the moulded substrate or other mechanical properties. Mixing techniques range from simple tumbling
with polymer pellets, pre-extrusion as a masterbatch concentrate, or complete pre-compounding. For
nanocomposites (e.g., carbon nanotubes and nanoclays), where effective exfoliation must take place in
order to eliminate agglomerations, special twin-screw extrusion techniques have been developed and
much research continues to optimise the processing.
Among tactile effects, electrically conductive polymers also provide a cold touch, even though their
primary usage is for functional purposes. The high loading levels often used means that surface quality
may not be cosmetic, but a noticeable cold touch can be perceived at 4 W/m.K, whereas up to ten times
higher values are now available.
Millad® NX™ 8000 is a new clarifying agent for from MILLIKEN & COMPANY [1]; improved clarity,
heat conductance and resistance from nanocomposites have been developed by the UNIVERSITY
66
Part B: Materials
OF BAYREUTH [2]; ROQUETTE has announced its Disorben® clarifying products [3]; FS KOREA and
PORTOLA TECH INTERNATIONAL have developed products in wood-plastic composite materials [4];
STAR THERMOPLASTICS has developed a super-tacky 30-70° Shore A thermoplastic elastomer (TPE)
series for injection moulding called StarGrip-X 5000 [5]; researchers at DUKE UNIVERSITY have developed
a soft polymer that changes texture up to 1 mm when a voltage is applied [6]; nGrain wood-grain effect
masterbatch has been developed by AMERICHEM LTD., [7]; KRAIBURG TPE has developed Copec®
haptic masterbatches [8]; Therma-Tech™ compounds from POLYONE are 50-100 times more conductive
than conventional plastics [9]; compounds from RTP COMPANY provide thermal conductivities of up to
35 W/m.K [10]; CarboTherm™ hexagonal boron nitride from SAINT-GOBAIN makes plastics thermally
conductive [11]; at K 2013, HEXPOL TPE displayed Lifocork haptic blends of flexible polymers and cork
[12]; and PERFORMANCE ADDITIVES has introduced Ultraplast™ WF 109 AF for improved processing
of wood-plastic composites [13].
ARPRO from JSP is a lightweight, low-squeak material [14].
A new process for integrating fragrance or neutralising odours during compounding comes from EXILICA
and SEVEN SCENT [15]; SILVERGATE PLASTICS have claimed to have developed masterbatches with
a pleasant taste [16].
8.2.4 Surface Improvement
Spanish scientists have developed a new polymer that auto-heals and is called Terminator [17].
8.3 Patent Trends
Table 8.2
3D, tactile and depth effects Clarity • Cold touch (thermally conductive) • Fibre filling • Imitation stone • Imitation
wood • Leather pellet masterbatch • Low haze • Rubbery • Slippery • Soft touch •
Tactile • Translucent
Acoustic effects Low friction
Gloss and matte effects Gloss modification • Matte effects
Olfactory effects Scented latex toy
Surface quality improvement Class A surfaces • Decoratable, paintable, plateable materials • Discoloration
resistance • Gloss • Low clarifier bleeding • Low crazing • Non-blistering • Scratch
resistance • Self stratifying hard layer • Surface finish • Thermally conductive
(reduction of cycle time without deformation) • Wetting improvement of inks and
coatings
Table 8.3 ranks the focus on types of 3D, tactile and depth effects.
67
Part B: Materials
Table 8.3
Repartition of 3D, tactile and depth effects
Rank Effect Number of patents %
1 Soft touch and haptic 11 50
2 Translucency 9 41
3 Cold touch (conductive) 1 5
4 Slip 1 5
DOW is the company that innovates the most as shown in Table 8.4.
Table 8.4
1 DOW CORNING CORPORATION 4 9
Acrylonitrile-butadiene-styrene materials with improved surfaces for finishing operations; additives for
improved surfaces; a self-stratifying hard coat layer; cold touch effect; imitation stone; leather pellet
masterbatches; a metal soap-free lubricant to improve wettability and adhesion of inks and coatings.
Surface quality improvement, notably gloss, paintability, and scratch resistance; 3D, tactile and depth
effects, and notably artificial material effects and soft touch effects.
8.4 Listed Patent Literature 2011-2103 (for dispersed in a polypropylene in such a manner that the
search phrases see Part A, Section 2) molten elastomer particles are frozen in an elongated
form that yields low haze and high transparency.
8.4.1 Three-dimensional, Tactile and Depth

Effects Organic silicone particles, method of
producing organic silicone particles, and
cosmetic, resin composition and coating
Highly thermally-conductive moldable
composition containing organic silicone
thermoplastic composites and compositions.
particles.
EP2287244A1 Feb 23rd 2011.
WO2011111179A1 Sep 15th 2011.
LAIRD TECHNOLOGIES INC
TAKEMOTO YUSHI KABUSHIKI KAISHA
Compositions with conductivities in the order of 20-35
W/m.oK. Porous hollow organic silicone spheres enable superior
optical, tactile and matting properties in polymers and
Molded polymeric article with low haze and coatings.
high clarity.
WO2011066194A1 Jun 3rd 2011. Transparent molding composition.
DOW GLOBAL TECHNOLOGIES LLC US20110244209A1 Oct 6th 2011.
This invention seeks to avoid haze problems caused DEGUSSA AG
by blending polymers with different refractive indices. A transparent polyamide resin suitable for decoration
A discontinuous phase of olefin-based elastomer is to be used for moulding or laminating.
68
Part B: Materials
Moulding composition with reduced light Compositions and methods for making
scattering. clarified aesthetically enhanced articles.
WO2011138185A1 Nov 10th 2011. US20120316272A1 Dec 13th 2012.
BASF SE A very low loading (<5 ppm) of colouring agent improves
A moulding material with good translucency and the clarity of a moulded polypropylene component.
minimum haze without compromising impact resistance.
Painted polyolefin articles.
Modified polypropylene for packaging US20120308752A1 Dec 6th 2012.
applications. Soft rubbery leachable-free polyolefin materials that
WO2011159552A1 Dec 22nd 2011. are paintable without the need for a primer.
FINA TECHNOLOGY INC
A metallocene polypropylene blended with clarifier that Polymeric compositions and processes for
produces a gloss level 6% greater gloss than a Ziegler- molding articles.
Natta polypropylene. US20130012608A1 Jan 10th 2013.
DOW GLOBAL TECHNOLOGIES INC
Super-soft thermoplastic elastomers. A polyolefin composition that can provide a resistant
WO2011140381A3 Mar 29th 2012. soft-touch effect.
POLYONE CORPORATION
A soft thermoplastic elastomer resulting from low-cost Cotton straw enhanced plastic wood product
manufacturing processes. and preparation method thereof.
WO2013013473A1 Jan 31st 2013.
Method for producing leather pellets and SHENZHEN GEM HIGH-TECH CO LTD
compound granules, and use thereof. A plastic material integrating wood fibre and cotton.
US20120133071A1 May 31st 2012.
BADER GMBH & CO KG Fully plastic wood-imitation material and
A method for producing leather pellet masterbatches preparation method thereof.
for injection moulding. Manufactured products have CN102336977B Mar 27th 2013.
original optical and haptic properties. UNIV XIAMEN
An imitation wood material that does not contain wood
Polyamide moulding compositions based on and can be injection or extrusion moulded.
mixtures made of transparent copolyamides
and of aliphatic homopolyamides for Ageing resistant wood plastic composite
producing transparent mouldings. modified by titanium oxide fiber and lignin and
US20120142810A1 Jun 7th 2012. preparation method thereof.
EMS-PATENT AG CN102417738B Mar 27th 2013.
An improved translucent and low-haze polyamide resin CHANGSHU YUTYRONE ADVANCED WEAR MATERIALS
for injection moulding. TECHNOLOGY CO LTD
An ageing-resistant wood-plastic composite.
Articles having improved clarity, prepared
from propylene-ethylene copolymers. Wood-like co-extrusion PMMA modified
US20120207958A1 Aug 16th 2012. material and preparation method thereof.
FINA TECHNOLOGY INC CN101457006B Mar 27th 2013.
A low-haze polypropylene random copolymer. DONGGUAN JINFULIANG PLASTIC MA
A polymethyl methacrylate material with the appearance
Propylene impact copolymers having good of wood.
optical properties.
US20120302701A1 Nov 29th 2012. Straw plastic and preparation method thereof.
DOW GLOBAL TECHNOLOGIES LLC US20130237647A1 Sep 12th 2013.
Polypropylene copolymers with improved transparency JIANGSU JINHE HI-TECH CO LTD
and haze. (See also WO2012162396A2) A straw-containing polymer for moulding a wood
appearance.
69
Part B: Materials
Polymer compositions with improved surface 8.4.4 Olfactory Effects

properties.
US8541515 Sep 24th 2013. Releasable entrapment of aroma using a
TRILLIUM SPECIALTIES LLC polymeric matrix.
An improved release and slip agent that does not WO2012006328A1 Jan 12th 2012.
migrate. PEPSICO INC
A method for encapsulating an aroma in a container
Thermoplastic resin composite material closure.
modified with non-metallic material and
product manufacturing method using the same. Scented stuffed toy and method for producing
EP2471860A4 Oct 2nd 2013. the same.
SHANGHAI HUDA INVEST & DEV CO LTD US20120145091A1 Jun 14th 2012.
An imitation stone thermoplastic material for injection A compressible latex toy which has the scent of an
moulding. animal.
Polycarbonate blend articles and method of

producing the same. 8.4.5 Surface Quality Improvement
WO2013154694A1 Oct 17th 2013.
ROHM & HAAS COMPANY Multi-layer blow-molded container, and
A scratch-resistant and translucent polycarbonate/ process for production thereof.
polymethyl methacrylate blend with improved scratch WO2011090101A1 Jul 28th 2011.
resistance over polycarbonate. PRIME POLYMER CO LTD
A polypropylene high-gloss multi-layer container with
good surface appearance due to a propylene exterior
layer.
Thermoplastic resin composition for Additive for thermoplastic resin and method
squeaking noise reduction and squeaking for producing same, thermoplastic resin
noise reducing structure. composition and molded article.
WO2013031946A1 Mar 7th 2013. EP2418245A1 Feb 15th 2012.
TECHNO POLYMER CO LTD MITSUBISHI RAYON CO LTD
A polymer blend that reduces noise due to friction A tetrafluoroethylene and alkyl methacrylate additive
between two assembled parts. for improving surface finish and flame retarding
properties with improved dispersion characteristics in
8.4.3 Gloss and Matte Effects thermoplastic resins.
Thermoplastic resin composition having

Polymer blend for matte injection moulded
excellent flame retardancy, coloring properties
parts.
and scratch resistance.
US20110230610A1 Sep 22nd 2011.
WO2012036360A1 Mar 22nd 2012.
ROEHM GMBH & CO KG
LG CHEM LTD
A matte polymethyl methacrylate polymer mixture that
An acrylonitrile-butadiene-styrene/styrene-acrylonitrile
provides high abrasion resistance on moulded parts.
polymer with improved scratch resistance.
Method of modifying gloss with silica additives

Metallocene-produced polyethylene for glossy
and related products and uses.
plastic containers.
US20110263733A1 Oct 27th 2011.
US20120068385A1 Mar 22nd 2012.
BASF SE
Metallocene polyethylene was used to produce high
Silica containing additives that allow gloss modification
gloss polyethylene bottles with improved mechanical
without compromising scratch resistance or
properties and scratch resistance.
necessitating textured moulds.
70
Part B: Materials
Uncoated highly reflective impact-resistant Composition for coating and molded product
injection-molded article and process for using the same.
producing same. US8519052 Aug 27th 2013.
WO2012043790A1 Apr 5th 2012. TECHNO POLYMER CO LTD
ASAHI KASEI CHEMICALS CORPORATION An acrylonitrile-butadiene-styrene resin with improved
Rubber has been added to a thermoplastic resin in combination between coatability, adhesion and paint
order to improve surface gloss. solvent resistance.
High gloss thermoformed article and process ABS compositions with improved surface after
for producing same. heat-moisture storage.
WO2011031443A3 May 3rd 2012. US20130281595A1 Oct 24th 2013.
DOW GLOBAL TECHNOLOGIES LLC BAYER INTELLECTUAL PROPERTY GMBH
A process and material with a high melt strength and An acrylonitrile-butadiene-styrene material which
high gloss retention after thermoforming. does not blister and retains Class A surface quality for
metallising even after storage in high humidity and heat.
Metal plating polyacetal compositions.
US20130078481A1 Mar 28th 2013. Impact-modified polycarbonate compositions
TICONA LLC for the simplified production of low-
A plateable grade of polyoxymethylene. temperature resistant components with high-
gloss and matt component sections.
Partially metalized plastic product and WO2013150011A1 Oct 10th 2013.
manufacturing process. BAYER MATERIALSCIENCE AG
US2013156995A1 Jun 20th 2013. A high-gloss polcarbonate that can also readily
ALBEA SERVICES replicate mould surface features.
A polyolefin substrate suitable for direct metallising
by sputtering while maintaining good adhesion after Wood plastic composites and manufacturing
ultraviolet topcoating. method thereof.
WO2013151287A1 Oct 10th 2013.
Printable molded articles made from a LG HAUSYS LTD
polyoxymethylene polymer composition. Wood-plastic composites with improved discoloration
WO2013101624A1 Jul 4th 2013. resistance.
TICONA LLC
A decorable or paintable polyoxymethylene. Plastic bottles for perfume compositions
having improved crazing resistance.
Rubber modified acrylic resin composition US20130270212A1 Oct 17th 2013.
excellent in jet-blackness and molded product THE PROCTER & GAMBLE COMPANY
thereof. Polyethylene furanoate is used in various manners to
US20130184375A1 Jul 18th 2013. reduce crazing of polymer bottles containing perfume.
KANEKA CORPORATION
A jet-black rubber-modified acrylic resin. Thermally conductive polymer compostions to
reduce molding cycle time.
Method for improving the wettability and/or WO2013158741A1 Oct 24th 2013.
the adhesivity of plastic surfaces, in particular, MOMENTIVE PERFORMANCE MATERIALS INC
to facilitate printing. Boron nitride filler is used to reduce mould cycle time
US8501852 Aug 6th 2013. by increasing the thermal conductivity of a polymer.
PHOENIX CONTACT GMBH & CO KG
A metal soap-free lubricant (as opposed to conventional Polyester elastomer resin composition and
metal soap) is added to plastics substrate (acrylonitrile- moulded article formed using same.
butadiene-styrene and polybutylene terephthalate) for WO2013157593A1 Oct 24th 2013.
processability and in order to improve wettability and TOYOBO CO LTD
adhesion of inks and coatings. A clarified polyester elastomer with reduced bleeding
of the clarifier.
71
Part B: Materials
Resin blend for melting process. Polyolefin compositions having improved

US20130302615A1 Nov 14th 2013. optical and mechanical properties.
LG CHEM LTD US8617463 Dec 31st 2013.
A self-stratifying resin blend that produces a hard BOREALIS TECHNOLOGY OY
layer during moulding, thereby avoiding the need A polypropylene that retains its optical properties after
for secondary processing to produce a protective sterilisation.
hardcoat.
References
1. Clarifying Agent Gives Ultra-Clear Transparency to Food Containers and EBM Containers, Omnexus.
2. Miscible Nanocomposites to Offer Great Potential, European Coatings.

3. ROQUETTE in Expands Its Range with Third-Generation Sorbitol-Based Clarifier, Additives for
Polymers, 2013, 7, 4.
4. Shenzhen Reports Utilization of Wood-plastic Composite Materials for Cosmetic Packaging, Omnexus.
http://www.omnexus.com {Accessed June 2014}
5. Super-Tacky TPE for a Tight Grip, Plastics Technology.

http://www.ptonline.com {Accessed June 2014}
6. Process Allows Plastic to Adapt on Demand, Design News.

http://www.designnews.com {Accessed June 2014}
7. nGRAIN® Simulated Woodgrain, Americhem.

http://www.americhem.com/brands/ngrain {Accessed June 2014}
8. COPEC® - Great grip feeling and chemical resistance, Kraiburg.

http://www.kraiburg-tpe.com/en/products/copec {Accessed June 2014}
9. PolyOne Acclaimed for Its Metal-Replacing Therma-Tech™ Thermally Conductive Grades for
LEDs, Omnexus.
10. RTP Company Develops Thermally Conductive Compounds for Reducing Vehicle Weight by
Replacing Metal, RTP Co.
http://www.rtpcompany.co {Accessed June 2014}
11. Saint-Gobain Fillers Provide Thermal Conductivity to Plastics, Additives for Polymers, 2013, 6, 5.
12. TPE GROUP Set to be Corker at K, Eppm Magazine.

http://www.eppm.com {Accessed June 2014}
13. Performance Additives Extends Product Range for Wood–Plastic Composites, Additives for
Polymers, 2013, 9, 4.
14. ARPRO® Low-Squeak Makes Noise in the Automotive Market, British Plastics & Rubber.
http://www.britishplastics.co.uk{Accessed June 2014}
15. Exilica teams up with Seven for Fragrance Technology, European Plastics News.
http://www.europeanplasticsnews.com {Accessed June 2014}
72
Part B: Materials
16. Masterbatch Manufacturer Gets a Taste for Flavoured Plastics, British Plastics & Rubber.
http://www.britishplastics.co.uk {Accessed May 2014}
17. Spanish Scientists Reported First Self-Healing Polymer Called Terminator, AZoM.
73
Part B: Materials
74
Part C: In-Mould Processes
PART C: IN-MOULD PROCESSES
3
9 Coloration, Co-injection, Multilayer Moulding and Multiple Material

Moulding
Table 9.1
9.1 Background
This section covers moulding techniques that involve one or more colours, molten polymer layers or
materials to form an object. Surface quality improvement techniques for such processes are largely
covered in Part C, Section 13. A decorative intent is likely to include one or several of the following:
1. To provide colour to a substrate.
2. To protect, hide or enhance a substrate with an opaque coloured layer.
3. To provide a look of depth with a top translucent layer.
4. To provide a tactile, e.g., soft touch, finish (for relief surfaces obtained from mould cavity etching, see
Part C, Section 12).
5. To mould substrates in more than one colour.
6. To create a marbleised look or similar random effect, or the appearance of another material.
7. To create colour gradients by varying the thickness of a visible layer.
8. To mould substrates in more than one material (for the purpose of selective electroplating, see Part D,
Section 25).
9. To provide matte and gloss regions on the same part by using different resins.
Colours are usually provided by organic or inorganic pigments, and addition is very often achieved by
dosing pigment, masterbatch or liquid colour concentrates at the hopper. Good additive dispersion is
key and therefore dispersing aids, choice of any carrier media, total concentration, screw design and
temperature profile all have to be taken into consideration in order to optimise the process. The pigment
or additive must be broken down in order to remove any agglomeration and then wetted and effectively
enrobed by the base polymer. Pre-compounding, either to provide a concentrate for subsequent let-down
or a fully coloured polymer, may involve a range of high-shear mixers, blenders or multiple-screw extruders.
If substrates to be over-moulded have undergone an intermediate decoration or coating process, care

must be taken to choose gate designs and their position so as to minimise wash-out effects as a result
of injection temperatures and pressures.
75
Table 9.1 shows that three quarters of innovation here has focused on colour and three-dimensional (3D),
tactile and depth effects. To achieve any of the multiple decorative effects covered here, the substrate
may have to undergo successive injections on different machines, or alternatively be processed on a
single multi-barrel machine with the use of rotating moulds, sliding dies, or robotic transfer between
different cavities on the same machine. In the case of multilayer solutions, the different materials may be
co-extruded through the same die or be over-moulded.
Terms used for techniques referred to for such effects include bi-injection, co-extrusion, co-injection,
core-back moulding, insert moulding (IM), marbleising, multi-material, multi-shot moulding, over-moulding,
and phase-separation or self-stratification moulding.
This subject area is predominantly classified using either of International Patent Classification (IPC)
codes B29C (Shaping or Joining of Plastics; Shaping of Substances in a Plastic State, in General; After-
Treatment of the Shaped Products), and/or B32B (Layered Products. Outside the realm of aesthetic
effects covered here, there is a significant amount of innovative activity around the use of multilayer
moulding for barrier properties.
9.2.1 Colouring Processes
Recently publicised innovation includes FRAUNHOFER’s work to employ CO2 in order to impregnate
plastics with dyes or medical compounds [1]; NOVOSYSTEMS have developed Novopearls, which
are small granules in wax dispersions as an alternative to masterbatch or liquid colour [2]; CLARIANT
MASTERBATCHES’ new Liquid Vehicle Technology for extrusion blow moulding bottles allows higher
concentrations without screw slippage or weld-line issues [3]; SUMITOMO (SHI) DEMAG has developed
a rapid colour change process called activeColourChange [4]; the KRAUSSMAFFEI GROUP showed
its quick colour change and direct colouring screw at K 2013 [5]; and ACCURATE talked of gravimetric
feeder performance for moulding [6].
9.2.2 Processing
MOLD-MASTERS announced its Iris co-injection technology for mounting to the tool on single-screw
machines [7], and at K 2013 demonstrated it by including an ethylene-vinyl-alcohol barrier layer in a
16-cavity high-density polyethylene closure mould with detection equipment provided by IMD, Brügg,
Switzerland. Two other stands at K 2013 showed thin-walled containers also being moulded with Iris
technology [8]; The IKV INSTITUTE OF PLASTICS PROCESSING has employed variotherm dynamic heating
and cooling in order to improve interlayer adhesion between certain materials including polypropylene,
polyamide and thermoplastic elastomers [9]; INSA at Lyon, France, has developed a method for visualising
polymer behaviour in an injection moulding barrel [10]; researchers in Bangkok have reported on a design
of experiments for purging a moulding machine [11]. NORDSON XALOY has developed its Twinshot®
process that uses a special screw for injection moulding to produce two layers of different materials, e.g.,
a base material with soft touch surface [12].
76
9.3 Patent Trends
Table 9.2
3D, tactile and depth effects Cushioning • Elastomer coating • Foamed layer • Imitation wood • Integrally
moulded indicia • Multi-layer depth effect • Partially tactile surface • Skins • Tactile
effects
Colour effects Colour control • Colour gradient • Colour layer manipulation • Colour swirls, waves,
streaks • Improved colour mixing • In-line compounding • Multi-colour effects •
Variable colouring • Variable stripes in extrusion
Metallic or reflective effects Crystal look • Foamed cell metallic effect • Improved pigment dispersion •
Refracted light • Self-stratification of metallic layer
Surface quality improvement Flash reduction • Surface quality improvement
Patents here are dominated by many different ways to create colour effects as well as 3D, tactile and
depth effects, as shown in Table 9.2, and these are ranked in Table 9.3 for colour effects and Table 9.4
for 3D, tactile and depth effects. Of particular note in colour effects is the use of an internal co-extruded
layer which is deliberately varied in order to produce gradients, swirls and so on (e.g., WO2011137997A2
10th November 2011, CLARIANT MASTERBATCHES (ITALIA) SPA [13]; EP1876009A4 18th July 2012,
YOSHINO KOGYOSHO CO LTD) [14]. US8061541 (22nd November 2011, CONOPCO INC) [15] describes
using an internal blowing agent to selectively create 3D patterns. Creating relief surfaces via mould surface
manipulation is covered in Part C, Section 12.
Table 9.3
Repartition of methods used to create colour effects
Rank Method Number of patents %
1 Layer manipulation 6 33
2 Masterbatch, additive, blend and partial mixing 5 28
3 Multi-material/multi-shot 4 22
4 Variable colour feed 2 11
5 Extrusion manipulation 1 6
Table 9.4
Repartition of methods used to create 3D, tactile and depth effects
1 Skinning with molten polymer 5 42
2 Imitation material effects 3 25
3 Internal layer manipulation 3 25
4 Thick translucent outer layer 1 8
In the realm of metallic effects, US8197730 12th June 2012, COOL OPTIONS INC [16], describes self-
stratification so that a metal skin is formed on the polymer surface from a polymer blend containing metal.
Patents related to the use of multi-shot moulding to enable subsequent selective metallisation by plating
are covered in Part D, Section 25.
77
Top ranking innovators are listed in Table 9.5.
Table 9.5
1 TOYO SEIKAN 4 10
2 YOSHINO KOGYOSHO 3 8
Integrally moulded indicia; intermediate foamed layer; varying inner coloured layer; metallic appearance
from foamed cells; and metallic surface from self-stratification.
Varying inner layer or multi-material moulding for colour effects; multi-shot or multi-material moulding.
9.4 Listed Patent Literature 2011-2103 (for Blow molded camouflage bottle.
search phrases see Part A, Section 2) US8061541 Nov 22nd 2011.
CONOPCO INC
A 3-layer blow moulded container contains an
9.4.1 Three-dimensional, Tactile and Depth intermediate layer comprised of a foamed resin to give
Effects an unevenly distributed patterned colour.
Multi-layered plastic container having superior Plastic article.

US8080295 Dec 20th 2011.
appearance characteristics.
PLASTIPAK PACKAGING INC
WO2011033928A1 Mar 24th 2011.
A method for moulding a partial tactile surface onto an
TOYO SEIKAN KAISHA LTD
extrusion blow moulded article.
A multi-layer container with a visual depth effect.
Coinjection hot runner injection molding
Patterned container having integrally molded system.
indicia. WO2012037682A3 Jun 21st 2012.
US20110155686A1 Jun 30th 2011 MOLD-MASTERS (2007) LIMITED
Co-injected patterning in an internal layer is proposed A hot runner system that produces a skin on a moulded
on a container in order to avoid the need for a separate part.
label.
Wet friction material for blow molded articles.
US2012171400A1 Jul 5th 2012
Modified injection-moulded part and method
In-mould application of a thermoplastic elastomer
for producing the same.
coating onto the handle of a blow moulded container.
WO2011121026A1 Oct 6th 2011.
ULRICH STIELER KUNSTSTOFF SERVICE EK
Co-extrusion process for making decorative
A method for providing a skin on an injection moulded moldings having simulated wood appearance
substrate using gas injection technology for the core. and decorative molding made thereby.
The core is injected secondly under pressure, and can US8323545 Dec 4th 2012.
be a soft material, e.g., for a shoe sole. PLASTIBEC INC
78
A co-extrusion method for profiles designed to produce An internal coloured layer of a polyethylene terephthalate
a simulated wood appearance on the surface. preform is varied in thickness in order to produce a
decorative effect.
Blend of plastics with wood particles.
US20130093114A1 Apr 18th 2013. Color variation control process for molding
RUST, HARALD plastic and composite multi-color articles.
A method for blending plastics with wood particles or US20120193826A1 Aug 2nd 2012.
particles of other fibre origin. A method for providing random colour variation in
injection moulded objects using variable feed.
Method for producing a multi-layered molding.
US8512616 Aug 20th 2013. Rotationally moulding two materials or
GEORG KAUFMANN FORMENBAU AG differently coloured materials.
A foamed layer is injected into a cavity between a GB2489591A Oct 3rd 2012.
substrate layer and decorative layer of a panel. LEAFIELD ENVIRONMENTAL LTD
A method for rotationally moulding two differently
Process for making a molded part. coloured materials.
WO2013122658A1 Aug 22nd 2013.
WEYERHAEUSER NR COMPANY Molded articles having a swirl-like or marble-
Moulding a substrate with the appearance of wood. like appearance and compositions for
producing same.
Container manufacturing method and WO2012138493A1 Oct 11th 2012.
structure of container product thereof. TICONA LLC
CN102049860B Sep 25th 2013. Immiscible polymers are used to create swirls or marble
XIANLIAN, LIU appearance in an injected article.
A method for producing tactile surfaces of varying
colours. Laminated and molded body and
manufacturing method therefor.
9.4.2 Colour Effects US20120256356A1 Oct 11th 2012.
YOSHINO KOGYOSHO CO LTD
Process for the production of multi-layer blow- Varying the thickness of a coloured layer in order to
molded hollow articles. produce a varied colour effect.
WO2011137997A2 Nov 10th 2011.
CLARIANT MASTERBATCHES (ITALIA) SPA Synthetic resin bottle having a gradation
Colour swirls, waves, droplet-like elevations, crater-like pattern, and process for injection molding the
cavities, streaks or varying transparency are achieved preform for use in such a bottle.
in a multi-layer bottle by a discontinuous layer of US20120263901A1 Oct 18th 2012.
controlled higher viscosity and extruded at a controlled YOSHINO KOGYOSHO CO LTD
lower rate than the continuous layer from a mandrel Parison manipulation is used to vary the thickness of a
head co-extrusion die. colouring layer. (See also US20120263900A1)
Method and extrusion machine for Moulding die for multi-colour moulding,
manufacturing a blow moulded plastic method for moulding multi-coloured moulded
packaging or bottle and the bottle or article, and multi-coloured moulded article.
packaging obtained. WO2012141005A1 Oct 18th 2012.
WO2012045896A1 Apr 12th 2012. OLYMPUS CORPORATION
CASADEVAL A multi-colour moulding.
A decorative effect obtained in bottles by mixing two
materials. Two-color molding die and two-color molding
method.
Bottles with gradation patterns and process WO2012165592A1 Dec 6th 2012.
for injection molding of preforms. KOTO ENGRAVING CO LTD
EP1876009A4 Jul 18th 2012. A method for injecting a substrate with parts in different
YOSHINO KOGYOSHO CO LTD colours.
79
Method and apparatus for forming extruded 9.4.3 Metallic or Reflective Effects
striped plastic products with variations in
width of the stripes along the length of the Molding method for forming in-mold
products and for blow molding articles formed metallized polymer components.
from such extruded parts.
US8197730 Jun 12th 2012.
US20120305578A1 Dec 6th 2012.
COOL OPTIONS INC
A method for varying the widths of coloured stripes of
A metallised injection moulded substrate is formed by
an extruded parison in order to produce an object with
self-stratification so that there is a net concentration
a pronounced multi-colour pattern.
of metal alloy on its outer surface. The metallic layer
is provided by a low melting-point metallic alloy, such
Two-color molded article and process for
as 95% tin and 5% antimony, 60% tin and 40% zinc,
production thereof.
where in each case the polymer has about the same
US20130004725A1 Jan 3rd 2013.
melting point as the alloy.
NIFCO INC
A method for moulding a two-colour article.
Preparation method for aesthetic resin for
improving affinity of aluminum powder pigment.
Coloured polymeric moulded bodies, and
CN102372904B Jan 23rd 2013.
method and device for producing the moulded
SHANGHAI KUMHO SUNNY PLASTICS
bodies.
A method for improving the dispersion of aluminium
WO2013037468A1 Mar 21st 2013.
KLOECKNER PENTAPLAST GMBH & CO KG
powder pigment in polymer.
Improved automatic colour control for moulded objects.
Plastic article and method for manufacturing
Just-in-time compounding in an injection same.
molding machine. US20130142999A1 Jun 6th 2013.
US20130072627A1 Mar 21st 2013. FIH (HONG KONG) LIMITED
RUTGERS, THE STATE UNIVERSITY OF NEW JERSEY A 2-layer moulded part has a crystal look.
Axial fluted extension elements are incorporated into
the screw of an injection moulding machine in order to Toothbrush with refractive faces.
avoid the need for pre-compounding. US20130174366A1 Jul 11th 2013.
RANIR LLC
Method for forming color swirls in plastic Refracted light is used to provide a visual effect.
containers.
WO2013040194A1 Mar 21st 2013. Stretched foam plastic molded article having
PEPSICO INC metallic appearance.
Methods for producing colour swirls in bottles include WO2013146109A1 Oct 3rd 2013.
a notched screw and other means. TOYO SEIKAN GROUP HOLDINGS LTD
Optical reflection from elongated foam cells coupled
Method of manufacturing a preform. with non-flake pigment produces a gold or silver
WO2013040344A1 Mar 21st 2013. metallic appearance.
PEPSICO INC
Techniques for varying the colour of an intermediate or
outer layer of a bottle.
Injection molding compounder. Two-color molded article and production

WO2013121049A1 Aug 22nd 2013. method thereof.
EXIPNOS UG WO2011096443A1 Aug 11th 2011.
An in-line compounder for injection moulding. NIFCO INC
A 2-colour moulded object without burn marks or weld
Plastic container with excellent decoration. lines.
WO2013153855A1 Oct 17th 2013.
TOYO SEIKAN GROUP HOLDINGS LTD High-gloss multi-layer plastic container.
A coloured layer of gradated thickness provides a US8097317 Jan 17th 2012.
decorative effect in a multi-layer container. TOYO SEIKAN KAISHA LTD
80
A solution for manufacturing a multi-layer container Apparatus and process for producing
consisting of polyester and polyolefin layers with a products from pigment-containing polymer
lustre pigment and superior aesthetic surface quality mixtures.
which includes adding a lubricant to the intermediate US20130113134A1 May 9th 2013.
adhesive layer. BAYER INTELLECTUAL PROPERTY GMBH
A method for melt compounding of black masterbatch
Roto-moulded articles comprising a layer of containing polycarbonate in order to improve surface
polyolefin and polyester. appearance of the final product.
WO2013034702A1 Mar 14th 2013.
TOTAL RESEARCH & TECHNOLOGY FELUY Deformable weldment of cosmetic
A roto-moulding material blend that improves surface overmolding.
quality. (See also WO2013034701A1) US20130307192A1 Nov 21st 2013.
A method for avoiding flash on over-moulded products
involves using a deformable portion in the mould.
References
1. Impregnating Plastics with Carbon Dioxide, Fraunhofer.
http://www.fraunhofer.de {Accessed June 2014}
2. Additives for Polymers, 2011, 12, 3.
3. Liquid Colour Technology Developed for Polyolefin Blow Moulding, Observatorio del Plástico.
http://www.observatorioplastico.com/detalle_noticia.php?no_id=181402&seccion=&id_categoria=
{Accessed May 2014}
4. activeColourChange and SL Plastification System – New Technology Modules from Sumitomo

(SHI) DEMAG Increase Performance during Injection Moulding, Sumitomo (SHI) DeMAG.
http://www.sumitomo-shi-demag.eu/home.html {Accessed June 2014}
5. 5-Zone Mixing Screw Improves Melt Quality, KraussMaffei Group.

http://www.kraussmaffeigroup.com {Accessed June 2014}
6. T.D. Messner, Improve the Performance of Your Gravimetric Feeder, Plastics Technology.
7. T. Deligio, Mold-Mounted Co-injection Unit Generates Buzz for Mold-Masters, Plastics Today.
http://www.plasticstoday.com {Accessed June 2014}
8. Mold-Masters Iris Co-Injection Technology is Very Busy at K 2013, be Sure to Catch It Running Live
in a Number of Booths, Mold Masters.
http://www.moldmasters.com/index.php?s=company&o=article&id=114 {Accessed June 2014}
9. D. Vink, IKV Institute Strengthens Multicomponents, European Plastics News.

10. T.L. Pham, J. Balcaen, S. Chhay, Y. Bereaux and J-Y. Charmeau in Proceedings of the SPE
EUROTEC 2013 Conference, Lyon, France, 2013, p.425.
11. W. Sriseubsai in Proceedings of the SPE EUROTEC 2013 Conference, Lyon, France, 2013, p.280.
12. D. Gray, Two-Shot Components Possible in Single-Shot Process, Eppm.

http://www.eppm.com {Accessed June 2014}
13. M. Torchio and C. Minotti, inventors; Clariant Masterbatches (Italia) SpA, assignee; WO2011137997A2,
2011.
81
14. A. Minoru, T. Tetsuo, S. Masato, S. Hiromi and C. Junichi, inventors; Yoshino Kogyosho Co Ltd,
assignee; EP1876009A4, 2012.
15. T.C. Trumpp, B.C. Domoy and J.K. Zaniewski, inventors; Conopco Inc., assignee; US8061541,
2011.
16. K.A. McCullough, inventor; Cool Options Inc., assignee; US8197730, 2012.
82
10 In-mould Coating and On-mould Painting
Table 10.1
10.1 Background
Processes have been developed in recent years to skin or coat a substrate during the injection moulding
process, most often using materials that have a low viscosity even in the unheated state and that are capable
of crosslinking. The result is an in-mould, painted or clear-coated substrate, and sometimes the technique is
also used in order to avoid a separate base coating step prior to any follow-on surface treatment process.
Techniques entail either: a) injecting a coating during the injection moulding cycle after partially retracting
the male part of the tool (core-back), or rotating or sliding the mould to provide a larger cavity, or b) spraying
the cavity with a coating, paint or powder prior to clamping (on-mould painting). Although rendering the
mould, equipment and overall process more complex, these solutions provide the distinct advantages of
avoiding post-painting operations, as well as the environmental issues often associated with these. They also
guarantee a more controllable final result because all the operations are carried out at the same time, and
thus, substrate surface quality is better controlled. Coatings commonly referred to in these developments
are often formulated with heat or ultraviolet (UV) curing liquid resins. Applications tend to be for shallow
shapes and low cavitation. Included here are a number of on-mould applications, not necessarily directed
towards injection moulding processes, in order to illustrate the decorative potential for this type of process.
Table 10.1 shows that most of these processes are intended to provide 3D, tactile and depth effects.
Past innovations in this area, largely covered by the International Patent Classification (IPC) code B29C
(Shaping or Joining of Plastics; Shaping of Substances in a Plastic State, in General; after- Treatment of the
Shaped Products, e.g., Repairing), have included the Inspire process (developed by the UNIVERSITY OF
WARWICK, UK) for applying a powder coat in-mould, or by in-mould metallising (e.g., the interior surface
of reflectors) using JSW die-slide technology [1]. At the KUNSTSTOFF (K) show in 2010, KRAUSSMAFFEI
and EVONIK RÖHM demonstrated a process (CoverForm) for in-mould base coating a finish using this
technique before vacuum metallising by sputtering in-line with a PlastiCoater from IMPACT COATINGS.
The principal challenges faced by these technologies are: a) addressing deeper and more complex shapes,
and b) higher tool costs for an overall environment that on average sees increasingly shorter run lengths.
TVS MOTOR COMPANY has adopted in-mould spray painting (INSPIRE process) for its thermoset polyester
and skinned acrylonitrile-butadiene-styrene (ABS) substrates [2]; KRAUSSMAFFEI introduced its one-
step SkinForm process using an injected aliphatic polyurethane coating [3]; BAYER and KRAUSSMAFFEI
introduced the DirectSkinning process for in-moulding to apply soft touch coatings to moulded substrates
[4]; KRAUSSMAFFEI has developed its ColorForm in-mould lacquering process for its SpinForm 2K
injection moulding machine [5]; ENGEL demonstrated its Clearmelt technology [6]; ENGEL, GEORG
KAUFMANN, BASF and P-GROUP have co-developed the Dolphin process for producing a soft touch
effect on moulded substrates [7]; ENGEL, GEORG KAUFMANN, BASF and SO.F.TER have used the
Combimelt process and MuCell® technology to produce a soft-touch surface [8].
83
10.3 Patent Trends
Table 10.2
3D, tactile and depth Depth effect • Differently coloured moulded skins • In-mould coating a painted substrate
effects • In-mould UV curing • Skinning • Stonewash effect • Variegated skins
Surface quality In-mould applied vacuum coating basecoat
improvement
In-mould coating technology appears to be led by technologies provided by ENGEL and KRAUSSMAFFEI,
applied to many different product types. On-mould painting has received much attention from automotive
suppliers. Table 10.3 shows that the level of development activity in, in-mould coating is about the same
as on-mould painting. The activity in both is relatively high, in part because of an apparent surge in patent
activity in 2012.
Table 10.3
Repartition of principal patent subject trends
1 In-mould coating 11 50
2 On-mould painting 11 50
The most frequently innovating companies are listed in Table 10.4. Applications for automotive markets
appear to dominate.
Table 10.4
1 RECTICEL 4 19
2 KRAUSSMAFFEI 3 13
Differently coloured moulded skins, in-mould base coating, and variegated effects.
Depth effects and skinning.
10.4 List of Patent Literature 2011-2103 (for search phrases see Part A, Section 2)
In categorising patent focus, it is assumed by default that the creation of 3D, tactile and depth effects is
intended unless otherwise specified.
84
10.4.1 Three-dimensional, Tactile and Soft component with decorative surface finish.
Depth Effects – In-mould Coating US20130017356A1 Jan 17th 2013.
JOHNSON CONTROLS TECHNOLOGY COMPANY
An in-mould method for applying a decorative and
Method for coating material article with
topcoat layer to a skin foamed surface.
coating composition and method for
manufacturing injection moulded product and
injection moulded product. Method for the mechanical and/or optical
functionalisation of a transparent timepiece
WO2011086237A1 July 21st 2011.
component.
UPM-KYMMENE WOOD OY
WO2013050372A3 Jun 20th 2013.
A coating material encapsulates the substrate in an
ETA SA MANUFACTURE HORLOGERE SUISSE
injection moulding in-mould coating process.
Coverform polymerisable material from EVONIK is
in-mould injected over a polymethyl methacrylate
Device and method for producing a coated
substrate in order to improve abrasion resistance.
substrate element.
WO2011154305A1 Dec 15th 2011.
Injection-moulded decorative moulded article
KRAUSSMAFFEI TECHNOLOGIES GMBH
with effect pigments and manufacturing
In-mould coating solution.
method.
WO2013123960A1 Aug 29th 2013.
Processing method for in-mold coating
DAIMLER AG
integrative system.
In-mould coating of a moulded part that has been
US20120043702A1 Feb 23rd 2012
painted with effect pigments.
An in-mould coating system using topcoat injection
and integrated ultraviolet curing.
10.4.2 Three-dimensional, Tactile and
Method and a device for thinly coating Depth Effects – On-mould Painting
a component on all sides, in particular a
decorative element, and component having a Painting and hardening of the paint on
thin coating. moulded parts in a tool with a turnable mould
WO2012025300A1 Mar 1st 2012. part.
TAKATA-PETRI AG EP1458555B1 Jul 13th 2011.
A 1 mm thick coating is applied all around a part in a GRAM
mould as an alternative to spray painting with solvents. Spraying and ultraviolet curing in the mould.
Apparatus and method for manufacturing Method for manufacturing an automotive trim
multi-component plastic molded parts. part.
US20120086141A1 Apr 12th 2012. EP1970257B1 RECTICEL Dec 21st 2011.
KRAUSSMAFFEI TECHNOLOGIES GMBH AUTOMOBILSYSTEME GMBH
A method for increasing productivity of injection A skin is sprayed onto the surface of a mould in order
moulding multi-component parts, for example for an to produce an automobile trim part.
in-mould coating operation.
Applicator device for plastic moulding
Method and device for coating the surface of machine.
three-dimensional shaped components. WO2012007717A1 Jan 19th 2012.
WO2012130717A1 Oct 4th 2012. UPCYCLE HOLDINGS LIMITED
VOTTELER LACKFABRIK GMBH & CO KG A device for metering particulate matter to the surface
Coating and ultraviolet curing of a 3D object in a mould. of a horizontal mould in order to form a skin.
The film thickness is 300-1,000 microns.
Method and device for producing plastic
Process for producing a coated moulding and molded skins having different subregions.
apparatuses therefor. US20120025415A1 Feb 2nd 2012.
WO2012139977A2 Oct 18th 2012. PEGUFORM GMBH
KRAUSSMAFFEI TECHNOLOGIES GMBH A simplified method for masking areas of a mould in
A moulding concept for in-mould coating. order to produce differently coloured moulded skins.
85
Method for producing a multi-layered part. FAURECIA INNENRAUM SYSTEME GMBH

US20120064320A1 Mar 15th 2012. A multi-coloured plastisol moulded skin with a
RECTICEL AUTOMOBIL SYSTEM GMBH ‘stonewash’ visual effect.
An alternative method for reaction over-moulding a
flexible skin for smaller substrates. Method for producing a plastic trim part.
WO2013050208A1 Apr 11th 2013.
Molded skins produced from a plurality of SAINT-GOBAIN GLASS FRANCE
plastic materials having improved properties A film insert moulding process that includes a spraying
during airbag deployment at low temperatures. step.
US20120076998A1 Mar 29th 2012.
JOHNSON CONTROLS INTERIORS GMBH & CO KG Method of fabricating a painted substrate that
Improved moulded plastic skins for automobile interiors. is electrically non-conductive.
US8563078 Oct 22nd 2013.
Method of making an elastomeric skin and EUROCOPTER
skin obtained by that method. A method for painting plastic substrates in which one
US20120114954A1 May 10th 2012. option includes applying a powder coat to a treated
RECTICEL AUTOMOBILSYSTEME GMBH mould cavity prior to injecting. Various means are
A skin of variegated appearance produced by on-mould proposed for melting and curing the paint or varnish.
painting.
Method for manufacturing a trim part for the
interior of an automobile vehicle or at least a
skin therefor. Abrasion resistant plastic glazing with in-mold
EP2275307B1 Dec 19th 2012.
coating.
US8236383 Aug 7th 2012.
RECTICEL AUTOMOBILSYSTEME GMBH
EXATEC LLC
A flexible skin, foam and moulded insert combination.
A method for protecting moulded substrates entails
in-mould injecting a basecoat or applying an in-mould
Molded skin and method of producing a
film that acts as a basecoat prior to a vacuum deposited
molded skin.
plasma enhanced chemical vapour deposition
US20130059129A1 Mar 7th 2013.
abrasion-resistant layer.
References
1. U. Takao and I. Shiyu, inventors; Oshima Denki Seisakusho, assignee; JP2004338328A2, 2004.
2. D.B. Priddy, Opportunities for In-mould Painting, Omnexus.

3. D. Smock, One-Step SkinForm Process Went Live at NPE2012, Plastics Today.

4. Directskinning Technology for Products with Customizable Look and Feel, Dr. Gupta Verlag.
http://www.gupta-verlag.com {Accessed June 2014}
5. KRAUSSMAFFEI Sees Bright Prospects for Technology Fusion, Plastics Today.

http://www.npe.plasticstoday.com {Accessed June 2014}
6. D. Vink, Looking Beyond Piano Black in Automotive, European Plastics News.

7. Dolphin: First Series Production Has Started, Injection Magazine, Engel, February 2012, p.13.
8. Soft-touch and lightweight, Plastix World.

http://www.plastix-world.com/soft-touch-and-lightweight/ {Accessed June 2014}
86
11 In-mould Film Techniques

Table 11.1
11.1 Background
This section covers the introduction of a separately manufactured film, thin flexible material (cloth, flock,
leather and so on) or label into the moulding process for decorative purposes, thereby avoiding subsequent
secondary operations where possible. Innovations related to films for such applications are listed in Part
B, Section 6. The usual implication is that the film contributes in some way to the top surface of the final
object, but also included here are innovations in which the film itself becomes overmoulded. Table 11.1
shows that the greatest focus has been on methods to create 3D, tactile and depth effects, although this
appears to be declining over the three-year period covered, despite the fact that use of the technique
remains significant.
The adoption of in-mould film techniques has accelerated over the last 20 years. As with other in-mould
processes, apart from the obvious intention of reducing costs associated with off-line processes, its
popularity can be explained by: a) the need for moulders to integrate value added operations, and b)
the technical difficulties encountered when moulding and decorating or surface treatment are carried
out separately. In an in-mould process, the substrate surface quality remains under control, no cleaning,
solvents or special treatment are required, quality feedback is instant, and extra handling, transport and
storage are all avoided. As can be seen from the number of patent applications in Section 11.4, the level
of innovation in this area is high.
In what is commonly referred to as in-mould labelling (IML), in injection moulding, for example, the robot
arm is double sided, allowing it to remove a substrate from the mould core and place a label in the cavity
opposite in a single operation. The pose time can, therefore, result in minimal penalisation of the overall
cycle time, e.g., as little as one second. Labels are either cut-in-place or pre-cut and fed from hoppers
to the robot arm. Usually attached to the cavity surface using electrostatic attraction (often the label is
manufactured in polypropylene to facilitate this) and/or with vacuum devices, the design of the substrate
must ensure that the label is not dislodged by injection pressures and material flow. A butt-join is preferred
to an overlap as this avoids a loose or protruding edge, and once the injection has taken place the label is
flush with the injected polymer. Technical challenges include ensuring accurate positioning and avoiding
wrinkling or delamination because of different shrinkages of polymer and label. Therefore, laminates for
IML have to be manufactured with good adhesion between the layers. The process is mostly used for
decorative purposes, particularly in packaging applications, but functional properties such as a barrier
against permeation from the container can also be enhanced.
In-mould decoration (IMD) traditionally refers to the transfer of an image, coating, or metallisation from
a carrier film fed through the mould, in a manner analogous to off-line hot foil stamping or heat transfer
processes (Part D, Section 18). The term in-mould roller (IMR) is also sometimes used in this context.
87
In a typical application for injection moulding, a reel-fed transfer foil is positioned in relation to the top
surface of a substrate prior to injection [1]. The used foil backing is rewound at the other side (usually
below) the mould. The process can be used for decorating and/or simply protecting an object with a
scratch-resistant coating, and is usually limited to flat, near-flat surfaces or simple shapes. Tooling, setup
and process stabilisation imply that this process is economically best suited to long-run products.
In other film processes, variously referred to by terms including film insert moulding (FIM), in-mould forming
(IMF), in-mould laminating, IMR, IM, and several other variants, the backing film, which can be as much as
200 μm thick, becomes part of the final object. The various processes are often not simple or particularly
low-cost, and in part because of this a large number of variants have appeared claiming improvements,
referred to, not always consistently, by a range of acronyms and abbreviations [2]. For shaped requirements
the film is heated, stretched and trimmed in the mould, or alternatively these operations are carried out
separately beforehand using high-pressure thermoforming, and the formed shell is placed in the cavity
for back moulding. One example of IMF, IMD type S, is a process developed by NISSHA PRINTING
COMPANY whereby the film is cut, heated and pulled by vacuum towards the mould cavity before closure
of the mould [3]. In this particular case final trimming of the component takes place after part ejection.
Much innovation effort today focuses on reducing costs by carrying out as many operations as possible
in one single manufacturing cycle, even including in-line decoration of the film. In these processes there
may be a reason to remove a top layer after moulding – this may be a temporary protective layer to avoid
damage during the forming process, or it may be a relief film that contributes to leaving a relief on the
final object by impression or mating of male and female film surfaces of which the outer layer is removed.
Some companies specialise in providing custom pre-formed inserts for back moulding.
In-mould film processes relate to thermoforming and blow moulding as well as injection moulding, although
patents listed in Section 11.4 are mostly concerned with the latter. Form Over Part Technology, whereby
a film is vacuum formed over a substrate without employing a mould, is covered in Part D, Section 20.
Much of the innovation in these areas focuses on developing materials and processes that allow deeper
draws.
11.2.1 In-mould Film Processes
DSM offered licences for its process that allows a tactile pre-printed film to be in-mould formed [4];
a re-closable retortable injection moulded container with integrated aluminium foil was presented by
NETSTAL, GLAROFORM and ILSEMANN AUTOMATION [5]; SKODA and HBW-GUBESCH KUNSTSTOFF-
ENGINEERING co-developed their IMD-Pro film insert moulding (FIM) process which avoids having to
pre-form the shell separately and runs from reel-fed material [6]; KRAUSSMAFFEI showed its two-platen
CX technology using IMD [7]; INTERSTATE GRAPHICS has adopted digital printing prior to thermoforming
using VUTEk GS-TF inks and VUTEk GS2000 Pro-TF printing equipment from EFI [8]. ENGEL and partners
demonstrated their Varisoft process to produce in-mould soft touch components using a decorative
overlay over a foam layer [9].
11.2.2 In-mould Labelling
IML flexible tubes were announced by VIVA [10] and TOPLINE [11]; MOLD-MASTERS showed its Melt-
Cube and iFlow technologies for improved productivity in IML [12]; INLAND LABEL has demonstrated
88
reel-fed, in-mould labels cut in-line [13]; INMOLD TECHNOLOGY, ENGEL, BAYER MATERIALSCIENCE,
together with WANDRES for cleaning brushes and MAX PETEK REINRAUMTECHNIK for cleanrooms,
co-developed an IML process on thin substrates of less than 1 mm [14]; and WITTMANN claimed a first
with its 3D quality inspection system for an IML operation running a four-cavity mould at a cycle time of
4.5 s [15].
11.3 Patent Trends
Table 11.2
3D, tactile and depth effects Cloth, fabric, leather, wood films or effects • Convex and concave patterns •
Cushioned and localised cushioned effects • Depth effects • Double sided IMD •
Fibrous effects • Flock • Lenticular effects • Multiple decorated layers • Multiple
inserts • Placing relief film in the mould to emboss the substrate • Relief effects with
film or labels • Selective relief effects achieved by printing with IR absorbing inks prior
to thermoforming • Single or double sided over-moulding of a decorative film • Tactile
finishes • Skins • Wood effects
Definition, detail and contrast Definition improvement of transferred IMD image via multi-material moulding to
differentiate the image areas
Gloss and matte effects Surface foaming using active energy
Metallic or reflective effects Amorphous metal skin • Metallic effects from films • Mirrors • Non-conductive
metallic effects
Surface quality improvement Avoiding bubbles, cracking, creasing, deformation, delamination, distortion, flash,
foil damage, misalignment, tearing and wrinkling • Class A surfaces • Decorating
following after film deformation • Deeper draw• Easy-to-clean surfaces • Ink
adhesion improvement after deformation • Post UV curing • Pre-cure prevention •
Temporary protective sheet used during film forming
IMD: In-mould decoration
IR: Infrared
Processing of films produces a wide range of effects, as shown in Table 11.2. Table 11.3 ranks the
principal trends in patents in this field during the three-year period covered concerning 3D, tactile and
depth effects. These have been achieved either by employing films incorporating such effects by virtue of
their thickness and translucency or by choice of material (cloth and so on), special decoration techniques,
or else by tactile patterns on their surface, e.g., protected by a temporary mating cover layer.
Table 11.3
Repartition of methods to obtain 3D, tactile and depth effects
1 3D visual depth effects 26 44
2 Relief effects 14 24
3 Imitation or natural materials 14 24
4 Cushioned or soft touch effects 4 7
Several patents refer to the principle of using a removable relief film in order to leave an imprint
after moulding or by protecting a relief pattern with a mating pattern (e.g., US20110151208A1 [16];
89
WO2011081994A1 [17], WO2011115383A2 [18], WO2012112470A1 [19], US20120280426A1 [20], and

US8609010 [21]).
Patterns pre-printed onto the back of the film can allow selective behaviour in order to create relief
effects. In one case, this is combined with MuCell® technology and used to create a relief pattern in IML
(US20110039046A1 [22]). Printing an image in an IR absorbing ink so that selective thinning occurs during
back moulding is another proposed technique (US20130075959A1 DIC CORPORATION [23]).
Surface quality improvement essentially refers to techniques designed to maintain surface quality while
improving the draw ratio.
The most frequently innovating companies are ranked in Table 11.4. It is clear that, by virtue of the inherent
advantages of working from materials largely decorated beforehand, this subject will continue to retain the
significant amount of attention it has received of late for all types of decorative effects and increasingly,
for shaped parts. However, the impact of tooling costs and a more complex supply chain should not be
ignored and will in part ensure the continued survival of off-line decorating solutions.
Table 11.4
1 NISSHA PRINTING 6 6
2 FIH (HONG KONG) LIMITED/HON HAI 5 5
3 JOHNSON CONTROLS 5 5
4 DAINIPPON PRINTING CO LTD 4 4
5 BAYER MATERIALSCIENCE 3 3
6 INTERNATIONAL AUTOMOTIVE COMPONENTS 3 3
Injecting foam behind a film; in-line decorating IMF; in-mould flocking; selectively printing in-mould films
with IR absorbing inks; and use of MuCell® technology and selective printing to obtain relief effects in labels.
3D visual depth effects and techniques for surface improvement with deep draw.
11.4 Listed Patent Literature 2011-2103 (for 11.4.1 Three-dimensional, Tactile and
search phrases see Part A, Section 2) Depth Effects
In categorising patent focus, we assume by default

Method for producing at least one raised area
that the use of films to laminate the substrate is
on a plastic container.
to create 3D, tactile and depth effects unless US20110039046A1 Feb 17th 2011.
specified otherwise. VERIPLAST DECORATIVE
Use of Mucell technology combined with in-mould
labelling in order to obtain 3D relief effects on the
outside only of a container.
90
Production process for insert decorated Method for fabricating decorative film and
molding. decorated article formed with the same
US7897096 Mar 1st 2011. thereof.
DAI NIPPON US20110151208A1 Jun 23rd 2011.
A film insert moulding technique that includes two or A tactile finish is achieved using an in-mould roller
more inserts. process. The tactile finish is formed, for example,
in a ultraviolet curable resin which takes the form
Method for producing an interior trim for a of a releasing layer which is applied to a carrier and
motor vehicle including a substrate and a patterned prior to being fully hardened and filled with
coating having the appearance of wood. the resin.
WO2011023899A1 Mar 3rd 2011.
FAURECIA INTERIEUR INDUSTRIE System and method for overmolding of
A wood film is formed and back-moulded in the mould. decorated plastic parts.
WO2011071539A1 Jun 16th 2011.
In mold decoration process. FLEXTRONICS AP LLC
US20110049755A1 Mar 3rd 2011. Hardcoating for protecting laser marked or dye
A pre-printed sheet is formed into a 3D shape inside a sublimated decoration on a plastic surface is avoided
cavity and then back-filled with a second smaller core. by over-moulding with a translucent layer.
Decorated injection-moulded article, method Manufacturing method of decorative molding.

for producing one such article, and transfer WO2011081994A1 Jul 7th 2011.
film for using in one such method. 3M INNOVATIVE PROPERTIES COMPANY
US7906054 Mar 15th 2011.
A method is proposed for manufacturing a relief
LEONHARD KURZ STIFTUNG & CO KG
pattern on a moulding using the film insert moulding
An in-mould decoration technique is used to mould
process.
plastic both sides of an image in order to improve
decorative effect.
Mold decoration process.
US7976757 Jul 12th 2011.
Which does not need the transfer printing
JU TENG INTERNATIONAL HOLDINGS LIMITED
process, so as to ensure the stability of
A rotating mould is used in order to form in-mould
product quality.
forming and back-mould a film at the same time.
TW201109170A Mar 16th 2011.
LIN KENG-CHING
A film insert moulding process for a computer housing. Plastic molded structure.
CN201895520 Jul 13th 2011.
COMBINE WILL IND CO LTD
In mold lamination of decorative products.
A process for in-line decorating, thermoforming and
EP2301736A1 Mar 30th 2011.
in-mould back-filling a decorative sheet.
INTERNATIONAL AUTOMOTIVE COMPONENTS GROUP NORTH
AMERICA
A thin digitally-printed decorative layer is placed in a Molded part having a plurality of different
mould and back-moulded, and then the mould retracted decorative regions that abut each other and
in order to over-mould the face of the decorative layer. a method and device for the production
thereof.
Three-dimensional print film structure. US20110180961A1 Jul 28th 2011.
US20110117326A1 May 19th 2011. PEGUFORM GMBH
A 25-100 micron 3D relief is screen printed using a Simultaneous multiple in-mould forming of a substrate
thick paste onto a film in polyethylene terephthalate, with complex geometry.
for example. The film has been pre-decorated with an
image and possesses a release layer and adhesive A package having three-dimensional label and
layer. The 3D relief film is placed inside a mould, with the production method thereof.
relief in contact with the mould, and is back moulded WO2011095932A1 Aug 11th 2011.
such that the surface of the injection moulded part ARTUN
inherits the reverse shape of the relief, together with Methods of producing a label with a lenticular surface
the decorated layer. using in-mould labelling are described.
91
Film type soft stamper, preparation method Method for manufacturing plate-like decorated
thereof, and mold for injection molding and molded body, plate-like decorated molded
injection molding method using same. body obtained by this method and decorative
WO2011115383A2 Sep 22nd 2011. resin sheet used therefor.
SNU R&DB FOUNDATION JP2011218587A Nov 4th 2011.
A relief image is applied to a moulded substrate KEY TRANDING CO LTD
by placing a prepared relief film in the mould and A method for producing a 3D effect decorative surface.
subsequently peeling off the film from the finished
component. In-mold lamination of decorative products.
US20110272851A1 Nov 10th 2011.
Thin plastic shell with outer decorative coating INTERNATIONAL AUTOMOTIVE COMPONENTS GROUP NORTH
film and manufacturing method thereof. AMERICA INC
CN102215646A Oct 12th 2011. A depth of image effect is achieved by back-moulding
BOYI TECHNOLOGY CO LTD a decorative layer and then transferring to a mould for
A method for in-mould application of a cloth or leather front-moulding a protective layer.
film.
Embossed decorative injection-molded product
Thin-walled plastic shell with decorative and method of manufacturing the same.
coating film and preparation method thereof. EP2067597A4 Nov 16th 2011.
WO2011123969A1 Oct 13th 2011. DAINIPPON PRINTING CO LTD
PAO YI TECHNOLOGY CO LTD A 50-150 micron decorated acrylic film is embossed
A method for in-mould manufacturing a plastic casing and thermoformed and placed into a mould for back-
with an outer leather or fabric decorative layer using moulding.
an intermediate rubber adhesive layer.
Decorative member.
IMR (in-mold roller or in-mold release)/IMF (in- US20110281075A1 Nov 17th 2011.
mold forming) making method using a digital PANASONIC CORPORATION
printer printing and pre-forming technique. An improved 3D depth look is achieved by varying
US20110251706A1 Oct 13th 2011. substrate thickness in a convex manner as opposed
SHENG-LI HSU to a conventional stepped manner and backing with a
An in-mould decorating method whereby the decorated coloured reflective layer which can be a coated film.
image and protective and release layers are digitally (See also US20110262713)
printed onto a flat film which is subsequently
thermoformed in order to conform the object to be In mold lamination of decorative products.
back-moulded. US8083979 Dec 27th 2011.
INTERNATIONAL AUTOMOTIVE COMPONENTS GROUP NORTH
Method for manufacturing decorative sheet, AMERICA INC
and method for manufacturing decorative A depth of image effect is achieved by placing a thin
molded product. digitally printed decorative layer in a mould and back-
JP2011213067A Oct 27th 2011. moulding and then retracting the mould in order to
TOYODA GOSEI over-mould the face of the decorative layer.
To avoid a post sandblasting operation, a method is
described for creating a surface grain effect in an in- Injection molding apparatus.
mould film application without losing the grain effect US20120001364A1 Jan 5th 2012.
during back-moulding. SAMSUNG ELECTRONICS CO LTD
A method for forming a 3D micro-pattern on an object
Decorated device. using a film inserted into the mould.
US20110268907A1 Nov 3rd 2011.
ETANSI INC Production method for resin molded article,
An in-mould rolling technique is proposed to replace production device for resin molded article,
spray coating for a substrate with at least two and resin molded article.
decoration layers. WO2012008477A1 Jan 19th 2012.
NISSAN MOTOR CO LTD
92
A method for over-moulding a decorated item with a Decorative resin molded article and its
translucent protective layer and back-moulding a support. production method.
US20120196095A1 Aug 2nd 2012.
Friction resistance double-sided in-mold inlay In-mould lamination is used to apply a convex and
piece injection molded part. concave pattern to the exterior of a 3D object.
CN202123755 Jan 25th 2012.
SHENZHEN GOODYEAR MOLD CO LTD Mold for forming skin-integrated foam article.
A moulded substrate has a hardcoat decorative film US20120213880A1 Aug 23rd 2012.
on each side. TOYOTA BOSHOKU KABUSHIKI KAISHA
A process for injecting foam behind a skin placed inside
Method for producing transfer-decorated the mould.
product, transfer-decoration device, and
transfer-decorated product. Method of fabricating a textured surface on a
WO2012020621A1 Feb 16th 2012. molded part.
NISSHA PRINTING CO LTD WO2012112470A1 Aug 23rd 2012.
A method for decorating an object with a film and then NYPRO INC
back-moulding. A method for creating a relief pattern on an injection

moulded substrate without necessitating a tool change
entails inserting a temporary textured film or carrier
Film insert molded product.
into the mould.
WO2012029972A1 Mar 8th 2012.
YAZAKI CORPORATION
A component for an illuminating unit consists of a
Vehicle component and method for making a
translucent resin surrounded by a black film except in
vehicle component.
US8262968 Sep 11th 2012.
one corner.
A method for moulding multi-coloured substrates with
Method for producing a molded component
localised regions of cushioning.
comprising an electrically conductively coated
film back-molded with a plastic material and
Embossed decorative injection-molded product
molded component.
and method of manufacturing the same.
WO2012038356A1 Mar 29th 2012.
US20120228809A1 Sep 13th 2012.
BAYER MATERIALSCIENCE AG
A method for creating an embossed surface on a film
A method for film insert moulding a conductive film.
injection moulded part.
Film, housing using the film, and method for Decorated molded article and method for
manufacturing the housing. producing the same.
US20120134079A1 May 31st 2012. EP1818153A4 Oct 31st 2012.
FIH (HONG KONG) LIMITED
NISSHA PRINTING
A blow moulded and decorated sleeve is placed on a A moulded substrate with a 3D depth look achieved
core and over-moulded with translucent polymer. by in-mould application of a film with a projection layer
and screen layer.
Two-color molding equipment and two-color
molded product. Process of manufacturing a plastic product
US20120141722A1 Jun 7th 2012. with decorated surfaces.
A 2-stage moulding process which includes in-mould US8303880 Nov 6th 2012.
shaping of a pre-printed film in the first stage. In-mould applying a fibrous material to a plastic part.
Method for molding plastic rubber piece Plastic moulded body and method for the
tridimensional pattern and molding equipment production thereof.
using the method. WO2012163323A2 Dec 12th 2012.
CN101372146B Jul 4th 2012. WUNSCH, HORST
HONGFUJIN PREC IND SHENZHEN A method for producing lenticular 3D images on
An an-mould decorating technique that produces a a moulding involved in-mould applying a shaped
relief pattern. lenticular decorated film.
93
In-mold decorative fiber molded article and Die locking injection molding method for
manufacturing method for same. precutting soft small fabric.
US20130011624A1 Jan 10th 2013. CN102350766B Jun 26th 2013.
NISSHA PRINTING CO LTD CHANGCHUN FAWAY JOHNSON CONTROLS AUTOMOTIVE
Finely pleated paper is used to provide a pattern on a SYSTEMS CO LTD
fibre-containing material. A method for integrating a small piece of fabric during
injection moulding.
Co-molded direct flock and flock transfer and
methods of making same. Method for manufacturing resin molding with
US8354050 Jan 15th 2013. skin.
HIGH VOLTAGE GRAPHICS INC WO2013111680A1 Aug 1st 2013.
A method for in-mould flocking. HOWA TEXTILE INDUSTRY CO LTD
A method for in-mould applying skins to a moulded part.
Method for producing packing elements for
e.g., door panel of car, involves removing layer Natural coated handle and procedure.
of complex, and fixing skin on intermediate EP2628583A1 Aug 21st 2013.
layer of complex when skin is made of material IGESTEK INCREASE & WIN SL
other than material of layer. In-mould manufacturing of a handle with a die-cut
FR2971990B1 Mar 1st 2013. natural outer layer.
FAURECIA INTERIEUR IND
Improved methods for providing skins on injection Texturing a mobile electronic device part.
moulded substrates. WO2013126691A2 Aug 29th 2013.
RESEARCH IN MOTION LIMITED
Trim part, in particular for the interior of a A 3D textured film is placed onto the cavity and
vehicle, and manufacturing method. removed from the part after moulding.
WO2013030090A1 Mar 7th 2013.
JOHNSON CONTROLS INTERIORS GMBH & CO KG
Method of forming an injection plastic part
A method for making a cushioned part with a surface
with a covering.
layer of multi-layered film.
US20130255871A1 Oct 3rd 2013.
AERON LIFESTYLE TECHNOLOGY INC
Method for manufacturing an injection-molded A method for film insert moulding a natural material
object. involves preforming the material for insertion into a
US20130075959A1 Mar 28th 2013.
mould.
DIC CORPORATION
A method for creating relief surfaces in an in-mould
Film transfer method and appearance member
film process involves selectively printing the film with
manufactured by using the same.
infrared absorbing inks so that the film selectively thins
US20130264727A1 Oct 10th 2013.
in those areas during back-moulding.
COMPAL ELECTRONICS INC
A method for producing a textured surface employing a
In-mold roller manufacturing method and
textured in-mould film that is subsequently peeled off.
casing product made thereby.
US20130140266A1 Jun 6th 2013.
Thin film structure and manufacturing method
MING-HUNG HUANG
An in-mould roller technique using a film with a release
thereof.
CN101596803B Oct 30th 2013.
layer is used to create a leather feel on a moulded
ENTIRE TECHNOLOGY CO LTD
component.
Film insert moulding using a decorated sheet that has
a fluffy feeling.
Method for making a vehicle component.
US8458905 Jun 11th 2013.
Method of manufacturing a shape with a
A method for providing a cushioned region on a lenticular stereoscopic image from plastic
substrate. materials on a plastic substrate.
EP2666610A1 Nov 27th 2013.
CZAJKOWSKI, WOJCIECH
94
In-mould labelling of a lenticular material to provide a SANWA SCREEN CO LTD

stereoscopic image. A method to protect the edge of a metallised area of a
sheet for film insert moulding.
Molding method providing micro-structures
and articles molded by the method. Process for producing a moulding and
US8609010 Dec 17th 2013. moulding.
HON HAI PRECISION INDUSTRY CO LTD WO2012001146A1 Jan 5th 2012.
An in-mould method for creating a relief surface on a KUNSTSTOFF-TECHNIK SCHERER & TRIER GMBH & CO KG
substrate that involves employing a relief film. In-mould decoration using a roll-fed decorative film, for
example with a decorated or metallised layer.

Metal laminate via in-mold film.
US20120008271A1 Jan 12th 2012.
Transfer mold body. DELL PRODUCTS LP
US2013288020A1 Oct 31st 2013. A solution for in-mould moulding a metallic film to a
TOKAI RIKA CO LTD plastic substrate.
Position of an in-mould heat transfer of an image is
controlled by moulding the substrate in amorphous Surface treatment process for plastic product.
(image receptive) and crystalline (non-image receptive) CN102336023A Feb 1st 2012.
materials. DONGGUAN JIN SHENG PREC COMPONENTS CO LTD
A decorative in-mould film is ultraviolet coated,
11.4.3 Gloss and Matte Effects embossed, cured, vacuum metallised with a
non-conductive metallisation in order to avoid
electromagnetic/radio-frequency interference, and then
Thermal transfer film, decorated molded decorated in order to provide a 3D effect.
product and method of manufacturing same.
TW201309491A Mar 1st 2013.
Housing and method for manufacturing same.
DAINIPPON INK & CHEMICALS
US20120088047A1 Apr 12th 2012.
A method for producing a durable mat finish using an in-
mould film and foaming the final product after moulding
In-mould laminating of an injection moulded substrate
by using active energy and removing the release film.
in order to produce a metallic effect.
11.4.4 Metallic or Reflective Effects Composite material of amorphous metal

and plastic, composite shell and preparation
Metallic tone decorative film, metallic tone methods thereof.
decorative resin molding, and method of WO2012065323A1 May 24th 2012.
manufacturing the metallic tone decorative LIU BIN
resin molding. An injection moulded substrate with an in-mould

JP2011000857A Jan 6th 2011. applied amorphous metal skin.
POLYMATECH CO LTD
A metallic effect that does not provide electromagnetic Process for the production of a molded article.
interference is achieved on a plastic substrate by US8287789 Oct 16th 2012.
applying a physical vapour deposition-applied non- BAYER MATERIALSCIENCE AG
conductive indium film. The performance properties A film, for example metallised, is placed in a mould
are improved and any cracking avoided by adding an and polymer is injected against the film. Then the
adhesive layer between metallic and topcoat layers and moulded substrate is placed into a larger cavity so
post-curing after in-mould application. that a protective coating can be injected to protect the
polymer. Proposed for mirrors.
Metallic decorative sheet, production method
of metallic decorative sheet, and production
method of insert molded body using metallic
decorative sheet.
US20110318545A1 Dec 29th 2011.
95
11.4.5 Surface Quality Improvement Decorated device and easy-cleaning film.

US20110159246A1 Jun 30th 2011.
Capable of preventing transfer film from being SIPIX CHEMICAL INC
wrinkled and cracked during mold processing. An in-mould roller technique employs a film containing
TW201105482A Feb 16th 2011. a release layer, a fluoropolymer layer, an adhesion
XU XI-YUE layer, and a decorated image to impart easy-to-clean
A film insert moulding process that avoids wrinkling properties to a moulded component.
and cracking problems.
Method of manufacturing decorated molded
Release layer for in-mold decoration. element, and decorated molded element.
US7910205 Mar 22nd 2011. EP2357072A1 Aug 17th 2011.
SIPIX CHEMICAL INC POLYMATECH CO LTD
A material is proposed that avoids accidental pre-curing An optionally pre-printed protective film is shaped in
of a protective hardcoating applied from release film a die prior to back-moulding in order to improve edge
during an in-mould decorating process and also avoids alignment and reduce tendency to be subsequently
changes in photosensitivity for the post-moulding detachable or creased in the assembly process.
ultraviolet-curing step.
Method of manufacturing decorative molding.
In-mold double-side decorating mold and JP2011161692A Aug 25th 2011.
DAINIPPON PRINTING CO LTD
method of manufacturing in-mold double-side
decorated product. After an in-mould film decoration process, the moulded
product is removed, the release film removed, and
EP1717011B1 Apr 6th 2011.
the abrasion-resistant topcoat ultraviolet-cured in an
NISSHA PRINTING CO LTD
oxygen-starved atmosphere.
This patent application resolves the problem of tearing,
foil damage and flash occurring when two opposing faces
of a substrate are in-mould decorated at the same time. Molded article and method for making the
same.
US20110318592A1 Dec 29th 2011.
IMD/IMR transfer pattern method.
US20110079933A1, Apr 7th 2011.
A method to resolve cracking problems at the edge of
SHEU
an in-mould labelled part. (See also US2011318591A1)
Wrinkling and other defects encountered with in-mould
decoration of a 3D object are resolved by conducting a
In-mold decorative applique over textured
film insert moulding process (inserting a thermoformed
surface.
and trimmed shaped decorating film with backing shell),
US20120021182A1 Jan 26th 2012.
back-moulding, and then removing the protective shell.
FORD GLOBAL TECHNOLOGIES LLC
So as to avoid print distortion, a decorative film is
IMD mold, injection molding apparatus having
printed after thermoforming and prior to insertion for
such an IMD mold and method for producing
back-moulding using a textured cavity.
a foil-decorated plastic part.
WO2011038895A1 Apr 7th 2011.
In-mold decorative method.
HBW-GUBESCH KUNSTSTOFF-ENGINEERING GMBH
CN101712193B Jun 27th 2012.
A film insert moulding solution for highly shaped objects
TAIYI PREC CO LTD
requiring more than 30% film stretching.
An in-mould decorating process for reducing damage
to the film decoration.
Method for producing molded plastic parts
having functional surfaces.
Mould for forming in-mould decoration
US7935291 May 3rd 2011.
transfer printing device.
BASF COATINGS AG
CN101670651B Jul 4th 2012.
A temporary protective sheet is applied to the film
ASUSTEK COMP INC
containing the functional surface prior to it being An improved in-mould roller process.
inserted into a mould for back moulding. The protective
sheet allows considerable improvement in quality and
is removed after moulding.
96
Steering wheel having in-mold film. with such method.

WO2012098961A1 Jul 26th 2012. EP2147767B1 Apr 10th 2013.
AUTOLIV DEVELOPMENT AB PEZZUTTI ALDO SRL
A method for avoiding bubbles in an in-mould film. An in-mould labelling method of a relief substrate that
avoids label wrinkling or shifting during the moulding
Process for partial shrinkage compensation in cycle.
plastics mouldings.
US20120213977A1 Aug 23rd 2012. Method for manufacturing plastic article.
BAYER MATERIALSCIENCE AG US8431056 Apr 30th 2013.
A method for avoiding deformation from uneven HON HAI PRECISION INDUSTRY CO LTD
shrinkage in film inset moulded substrates where the A method for attaching a protective layer to a moulded
film is intended to be only partially back-moulded. article using in-mould decoration without inducing
damage.
Decorative element, instrument panel and
method of manufacturing a decorative element. Method of combining laser-engraving and in-
WO2012116805A1 Sep 7th 2012. mold decoration techniques to laser-engrave
JOHNSON CONTROLS AUTOMOTIVE ELECTRONICS SAS pattern on plastic product.
A method for improving the visual quality of a EP2199054B1 May 22nd 2013.
JU TENG INTERNATIONAL HOLDINGS LTD
multi-decorated flat polycarbonate substrate after
thermoforming in order to produce a 3D object. In-mould decoration and laser decoration are combined
in order to avoid distortion issues related to in-mould
decoration and reduce plate costs.
Combined type in-mould decorating printing
film forming process and equipment.
CN101804693B Oct 3rd 2012.
In-mold decorating apparatus and method
for manufacturing in-mold decorated molded
SHANGHAI ZHIXIN NEW MATERIALS CO LTD
product.
In-mould forming of a decorative film.
CN101657312B Jun 26th 2013.
NISSHA PRINTING
Method for producing a molded article with a
A method to avoid wrinkling and cracking of an in-
laminated structure.
mould film used to decorate a shaped object.
US8313683 Nov 20th 2012.
MORIROKU TECHNOLOGY COMPANY LTD.
Multi-layer film for decorative molding,
A method for avoiding stretching and damage during
polyurethane resin, and method for producing
back-moulding of a film.
decorative molded body.
WO2013099829A1 Jul 4th 2013.
Hard coating forming method. TORAY INDUSTRIES INC
US20120301629A1 Nov 29th 2012. A protective coating on an in-mould film is cured during
A method for in-mould applying a hard coat film from the moulding process.
a sheet to a polymer object.
Film in-mold injection mold device and
Molding system and molded-in-color panel. molding method using the same.
US8343409 Jan 1st 2013. US20130207320A1 Aug 15th 2013.
FORD GLOBAL TECHNOLOGIES LLC PANASONIC CORPORATION
In-mould laminating a panel in order to produce a Class A method for allowing even stretching and preventing
A surface. damage to a deep-draw in-mould film when caught on
a mould edge.
Molded article coated with film.
WO2013008318A1 Jan 17th 2013. Transfer decorative sheet, process for
RIKEN TECHNOS CORPORATION producing decorated molded product, and
A film-protected moulded component. decorated molded product.
US8535788 Sep 17th 2013.
Method for producing a plastic label-inclusive DAI NIPPON PRINTING CO LTD
lid using the in-moulding technique, mould An in-mould transfer sheet that does not leave wrinkle
for carrying out such method and lid obtained patterns at weld lines when multiple gates are used.
97
Method for attaching an in-mold label. Injection-moulding mould for in-mould

WO2013139282A1 Sep 26th 2013. transfer printing.
HUAWEI DEVICE CO LTD CN102198721B Nov 6th 2013.
An ink film is used to improve adhesion of an in-mould KANGZHUN ELECTRONIC TECHNOLOGY KUNSHAN CO LTD
label. Crease reduction is obtained in an in-mould decorating
process by using vacuum.
Method of making an in-mold decorated
article. Molding tool for back-molding a plastic film
EP0995571B1 Nov 6th 2013. with a plastic melt.
NISSHA PRINTING US20130307186A1 Nov 21st 2013.
Edge delamination, warp problems, and crazing of a LEONHARD KURZ STIFTUNG & CO KG
metallic finish of a film insert moulded part are resolved An improved mould with film clamping system for
by achieving specified acrylic, polycarbonate, or wrinkle-free back-moulding.
polyvinyl alcohol film tensile strength and elongation,
shrinkage differences of film and substrate material, In-mold decorating method and in-mold
and specular gloss reduction, using preferred materials system.
and film thicknesses for the metallic layer. US20130341830A1 Dec 26th 2013.
PANASONIC CORPORATION
A method for avoiding foil breakage when opening the
mould after in-mould decorating a complex shape.
References
1. Back Molding Technology, Battenfeld, 2008.

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Technology, Ltd., Shawbury, Shropshire, UK, 2002, p.4.
Bourbon Automobile, Moules avec Décoration in Situ, Presentation at the Pôle Européen de
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Plasturgie, April 2010.
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M.H. Naitove and L.M. Sherman, Auxiliaries at NPE: New Solutions from Material Preparation to
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Post-Mould Operations, Plastics Technology.
14. D. Smock, New Laptop Covers: Ultrathin + In-Mold Polycarbonate Labels, The Molding Blog.
15. K 2013: WITTMANN Creates 3D Inspection for Round IML Containers, Plastics Today.
16. M-H. Huang, T-C. Hsu and C-Y. Liao, inventors, no assignee; US20110151208A1, 2011.
17. K. Amaya and K. Tsuda, Inventors; 3M Innovative Properties Company, assignee; WO2011081994A1,
2011
18. S.H. Park, D.E. Lee, S.H. Kang and W.I. Lee, inventors; SNU R&DB Foundation, assignee;
WO2011115383A2, 2011.
19. R. Moll, inventor; NYPRO INC, assignee; WO2012112470A1, 2012.
20. K. Amaya and K. Tsuda, inventors; no assignee; US20120280426A1, 2012.
21. C.Y Chang, inventor; Hon Hai Precision Industry Co., Ltd., assignee; US8609010, 2013.
22. Y. Ains, inventor; Veriplast Decorative, assignee; US20110039046A1, 2011.
23. DIC Corporation, inventor; DIC Corporation, assignee; US20130075959A1, 2013.
99
12 In-mould Printing, Marking, or Use of Engraved Cavities
Table 12.1
12.1 Background
This section concerns creating images or patterns in the mould via cavity marking or engraving. Traditionally
this subject involves machining or etching the mould cavity surface, or integrating a stamp into the
mould, in order to impart a relief finish, pattern or text. However, analogous to on-mould painting or film
decorating techniques, it is also possible to selectively print patterns in wet ink or dry powder prior to
de-moulding in order to impart an image to the final object, e.g., a cavity surface can be printed prior to
injection, or a moulded substrate can be printed prior to being ejected, other than by using dry foils. A
challenge is to obtain a corresponding mould design capable of reaching into a deep cavity and resisting
the high pressure and material flow during filling and any friction during mould opening. Inkjet and pad
printing techniques have been proposed for this technology [1, 2].
Recently publicised developments in this area have included a new technology from NISSAN to provide
a finely textured surface to achieve a soft feel [3]; LUMSON has developed new engraving techniques
for bottle surface finishes [4]; and NANO 4 U has developed a method for modifying the surface of an
injection mould cavity in order to produce holograms [5].
12.3 Patent Trends
Table 12.2
3D, tactile and depth effects Embossing • Imitation material textures • Localised relief effects • Mould polishing
• Moulding reliefs in bottles, containers and tubes • Mould surface texturing •
Patterning • Variegated roughness
Colour effects In-mould printing • On-mould printing • Patterning with pigment applied to the cavity
surface
Gloss and matte effects Gloss level control techniques
Interference effects Moulding surface profiles to produce structural colours
Table 12.1 shows that 3D, tactile and depth effects clearly dominate in terms of type of effect produced,
and Table 12.2 shows all the themes of patents listed in this chapter. Table 12.3 shows that in the majority
of cases, the patents refer to texturing the mould cavity surface.
100
Table 12.3
Repartition of principal patent subject trends in 3D, tactile and depth effects
1 Texturing a mould surface for patterns, grain, or matte effects 10 59
The innovating companies are diverse; no innovators with three or more patents were uncovered during
the three year period examined.
Moulding structural colours in surfaces; printing on a mould cavity surface before injection; regulating
gloss using cavity coating thickness and heat penetration coefficient.
Texturing mould surfaces.
12.4 Listed Patent Literature 2011-2103 (for Method for producing grained plastic
search phrases see Part A, Section 2) moldings and plastic molding.
US2012094073A1 Apr 19th 2012.
BENECKE-KALIKO AG
12.4.1 Three-dimensional, Tactile and A method for providing a relief surface during thermoforming.
Depth Effects
Production method for hollow container.
Method of making molded articles. WO2012057090A1 May 3rd 2012.
US20110177293A1 Jul 21st 2011. NISSEI ASB MACHINE CO LTD
POLYONE CORPORATION Motifs are moulded into the blow-moulded container
A surface-grained mould is used to simulate different wall during a final moulding step.
natural material effects (e.g., wood), typically for
moulding polyvinyl chloride. Method for manufacturing a polymer-molded
material using a mold which easily forms a
Mold part for molding resin and manufacturing 3-dimensional surface pattern, and molded
method therefor. material for a home appliance having the
WO2011129385A1 Oct 20th 2011. 3-dimensional surface pattern.
TANAZAWA HAKKOSHA CO LTD WO2012096446A2 Jul 19th 2012.
A decorative insert for a mould. LG HAUSYS LTD
Moulding a relief article.
Appearance treatment process for plastic
products. Interior component for vehicle.
CN102285292A Dec 21st 2011. WO2012105670A1 Aug 9th 2012.
SUZHOU MITAC PRECISION TECHNOLOGY CO LTD TRINITY INDUSTRIAL CORPORATION
A method for polishing and engraving a mould cavity. A mould surface texture that imitates fibre.
Invisible pattern contained plastic label. Method for reforming a portion of a plastic
US2012058284A1 Mar 8th 2012. container to include a transferable element,
A mould surface is given a micro-pattern followed by and the resulting container.
arc discharge machining to provide a specific surface US8257636 Sep 4th 2012.
pattern. GRAHAM PACKAGING COMPANY LP
101
A method for re-forming and embossing a moulded Light guide plate stamp and method of
plastic container. manufacturing the same.
US8616875 Dec 31st 2013.
Digital mold texturizing methods, materials, SAMSUNG DISPLAY CO LTD
and substrates. A method for improving the strength of a stamp
US20120237700A1 Sep 20th 2012. intended to create a pattern on a moulded part.
IKONICS CORPORATION
A method for texturing mould surfaces that includes
inkjet printing an acid-etch resistant ink onto an
intermediate carrier.
Ornamentation of composites.
Molding tool with a three dimensional surface US20120313281A1 Dec 13th 2012.
relief pattern and method of making the same. In a resin transfer moulding process loose pigment is
WO2012134466A1 Oct 4th 2012. placed on the preform thereby creating patterns after
TAIWAN GREEN POINT ENTERPRISES CO LTD injection.
A method for producing a moulding cavity with a 3D
relief pattern. Ink for printing on molded parts, and method
for using said ink.
Tube with projecting portion raised on tube US20130072612A1 Mar 21st 2013.
surface. In-mould skinning using inkjet printing to create intricate
US8313815 Nov 20th 2012. patterns.
A method for producing a relief surface on a laminated 12.4.3 Gloss and Matte Effects
tube.
Molding die and method for manufacturing

Injection molded product.
same, and method for providing consistent
US8349243 Jan 8th 2013.
glossiness.
LG ELECTRONICS INC
WO2012117881A1 Sep 7th 2012.
In-mould patterning of an object using contrast
TANAZAWA HAKKOSHA CO LTD
produced by different degrees of roughness.
A grained mould surface is used to modify gloss.
Container with relief decorations.

Gloss level adjustment.
US8479420 Jul 9th 2013.
US8512621 Aug 20th 2013.
LUMSON SPA
OC OERLIKON BALZERS AG
A container with a relief surface that can be decorated
The gloss of a moulded substrate is regulated by
or labelled.
the ratio of the cavity coating thickness to its heat
penetration coefficient.
Localized shaping for container decoration.
US20130193027A1 Aug 1st 2013.
ALTIRA INC 12.4.4 Interference Effects
A method for locally creating 3D decorations on bottles
using localised heat and thermoplastic ink. Method of making a substrate having multi-
layered structures.
Manufacturing method for plastic mold with US20110250407A1 Oct 13th 2011.
3D image on surface. AGENCY FOR SCIENCE, TECHNOLOGY AND RESEARCH
CN102181864B Aug 28th 2013. A moulding method for mimicking the optical effects
KUNSHAN INTE ELECTRONIC CO LTD of butterfly wings that avoids slow chemical vapour
A method for engraving a mould surface. deposition or multiple TiO2/SiO2 deposition and etching
steps.
102
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Design – Europe.
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5. D. Eldridge, Moulded Holograms Tackle Product Security, European Plastics News.

103
13 In-mould Surface Improvement
Table 13.1
13.1 Background
Substrate surface quality is a key requirement for aesthetics, and Table 13.1 shows that there is an
increasing interest in the subject using in-mould methods. Processes such as spray coating are often used
primarily to hide inferior surface quality of the moulded substrate, and improving substrate surface quality,
providing a so-called class A surface, can go as far to negate the need for such secondary processes.
Even where a subsequent decoration or surface treatment is employed, good substrate surface quality
can make the process more efficient as well as enable a reduction of material cost by applying thinner
films where possible.
Various techniques relate to the mould surface itself. Tool steel is designed to present an optimisation
between machinability, ease of polishing, corrosion resistance, toughness, and ductility (to avoid cracking).
The steel must not contain inclusions that appear during polishing. Electro-slag-remelting or vacuum-
arc-remelting hard stainless steel cavity surfaces, e.g., hardened to 50-52 Rockwell hardness C (HRC),
can be highly polished in order to improve moulded quality. With nitriding, plating, or a physical vapour
deposition applied coating if the cavity is not too deep or narrow for access and coverage, cavity surface
hardness can be increased up to 72 HRC (hard chrome), or 90 HRC (titanium nitride). These levels reduce
the need for re-polishing, for which stripping of any coating would be required first. Too high a level of
polish can cause sticking between substrate and cavity sidewalls, and over-polishing can actually cause
a decline in tool surface quality.
Polishing level can be defined by roughness measurements: roughness average (Ra), mean roughness
depth (Rz), and maximum roughness depth (Rmax). An optical polish, e.g., for an optical disc (e.g., DVD)
mould, might be considered to be Ra = 0.015, Rz = 0.1, and Rmax = 0.2. A typical high gloss finish for a
mould cavity is referred to as N1 on the International Standards Organisation (ISO) scale, or A2-diamond
on the Society of the Plastics Industry (SPI) scale, and is equivalent to an Ra value of 0.025 μm. SPI have
what is referred to as an A1-diamond finish defined as an Ra value of 0.012.
Gloss and surface quality (absence of sink marks, re-weld lines and so on) are mainly improved during
moulding by any of the following techniques:
• Using more fluid grades of polymer;
• Cavity surface heating techniques during the moulding cycle;
• Increased hold pressure; and
• Employing gas assist.
By increasing the cavity temperature from 40 to 80 °C, the 20° gloss value of an acrylonitrile-butadiene-styrene
(ABS) substrate has been increased by 25% [1]. Other processing techniques receiving attention include
forced venting of cavities and the use of ultrasonics (e.g., for moulding small features). Tool modifications
include manipulating surface polish, cavity surface treatment, and manipulating fluid flow paths.
104
Cooling can typically account for up to 50-70% of injection moulding cycle time. Significant cycle time
improvement can be achieved by running cooling channels closer to the cavity wall. So-called conformal
cooling channels can be manufactured, e.g., using direct metal laser sintering. The challenge to reduce
cycle time at the same time as increasing heating of the cavity has led to the concept of rapid heat cycle
moulding (RHCM) techniques, a term invented in Japan. The subject is also referred to by several other
terms such as Variomelt, Variotherm, heat/cool, temperature cycling injection moulding and rapid thermal
response. There are several heating options which include:
1. Heat conduction by steam, gas, water, or oil;
2. Remote heating by infrared (IR), microwave, flame or laser;
3. Resistance heating from cartridges or plates adjacent to the mould cavity or even a thin film deposited
on the cavity surface; and
4. Internal or external induction or high-frequency proximity heating.
Depending on the technology employed, heating rates can vary from <5 up to 25 °C/s or higher.
A method employed for improving the surface quality in the blow moulding of containers is to use the
product to be filled as a pressurising agent to improve contact with the polished mould surface.
The subject area of substrate surface quality improvement is largely covered by the IPC classification
code B29C (Shaping or Joining of Plastics; Shaping of Substances in a Plastic State, in General; After-
Treatment of the Shaped Products) and also includes cooling system design, environmental dust control
during moulding, mould release, and techniques for thick wall moulding without sink marks or deformation.
13.2.1 Cooling Improvements
OGM has installed an IsoFC system from ISOCOOL to reduce cooling costs by 25% [2]; MOLD-MASTERS
has teamed up with YGRENE TECHNOLOGIES to exploit RITEMP evaporative cooling technology which
reduces cycle times by 30% [3]; A Taiwanese company, CORETECH SYSTEM CO (MOLDEX3D) has
joined forces with the Japanese OPM LABORATORY COMPANY to develop lower-cost cavity cooling
where the cooling channels conform to the part shape. NYPROMOLD has also invested in additive
manufacturing in order to produce conformal inserts [4]; LINDE has developed a pulsed liquid CO2
system for cooling difficult-to-reach mould regions [5]; A new software developed by PÔLE EUROPÉEN
DE PLASTURGIE called Mcool® provides optimum cooling circuit design for moulds [6, 7]; CIMATRON
LIMITED and CORETECH SYSTEM CO LTD. (MOLDEX3D) have joined forces to market CimatronE
software for cooling design [8]; NORTHUMBRIA BLOW MOULDINGS aimed to save £80,000 per year
on cooling costs using ISOCOOL technology. Improved cooling has also significantly increased output
[9]; and a new software called Optimalmould was proposed to optimise mould cooling time and results
compared well with practice [10].
13.2.2 Other Surface Improvement Process Techniques
DUPONT advertised its in-mould hold pressure process for maintaining surface quality and reducing
cycle time for semi-crystalline materials [11]; the new Fondarex vacuum system for forced venting
105
of moulds claims improved gloss, filling of fine detail, and clean cavities requiring less maintenance
[12]; ENGEL talked of the use of multilayer moulding in order to shorten cycle time and reduce defects
in optical moulding of thick-walled parts [13]; and TREXEL has adapted its MuCell® process to blow
moulding applications [14].
13.2.3 Rapid Heat Cycle Moulding Techniques
Variomelt RHCM technology has been introduced by ENGEL [15]; EVONIK talked of its Vestakeep® PEEK
and Vestamid® products for use with ROCTOOL RHCM technology [16]; ROCTOOL and FLEXTRONICS
joined forces to manufacture electronics parts with high quality surfaces not requiring painting [17]; TREXEL
demonstrated the Variotherm RHCM technique together with the MuCell® process in order to combine
weight reduction and surface quality [18]; ROCTOOL, GWK, and FONDAREX technologies are being
used in the IMPRESS PROJECT to incorporate micro or nanoscale surface features for biological, health,
and energy applications [19]; WITTMANN BATTENFELD demonstrated its BFmold RHCM technology
[20]; and FRAUNHOFER IWM and KUNSTTOFF-ZENTRUM have developed a variotherm technique for
accelerating cycle time and improving part surface by sputtering layers of conductive and insulting layers
on a cavity surface [21].
13.2.4 Tool Surface Polishing and Treatment
FRAUNHOFER ILT in Aachen talked of using lasers to polish cavities to an Ra value of 50 nanometres
[22]; PLASMATREAT publicised its automatically-applied PT-Release® silicon-free release coating applied
in situ using the Openair® PlasmaPlus® system [23]; PANTOSTAMP has developed inserts with conformal
cooling channels to reduce cycle time without compromising quality [24]; and OERLIKON’s PPDTM
(pulsed plasma diffusion) technology for replacing chrome electroplating for tooling is expected to have
lower costs and improved surface finish [25].
13.3 Patent Trends
Table 13.2
Surface quality improvement Bubbling or fluorescing additives to indicate excessive temperatures • Burn mark,
gate blush and weld line suppression • Cavity heating techniques • Class A surfaces
• Conformal cooling channels • Cooling improvements • Even gloss distribution •
Forced vent cleaning • High melt temperature detection in parts • Hold pressure
control • Improved gloss • Improved microcellular surfaces • Improved stress
crack resistance • Increased surface crystallinity and clarity • Polishing techniques
• Reduced ejection force • Reduced surface defects • Reduced weld lines, sink
marks, flash • Ultrasonics for cavity filling • Using filled product to improve surfaces of
blown containers during moulding
Table 13.2 shows the different themes of patents listed in this chapter, and Table 13.3 shows that the
most commonly adopted method for surface improvement relates to heating the mould surface, which
accounts for 25% of all innovation in this area. Another 25% of patents relate to the use of (filled) fluid
pressure during blow moulding.
106
Table 13.3
Repartition of methods for surface improvement
1 Heating/cooling 9 25
2 Product filling, fluid pressure and during blow moulding 9 25
3 Pressure manipulation during injection moulding 4 11
4 Material flow manipulation 3 8
5 High temperature indicators 2 6
6 Ultrasonics 2 6
7 Venting 2 6
8 Other methods 4 11
Table 13.4
1 MITSUBISHI HEAVY INDUSTRIES PLASTIC TECHNOLOGY 4 12
2 NESTEC 3 9
Methods for cleaning mould vents; reduction of ejection force by controlled surface treatment of the
cavity; using bubbling or fluorescing additives to warn against excessive melt temperature.
RHCM techniques in injection moulding; improving blow-moulded surfaces using product filling during
the moulding cycle.
13.4 Listed Patent Literature 2011-2103 (for apparatus for rapidly heating/cooling same.
search phrases see Part A, Section 2) WO2011111986A2 Sep 15th 2011.
NADA INNOVATION CO LTD
An RHCM solution whereby a porous member is used
13.4.1 Surface Quality Improvement to channel the cooling medium.
Mold, method for manufacturing a mold Injection molding method, method for
and method for manufacturing a plastic or manufacturing molded product, and injection
composite material product by means of said molding device.
mold. WO2011114378A1 Sep 29th 2011.
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APERAM A cavity heating and cooling system for improving
A mould concept that integrates induction heating. surface finish.
Mold having porous member arranged Gas-assisted mold surface heating system.
together with electric heater and method and US8092208 Jan 10th 2012.
107
CHUNG YUAN CHRISTIAN UNIVERSITY Resin injection molding method.

A method for rapidly heating the mould cavity using US20120211921A1 Aug 23rd 2012.
high velocity hot gas in order to improve surface quality. MITSUBISHI HEAVY INDUSTRIES PLASTIC TECHNOLOGY CO LTD
An improved method for masking/suppressing weld
Heated injection molding system and method. lines involves injection via a plurality of paths.
US8105529 Jan 31st 2012.
BI GROUP SERVICES LTD Injection molding method, molded-article
A rapid heat cycle moulding method which involves producing method, and injection molding
injecting steam into the cavity, removing condensate, apparatus.
injecting polymer, and then using high pressure gas to US20120286451A1 Nov 15th 2012.
conform the part to the cavity surface. MITSUBISHI HEAVY INDUSTRIES PLASTIC TECHNOLOGY CO LTD
In a rapid heat cycle moulding process, resin is injected
Methods for microcellular injection molding. while the hot cavity has started to be cooled in order
WO2012034036A1 Mar 15th 2012. to reduce sink marks and flash.
PLAYTEX PRODUCTS INC
Surface quality of microcellular injection moulding Portable plastic mold shape follow-up
is improved by injecting a single-phase polymer- polishing machine.
supercritical gas wherein the concentration of gas is CN102211308B Dec 5th 2012.
optimised. UNIV HENAN SCIENCE & TECH
An automated cavity polishing apparatus.
Mold delay for increased pressure for forming
container. Ultrasound monitoring system for injection
WO2012037054A2 Mar 22nd 2012. molding of high polymer material.
AMCOR LIMITED WO2013013645A1 Jan 31st 2013.
A method for increasing the crystallinity of a polyethylene LU-MING
terephthalate bottle in order to improve barrier and at A device for monitoring ultrasonics used during a micro-
the same time limiting opacity involves high pressure moulding process.
forming with fluid improved by retracting the mould
cavity by up to 5% in order to achieve very high A mold component having a residue cleaning
pressures. feature.
WO2013016816A1 Feb 7th 2013.
Fluid-assisted injection molded articles and HUSKY INJECTION MOLDING SYSTEMS LTD
process. A method for cleaning mould vents during production
WO2012044362A1 Apr 5th 2012. employs a special cleaning cycle whereby the vent
TICONA LLC becomes exposed.
An improved fluid injection moulding process reduces
surface defects. Rotary system for simultaneously blowing and
filling plastic containers.
Injection molding machine for two-material WO2013020885A1 Feb 14th 2013.
molding. NESTEC SA
US20120087999A1 Apr 12th 2012. An in-mould filling device for bottles. (See also
MITSUBISHI HEAVY INDUSTRIES PLASTIC TECHNOLOGY CO WO2013020884A1)
LTD
A method to heat mould male and female portions Method of forming a container.
equally in masked time during bi-injection moulding WO2012166541A3 Mar 7th 2013.
using a rapid heat cycle moulding process reduces AMCOR LIMITED
cycle time while avoiding issues of unequal expansion. Surface definition of a polyethylene terephthalate
container is improved by using filled liquid product to
Weld-line elimination on molded plastic parts. create a supplementary pressure forming stage.
US20120204982A1 Aug 16th 2012.
NIDEC MOTOR CORPORATION Conformal cooling tool with rapid heat cycle
A method to eliminate weld lines in an injection moulded performance.
substrate involves splitting the material flow. WO2013049882A1 Apr 11th 2013.
108
MODI CONSULTING AND INVESTMENTS PTY LTD A method and system for blowing and filling
A solution for conformal cooling in a rapid heat cycle lightweight containers.
moulding process. WO2013092146A1 Jun 27th 2013.
NESTEC SA
Method of controlling pressure-maintaining The product to be filled is used in the final forming stage
step for injection-molding machine. of a blow moulded container.
WO2013051098A1 Apr 11th 2013.
TOYO MACHINERY & METAL CO LTD Methods, compositions and blends for forming
A method for accurately controlling the hold pressure articles having improved environmental stress
step for improving part surface quality. crack resistance.
US8518318 Aug 27th 2013.
Molding surface-heating apparatus and VIVA HEALTHCARE PACKAGING LIMITED
molding method. A method for improving the stress crack performance
US20130093120A1 Apr 18th 2013. of thin-walled injection moulded tubes.
HONDA MOTOR CO LTD
Induction heating is used to heat a mould surface. Apparatus for manufacturing injection-molded
articles, and method for manufacturing
Method of manufacture of a foamed core injection-molded articles using same.
Class ‘A’ article. WO2013129762A1 Sep 6th 2013.
CN102026786B Apr 24th 2013. LG CHEM LTD
DELTA ENGINEERED PLASTICS A mould concept for ensuring even gloss on parts.
A pressurisation method for producing a Class A
surface on a foamed article. A method and apparatus for blowing and
filling containers with release of liquid
Method and apparatus for forming and filling a overpressure.
container. WO2013131793A1 Sep 12th 2013.
US20130106027A1 May 2nd 2013. NESTEC SA
MAKI, KIRK EDWARD The blowing stage is assisted by injecting a controlled
A method for filling and forming a container at the amount of the liquid product to be filled into the
same time. container.
Method of forming a container by blowing and Molded-in-color panel and method for
filling. molding.
US20130113143A1 May 9th 2013. US20130248096A1 Sep 26th 2013.
SIDEL PARTICIPATIONS FORD GLOBAL TECHNOLOGIES LLC
A method for forming a container using the product Smoothness of the surface of an injection moulded
to be filled. coloured substrate is maintained by post laser welding
an internal rib.
Device for injecting at least two pressurized
fluids into the neck of a container in order to Method for manufacturing container
form said container. containing content fluid, method for
US20130122136A1 May 16th 2013. pressurizing interior of container, filled
SIDEL PARTICIPATIONS container, blow-molding method, and blow-
A method for forming a container using the product molding device.
to be filled. WO2013147065A1 Oct 3rd 2013.
Visual indication of improperly processed Contained liquid product is used to shape a container
plastic parts. and a post compression step is used to prevent post
US20130140727A1 Jun 6th 2013. deformation.
INTERNATIONAL BUSINESS MACHINES CORPORATION
An additive is designed to decompose and leave visible Apparatus and method for removing residue
bubbles if processing temperature is too high during from injection molds.
injection moulding. WO2013154263A1 Oct 17th 2013.
109
A method for cleaning a mould cavity using spray and Fluorescent compounds for detecting use of
vacuum. proper plastic molding temperatures.
US20130333199A1 Dec 19th 2013.
Treatment method for mold tool surface. INTERNATIONAL BUSINESS MACHINES CORPORATION
US20130270734A1 Oct 17th 2013. Fluorescent additives are used to detect the use of
JAPAN AVIATION ELECTRONICS INDUSTRY LTD excessive temperatures during moulding.
A surface treatment method for a mould tool in order
to reduce ejection force. Ultrasonic-assisted molding of precisely-
shaped articles and methods.
System and process for molding polymeric US20130345384A1 Dec 26th 2013.
articles while reducing gate blush. A method for using ultrasonics in order to mould
WO2013063380A3 Oct 31st 2013. precision delicate structures.
TICONA LLC
A method for avoiding gate blush in moulded articles
by using overflow passages.
References
1. C. Ghesquiere and E.B. Crutchley, inventors; Alcan Packaging Beauty Services, assignee;
EP2100714A1, 2009.
2. OGM cut cooling costs by 25%, ISO COOL.

http://www.isocool.ltd.uk/project/ogm/ {Accessed June 2014}
3. Mold-Masters Signs Exclusive Deal to Provide RITEMP Cooling Technology for Hot Runners, Mold
Masters.
http://www.moldmasters.com {Accessed June 2014}
4. D. Smock, Efforts Grow to Improve Conformal Cooling Technology, The Molding Blog.
5. M.H. Naitove, Liquid CO2 Spot Cooling Gets into Tight Spots in Molds, Plastics Technology.
6. Mcool: Optimal Design of Polymer Injection Mould Thermal Control System SPE.
http://www.4spe.org/Resources/resource.aspx?ItemNumber=5283 {Accessed June 2014}
7. A. Agazzi, V. Sobotka, R. Le Goff and Y. Jarny, Uniform Cooling and Part Warpage Reduction in
Injection Molding Thanks to the Design of an Effective Cooling System, Key Engineering Materials,
Volumes 554 – 557, TransTech Publications, Durnten-Zurich, Switzerland, 2013, p.1611.
8. Cimatron and Moldex3D to Introduce Innovative Cooling Simulation, Moldex3D.

http://www.moldex3d.com {Accessed June 2014}
9. Isocool Wins Coveted RAC Industrial & Commercial Project of the Year Award!, Isocool.
http://www.isocool.ltd.uk {Accessed June 2014}
10. C. Ramos, P. Carreira, P.J. Bártolo and N. Aves in OPTIMALMOULD Cooling System Influence
in Injection Moulding Cycle Time Optimization, Advanced Materials and Engineering Materials II,
Advanced Materials Research Volume 683, TransTech Publications, Durnten-Zurich, Switzerland,
2013, p.544.
110
11. DuPont Réduit le Temps de Cycle, Plastiques & Caoutchoucs.

http://plastiques-caoutchoucs.com/DuPont-rduit-le-temps-de-cycle.html {Accessed June 2014}}
12. Vacuplast Vacuum Systems, Fondarex.

http://www.fondarex.com/en/produits/injection-plastique/systemes-de-vide {Accessed June 2014}
13. C. Maier, J. Giessauf and G. Steinbichler, Thick-Walled Lenses: Efficient Production of Thick-Walled
Parts, Kunststoffe International, 2013, 9, 87.
14. Trexel Tackles Blow Molding Process, Plastics Today.

15. Engel Says Variomelt Improves Productivity, Plastics News.

http://www.plasticsnews.com {Accessed June 2014}
16. Molded Parts Made from Vestakeep® PEEK and Vestamid® HTplus Shine through Induction
Technology, Evonik Industries.
http://corporate.evonik.com {Accessed June 2014}
17. RocTool and Flextronics Sign a Production License Agreement, RocTool.

http://www.roctool.com/pressReleases.php {Accessed June 2014}
18. Process Solutions, Mold Making Technology.

http://www.moldmakingtechnology.com {Accessed June 2014}
19. Impress Platform Ready to Process!, Pôle Européen de Plasturgie. http://www.poleplasturgie.net

20. BFMOLD® Wittman.

http://www.wittmann-group.com/en_gb/injection-molding/process-technology/variotherm-
technology-bfmoldR.html {Accessed June 2014}
21. D. Vink, Thin-layer, Direct-Mold surface Heating Developed. European Plastics News Show Daily,
2013, October 18th, p.11.
22. Lasers Put a Shine on Metals, Fraunhofer.

http://www.fraunhofer.de {Accessed June 2014}
23. A. Stecher, Plasma Coating Technology for Injection Molding Tools, US TECH.
http://www.us-tech.com {Accessed June 2014}
24. How Can Mold Cycle Times be Reduced? Web Packaging.

http://www.webpackaging.com {Accessed June 2014}
25. Clean Surface Technology for Automotive Industry with up to 65% Cost Savings, Oerlikon.
http://www.oerlikon.com {Accessed June 2014}
111
112
Part D: Stand-alone or
In-line Processes
3
14 Atmospheric Plasma Deposition or Thermal Spray
Table 14.1
3D: Three-dimensional
14.1 Background
This section covers a range of deposition techniques typically employing nozzles and highly energised
metallic, ceramic or polymer deposition materials provided from liquid precursors or solid or powdered
feedstock. Applications are primarily functional and usually non-cosmetic in appearance. However, the
potential of some of these techniques to deposit decorative metallic or tactile effects, must be considered.
Table 14.1 shows that innovation in metallic effects has been most prominent in this subject area, followed
by 3D, tactile and depth effects.
The first technique is known as atmospheric plasma deposition. It is typically used for applying thin films
(<0.1 μm) of silica hardcoats or an SiOx barrier or primer coats, as well as anti-fingerprint coatings onto
plastic substrates, from chemical precursors. Some devices are capable of applying coloured and metallic
materials as well as fine patterning. The process is also used for applying release surfaces to mould
cavities (Part C, Section 13), and without the use of precursors is commonly used to raise the surface
energy of polymers in order to improve adhesion (Part B, Section 7) as an alternative to flame treatment.
The second technique is generally known as thermal spraying. Thermal spraying is a coating technique
typically used for applying thicker metallic, ceramic or polymer coatings onto substrates using flame, arc,
or plasma spray methods, from solid or powdered feedstock. Coatings of thicknesses up to hundreds
of microns or more are possible, depending on the choice of method and provided the substrate heat
resistance is sufficient. Substrate heating is not excessive, however, especially when thinner films are
applied, the technique can be considered for a range of polymer types. Typical applications include
thermal barriers, electromagnetic interference barriers, and wear and chemical resistance coatings.
There are a number of process variants, including arc spraying, cold spraying, detonation flame, high
velocity flame, laser spraying, plasma, powder flame and wire flame. The suitability of each for applying
coatings onto polymer surfaces varies; so-called cold spraying, whereby a metallic powder is projected
at supersonic speeds towards the thermoplastic polymer surface, is being increasingly used. The spray
temperature has to be optimised, and thick coatings require an interlayer [1]. It should be noted that
thermal spraying has also been mentioned as an alternative application method for powder coatings
(Part D, Section 26) [2].
The main considerations for these processes are:
1. Application speed. Processes may require multiple nozzles in order provide higher throughput.
2. Substrate heating. Choosing the thermal spray process where heat is most efficiently used for melting
the powder, wire, or other type of feedstock, and impinges least on the substrate surface.
113
3. Adhesion of the final coating to the substrate and any need to apply a coating in more than one layer
and of more than one material in order to maximise adhesion and minimise heat deformation of the
substrate.
4. The potential for the process to apply detail if selective deposition is required.
5. The quality and porosity of the final finish.
During the three year survey, patents for deposition equipment and processes have appeared from
companies that include ACCENTUS MEDICAL, EASTMAN KODAK, ECKART, FORD, FRAUNHOFER,
GOODYEAR, HONDA, INSTITUTUL NAȚIONAL DE CERCETARE, KRONES, LIEBNIZ-INSTITUT, MAGNA
INTERNATIONAL, REINHAUSEN and SCHOTT.
PLASMATREAT has developed a plasma deposition process for applying metallic powders to polymer
surfaces [3].
14.3 Patent Trends
Table 14.2
3D, tactile and depth effects Relief polymer coatings
Colour effects Anti-counterfeit markers • Ceramic finishes
Metallic or reflective effects Metallic finishes
Table 14.2 shows the themes mentioned in patents listed in this chapter. No innovators with three or
more patents were uncovered during the three year period examined.
Polymer, ceramic and metallic finishes.
14.4 Listed Patent Literature 2011-2103 (for Method of making golf ball with thermal
search phrases see Part A, Section 2) sprayed layer.
US20130260044A1 Oct 3rd 2013.
NIKE INC
14.4.1 Three-dimensional, Tactile and Thermal spraying is used to deposit layers of coating
Depth Effects onto a golf ball.
Thermal spray formation of polymer coatings.

US20120321811A1 Dec 20th 2012
A technique for thermally spraying polymer powders
onto a substrate which may itself be a polymer.
114
14.4.2 Colour Effects Method of applying a coating on a substrate,

coating and use of particles.
DE102011052118A1 Jan 31st 2013.
Device and method for marking a substrate,
ECKART GMBH
as well as a marking therefor.
A cold plasma spraying device for acrylate films of less
EP2674223A2 December 18th 2013.
than 2 microns containing flake shaped polymer-coated
REINHAUSEN PLASMA GMBH
metallic particles.
A plasma deposition device for depositing a resistant
and tamper-proof marker film on a substrate for anti-
counterfeit purposes. Direct-current pulsed arc processing system
and arc processing method.
CN102352476B Aug 21st 2013.
14.4.3 Metallic or Reflective Effects UNIV BEIJING TECHNOLOGY
A system for arc spraying metals onto polymer surfaces.
Coating, and method and device for coating.
WO2012123530A1 Sep 20th 2012.
REINHAUSEN PLASMA GMBH
An atmospheric plasma coating apparatus, for example
for applying metallic coatings.
References
1. A. Ganesan, M. Yamada and M. Fukumoto, Journal of Thermal Spray Technology, 2013, 22, 8,
1275
2. K. Biller, European Coatings Journal, 2013, 12, 74.
3. Un Procédé de Peinture en Poudre Basé sur une Buse Plasma, Veille Technologique.
http://www.industrie-techno.com {Accessed June 2014}
115
15 Dry Offset and Flexographic Printing
Table 15.1
15.1 Background
Dry offset and flexographic printing mainly employ rotary photopolymer or laser-engraved relief plates.
The rotary printing configuration combined with a multi-mandrel horizontal or vertical turret for shaped
substrates, or a horizontal conveyor for flat substrates, ensures high speeds - machines are typically
capable of 200-300 parts/min (i.e., linear printing speeds in the order of 50-100 m/min). Continuous
motion configurations commonly used, e.g., in two piece can decoration, give production rates of over
2,000 parts/min [1]. Both dry offset and flexographic printing techniques require precision and robust
engineering which represent a high capital cost and are used for the high volume decoration of tubes, tubs,
pots and covers, usually employing ultraviolet (UV) curing inks. Machine configurations of eight or more
stations (colours) exist. Table 15.1 shows that most innovation in this area has focused on improvements
in definition, detail and contrast produced by these processes.
In a typical dry offset printing configuration, each ink is metered from a duct via a series of metallic and
rubber rollers to a relief plate that carries the image. A common blanket cylinder, with a hardness of around
80 Shore A, receives each of the colours in turn. The blanket cylinder transfers the combined colours to
the substrate in a final film thickness of around 1-2 μm. Since inks are superposed on the blanket cylinder,
tack grading is important; higher tack inks are printed down first so that ink trapping works in favour of
the blanket, rather than allowing inks to reverse feed and cross-contaminate each other. A topcoat varnish
application by roller coating can be applied wet-on-wet on the same turret, or in-line after ink curing.
Newer printing techniques have recently been used in the metal can printing field and it is likely that
they will eventually be deployed for plastics. Waterless lithography uses flat plates and, with appropriate
temperature control, is capable of producing higher print quality than with relief plates [2]. Common dot
gain issues with relief printing processes are avoided.
Flexographic printing has the advantage of requiring a much simpler and more condensed configuration
consisting of a doctored engraved anilox cylinder that transfers a lower viscosity, UV-curable ink directly
to a rubber relief plate that carries the image. The liquid ink and softer plate mean that so-called pressure
settings (displacement between plate and substrate) are significantly more sensitive, requiring a precision
of 50 μm or less in order to avoid dot gain. Even though the first flexographic printers for 3D objects
were developed decades ago, the roll-out of the process has been slow because of this challenge.
Present machines owe their success to the development of UV curing, and more recently light-emitting
diode curing, (thus avoiding the need to use heat, which can result in turret deformation), together with
servo-driven print heads and mandrels which enable individual pressure adjustments and out-of-round
compensation on-the-fly. Offset (i.e., indirect) flexography is required to counter wall thickness variations
commonly encountered on rigid mouldings.
The advantage of flexographic printing is that, with these advances, higher definition is possible, e.g.,
60-80 lines/cm instead of around 50-55 lines/cm. Print quality from the flexographic process allows better
116
reproduction of softer tones. Even allowing for intermediate curing, the more condensed equipment
configuration readily permits space for incorporation of other processes such as screen printing and
varnishing on a single turret. A number of companies traditionally involved in dry offset printing have
developed flexographic solutions, these include APEX, OMSO, and VAN DAM. APEX offers its solvent-
free Flexapex process, which uses more viscous UV-curable inks to achieve print film thicknesses up to
3 μm or more. However, in their most common configurations, both processes apply relatively thin films
of ink. Whereas this may have shortcomings in some high contrast situations (e.g., white printing on a
black background), one positive aspect of thin films, especially when employing solvent-based inks, is
that metallic pigments are laid flatter and therefore provide more lustre.
Process and equipment developments are represented by a diverse range of International Patent
Classification (IPC) codes, including any of B41F (Printing Machines or Presses), B41N (Printing Plates or
Foils; Materials for Surfaces used in Printing Machines for Printing, Inking, Damping, or the like; Preparing
such Surfaces for use or Conserving them) and B41M (Printing, Duplicating, Marking, or Copying Processes;
Colour Printing). Recent innovation has focused on improved flexographic doctor blades (DAETWYLER
SWISSTEC, COMEXI GROUP); dry offset blankets (DAY INTERNATIONAL, CONTITECH ELASTOMER
BESCH, LG CHEM, TRELLEBORG ENGINEERED SYSTEMS); platemaking methods and materials
(FUJIFILM, SUMITOMO CHEMICAL and several others); wet-on-wet trapping for flexographic printing
(IDEON, LTDA, SUN CHEMICAL and TECHNOSOLUTIONS ASSESSORIA).
In recent years, the notable innovations have included the award-winning Dynamic Roller Positioning
System for flexographic printing from ISIMAT [3], and CX Technology from VAN DAM for conical dry offset
printing up to 650 cups/min [4]. VAN DAM is introducing the flexographic process to tub printing [5]. The
POLYTYPE Linearis™ machine can combine hot foil transfer, flexographic printing, screen-printing and
varnishing for flexible tubes [6].
15.3 Patent Trends
Table 15.2
Definition, detail and contrast Curing colours separately in dry offset • Dry offset roller chain concepts to reduce
ghosting • Increased tonal range • Improved definition • Improved ink take-up •
Improved mechanical precision and adjustment • Moiré and rosette reduction •
Offset flexography to absorb substrate variation • Reduced anilox ink retention •
Reduced dot gain • Temperature control in dry offset
Surface quality improvement Overlap improvement via halftone
Table 15.2 shows the themes of patents listed in this chapter. Most innovation has been aimed at
improving tonal range and ink deposition by plate design and halftone processing techniques, benefiting
from the wide deployment of these processes for printing onto flexible substrates. Patent subject trends
are noted in Table 15.3.
117
Table 15.3
Principal patent subject trends
1 Machine mechanical innovations 11 58
2 Physical plate structure 4 21
3 Moiré reduction 2 11
4 Ink temperature control 1 5
5 Overlap improvement 1 5
Experience in other printing fields, such as label printing, shows an increasing demand for being able to
mix and match processes that offer differing effects. Screen printing, for example, offers more opaque
films and a relief surface. Bright metallic effects through fast cold foil transfer (Part D, Section 18), varnish
embossing techniques, and laser marking, could conceivably follow. With its space saving potential,
flexographic printing has an advantage in this respect over dry offset. US20110067584A1 [7], describes
an horizontal mandrel machine concept combining different processes (see also [6]). The most prominent
innovators are ranked in Table 15.4.
Table 15.4
1 OMSO 3 16
Dot gain reduction, overlap blending using halftone and tonal range increase.
Printing machine mechanical modifications to improve quality and capability.
15.4 Listed Patent Literature 2011-2103 (for EP1513686B1 Dec 21st 2011.
search phrases see Part A, Section 2) POLYTYPE
Each dry offset ink is cured in turn.
EP2263875A1 Jan 4th 2012.
OMSO
An indirect flexographic printing head to absorb substrate
Mechanical innovations related to dry offset dimensional differences.
and/or flexographic machines.
US8110953 Feb 7th 2012.
EP2095949B1, Aug 3rd 2011. OMSO
ISIMAT A powered chuck bearing group.
An adjusting pressure system.
EP21007341B1 Aug 22nd 2012.
WO2011156052A1 Dec 15th 2011. POLYTYPE
STOLLE A mandrel centring device for a multi-mandrel machine.
A floating mandrel system to allow pressure adjustments.
118
WO2012111091A1 Aug 23rd 2012. EASTMAN KODAK COMPANY

I MER A platemaking technique for increasing the tonal range
A gear backlash reduction system. of flexographic printing below a minimum dot size of 4%
by increasing the size of the support base for small dots.
WO2012148576A1 Nov 1st 2012.
STOLLE
Enhanced halftone screening method for the
A large single form roller to improve ink control and
dry offset printing process.
ghosting.
US8400681 Mar 19th 2013.
US20120298002A1 Nov 29th 2012. MORAVCIK, GIRARD
APEX EUROPE An improved halftone screening method for dry offset
An improved flexographic anilox roll reduces ink retention printing in order to remove rosette and Moiré effects.
and foaming.
US8408121B2 Apr 2nd 2013. Relief printing plate.
OMSO US20130074717A1 Mar 28th 2013.
A rotating carousel. SHIGETA, NORIMASA
A flexographic printing plate that reduces dot gain and
US20130098256A1 Apr 25th 2013.
also improves ink take-up by removing the taper on
ST CLAIR
the end of dots.
Ink temperature control in dry offset.
US20130174753A1 Jul 11th 2013. High resolution, solvent resistant, thin
Roller assembly for reducing dry offset ghosting effects. elastomeric printing plates.
US8563220 Oct 22nd 2013.
Relief printing plate, printing device using E I DU PONT DE NEMOURS AND COMPANY
same, thin film manufacturing method, and A flexographic printing plate of shallow relief
organic EL element manufacturing method. differentiates between printing and non-printing areas
WO2011105455A1 Sep 1st 2011. through level of hydrophobicity.
SUMITOMO CHEMICAL COMPANY, LIMITED
A relief printing plate has small recesses in its surface
in order to carry more ink.
Reducing the visibility of color changes Seamless can, printing plate, curved surface
caused by color plane registration variations in printing machine, method for printing on
halftone color printing. seamless can, and method for manufacturing
US20110279831A1 Nov 17th 2011. seamless can.
HEWLETT-PACKARD DEVELOPMENT COMPANY LP US20110162542A1 Jun 7th 2011
A half-tone solution that eliminates possible unintended Unsightly overlaps on solid bands printed onto cylinders
Moiré effects and colour variation associated with in offset printing are avoided by rendering the edges
normal 4-colour printing and screen angling of each of the plate in the overlap zone in halftone in order to
colour. maintain constant ink deposition.
Method of making a relief image.

US20120118182A1 May 17th 2012.
References
1. Stolle Rutherford Decorator and Basecoater, Stolle Machinery.

www.stollemachinery.com {Accessed June 2014}
2. TS-500 Temp Control Waterless Rutherford, Total Process Control, Inc. 2007.
http://www.totalprocessinc.com {Accessed June 2014}
3. Flexographic Printing – ISIMAT Wins Award for Innovation, ISIMAT.

http://www.isimat.com {Accessed June 2014}
119
4. VAN DAM Exhibits CX Technology on NPE, Van Dam.

http://www.vandammachine.com {Accessed June 2014}
5. Copy of FlexoCon FlexoTub - Introduction Van Dam Flexo Printing, Prezi.

http://prezi.com {Accessed June 2014}
6. Linearis Multi-Decoration Machine Awarded by the North American Tube Council, Wifag Polytype.
http://www.wifag-polytype.com {Accessed June 2014}
7. B. Mueller, P. Cotting, T. Walther and I. Kurt, inventors; Polytype SA, assignee; US20110067584A1,
2011.
120
16 Embossing
Table 16.1
16.1 Background
Table 16.1 shows that most innovation in this area has focused on 3D, tactile and depth effects.
Embossing, as an off-line process, has long been used to provide a relief effect in plastic substrates,
most notably in conjunction with hot foil stamping using a metallic die (Part D, Section 18). Naturally,
this process competes with in-mould solutions, which remain favourite because of their lower cost
and ability to produce a deeper and well-defined effect, provided the opening method of the mould
can be made to suit.
Recent innovation has included the use of embossing to provide micro-featured surfaces for a number
of technical applications. This includes artificially creating the lotus effect (a relief surface of low surface
energy) for superhydrophobicity, e.g., for creating a water and oil repellent surface. The use of embossing
ultraviolet cured lacquer films on plastic substrates involves embossing before curing, or after an initial
pre-cure. This technique provides a method for selectively altering the matteness of a substrate, to provide
it with a tactile finish, or even to create lenticular effects if suitable precision can be achieved.
The use of such techniques to influence platelet-type pigment orientation is novel and is covered in
Part D, Section 24 on pigment orientation techniques.
None detected during the three-year period analysed.
16.3 Patent Trends
Table 16.2
3D, tactile and depth effects Embossed effects in lacquer • Embossed tubes • Fine surface patterning •
Lenticular effects in lacquer • Relief images • Stereoscopic effects
Gloss and matte effects Gloss level control in inks and coatings through embossing
Because of substrate wall thickness or dimensional variations, fine embossing techniques face a
challenge with complex three-dimensional (3D) shapes and are more likely to be exploitable on either
flat or cylindrical surfaces.
Table 16.2 shows the different themes of patents listed in this chapter. No innovators with three or more
patents were uncovered during the three year period examined.
121
16.3.2 Principal Trends MINUTA TECHNOLOGY

A pattern is pressed into a ultraviolet-curable coating
Creating embossed effects in coatings. prior to irradiation using a patterned translucent die and
then irradiated from behind before the die is removed.
16.4 Listed Patent Literature 2011-2103 (for Article with three-dimensional outer surface
search phrases see Part A, Section 2) representation and die for three-dimensional
outer surface representation.
WO2012150695A1 Nov 8th 2012.
NATIONAL INSTITUTE OF ADVANCED INDUSTRIAL SCIENCE
Depth Effects
AND TECHNOLOGY
An image created by optical effect provided by fine
Imprinting method and device utilizing grooves.
ultrasonic vibrations.
US20110076451A1 Mar 31st 2011 Method for coated product and product
Fine patterns are transferred to thermoplastic using manufactured by same.
ultrasonics and pressure without heating. US20130022791A1 Jan 24th 2013.
Method and device for the lenticular molding A method for producing a 3D relief in a coated surface
of a substrate previously printed with an using a die which lets past ultraviolet light in order to
encoded stereoscopic image. pre-cure the topcoat while in contact.
WO2011126355A1 Oct 13th 2011.
ABOITIZ LOPEZ, JUAN CARLOS Method of processing synthetic resin tubular
A lenticular pattern is moulded into the uncured body.
ultraviolet curable resin with an apparatus that EP1640138B1 Apr 17th 2013.
integrates the ultraviolet source. YOSHINO KOGYOSHO CO LTD
A method for embossing the sidewall of a flexible tube.
Method and apparatus for imprinting a three-
dimensional design into a synthetic material. Localized shaping for container decoration.
US20110293887A1 Dec 1st 2011. US20130193027A1 Aug 1st 2013.
RESEARCH IN MOTION LIMITED ALTIRA INC
A method for creating a relief image in synthetic material A method for locally creating 3D decorations on bottles
such as leather using a laser engraved image with a using localised heat and thermoplastic ink.
punch.
Apparatus and method for selective micro
Production method and production device pattern replication using ultrasonic waves.
for stereoscopic decoration piece made of US20130264746A1 Oct 10th 2013.
thermoplastic synthetic resin. SEOUL NATIONAL UNIVERSITY OF TECHNOLOGY CENTER
WO2011151904A1 Dec 8th 2011. FOR INDUSTRY COLLABORATION
KURODA, NOBUO A method for selectively imprinting a micro pattern on
High frequency heating and pressing are used to create a substrate.
a substrate with stereoscopic decoration.
Process for manufacture of surface elements.
Method, assembly and device for applying a US8597766 Dec 3rd 2013.
structured layer to a substrate. PERGO (EUROPE) AB
WO2011155819A3 Feb 23rd 2012. A method for embossing a radiation-curable lacquer
PPE HOLLAND surface in order to provide a tactile effect involves a
A method for forming a pattern in a lacquer whereby partial pre-cure before embossing.
assembly, pressing and curing take place at different
stations.
Manufacturing process of pattern ornament
through molding ultraviolet-curing resin. Methods for controlling coating gloss.
CN101282837B Mar 21st 2012. US20110117292A1 May 19th 2011
122
A ultraviolet coating is partially cured and then imprinted

in order to impart the required level of gloss.
Method for transferring textured surface to

curable gel ink.
US20110115861A1 May 19th 2011.
PALO ALTO RESEARCH CENTER INCORPORATED
A patterned roller applies pressure through a film onto
the flat printed substrate prior to ink curing in order to
affect gloss.
123
17 Flocking
Table 17.1
1 Selective coating deposition 1 0 0 1
17.1 Background
Flocking provides a unique and pleasurable tactile surface that can be applied to moulded substrates.
Table 17.1 shows that only one relevant patent has been found for the period studied.
The process involves firstly applying an adhesive to the substrate followed by exposing the coated
substrate to a cloud of electrostatically charged flock particles before the adhesive has started to skin,
and then finally drying and curing the adhesive in order to bind the particles. A patent for in-mould
application of flocked materials has been recently been granted to HIGH VOLTAGE GRAPHICS [1]. The
process of applying powders and particulates to a pre-applied adhesive is covered in Part D, Section 26,
on powder coating.
Adhesives for flocking are traditionally thermal-cure epoxy or polyurethane (PU) systems, although
electron-beam (EB) curing has also been used on three-dimensional substrates (EB curing provides better
penetration than ultraviolet curing and potentially higher resistance properties). The adhesive viscosity
and solids content are regulated in order to ensure that the film thickness is about one-tenth of the flock
length. Additives in the adhesive ensure adequate conductivity because the substrate must be effectively
grounded during flocking. The adhesive can be applied by any process capable of a thicker deposit,
e.g., spraying, dipping, inkjet or screen printing. Printing techniques allow the selective deposition of
flock, eventually leading to the possibility of multicolour solutions. However, cleaning a flocking machine
in order to remove all trace of tiny flock particles of any previous colour is a lengthy process, and so the
use of a separate flocking line per colour has to be considered.
Flock is often applied on chain-on-edge conveyor machines. Flock attraction (particle speeds can be
in the order of metres/second), even application, and final orientation on a substrate, are ensured by
controlled electrostatic charging of the flock fibres as they emanate from a gun nozzle or other type of
dispensing device. The technical challenges in flocking are to:
• Avoid bulk flock agglomerations (balling);
• Avoid Faraday and edge effects (common to all electrostatic processes) whereby recesses and sharp
corners are not covered evenly; and
• Avoid deposition of flock particles that are not upright and perpendicular to the substrate.
The flock deposition process requires judicious control of distance, direct current voltage ramp-up and
setting levels, as well as substrate grounding and tightly-controlled ambient relative humidity.
Flock is usually manufactured in Nylon (as it is more conductive), and its thickness is measured as weight
per unit length, e.g., DTEX (decitex) (g/10 km). A range of flock lengths are available. Lengths can be cut
124
to 2 mm or more (longer fibres tend to be in higher DTEX values to avoid balling during sieving). Shorter
lengths, e.g., under 0.3 mm, are ground instead of being cut.
As an alternative to a ground flock effect, Nextel® is a PU one or two-coat coating usually applied by spray,
and once extensively used for internal applications in automobiles and some furniture items. Nextel® is
commercialised by MANKIEWICZ.
JFA FLOCK has developed partial flocking on cosmetics applicators [2].
17.3 Patent Trends
Table 17.2
Selective coating deposition Laser removal of flock
Table 17.2 shows the theme of the single patent identified for this chapter.
17.4 Listed Patent Literature 2011-2103 (for

search phrases see Part A, Section 2)
Inner flock coating for vehicles with indicative

and/or decorative motif and its manufacturing
process.
US2011027521A1 Feb 3rd 2011.
ANTOLIN GRUPO ING SA
Use of a laser beam to selectively remove flock.
References
1. L.B. Abrams, inventor; High Voltage Graphics Inc., assignee, US8354050, 2013.
2. JFA Flock Offers Product Differentiation with Partial Flocking, COSSMA.

http://www.cossma.com {Accessed June 2014}
125
18 Foil Transfer Processes
Table 18.1
18.1 Background
Foil transfer decoration processes (Part C, Section 11 for in-mould decorating) are widely used for
their relative simplicity, stability, and absence of environmental issues. They involve the transfer of a
pre-applied and dried ink, coating or metallisation (or a combination of either) from a carrier foil (often
referred to as a decal) held in register to (and in contact with) the substrate surface. Different types of
foil are shown in Table 18.2. The reels of foil are usually purchased from specialist manufacturers pre-
cut to width, or remaining in full reels to be trimmed on site. The substrate may be moving or stationary
while transfer is taking place. The transferred decorative layer is held to its carrier via a release layer, and
the transfer process involves a combination of heat and pressure to melt the release layer and activate
an incorporated adhesive that will bind the transferred layers to the substrate. Exceptions to the use
of heat are: a) cold foil decoration, which relies on an image selectively pre-printed onto the substrate
in adhesive to pull away metallisation from the foil, and b) water slide decals, which require soaking in
water to dislodge the decoration from their carrier. In all versions of decal printing the spent backing
is usually wasted. Table 18.1 shows that recent innovation has mainly focused on improvements in
definition and detail.
The advantage of decal printing is that foils can be pre-printed and/or coated or metallised in web form
employing fast and high quality rotary processes such as flexography, gravure, offset, screen, or digital
printing. High plate costs associated with images printed by gravure printing have led to the use of offset
or screen printing and more recently digital printing.
The foil process is often used to impart metallic effects. Metallisation is carried out by unreeling and
re-reeling the web in a vacuum chamber and depositing a thin metallic film on-the-fly using thermal
evaporation or sputtering. If metallisation is only required in selected areas, various so-called de-
metallisation techniques are employed by the foil manufacturer.
126
Table 18.2
Examples of decal solutions
Common name Carrier type Typical application methods
Cold foil (metallic image) Polyester Roll-on - flat cylindrical backing roller, typically 90° Shore
Substrate is pre-printed with adhesive
Carried out at room temperature
Typical speed in rotary process = 120 m/min
Heat transfer Paper Roll-on - flat cylindrical backing roller
Typical pressure = 2 kg/cm2, temperature 60 °C
Typical speed in rotary process = 50 m/min
Heat transfer Poly/paper Flat hit or roll-on - flat backing plate or cylindrical roller
Typical speed in rotary process = 15-30 m/min
Hot foil (uniformly metallic or Polyester Flat hit with a die shaped to the surface, or roll-on with a flat or
pigmented coating) sometimes cylindrical die. For text and line work the die is in relief.
Heat transfer (image) Polyester Flat hit with flat silicone surface, or roll-on with flat surface or
cylindrical roller
Water slide Paper Manual process at room temperature
In cold foil transfer, a printed image in adhesive pulls the metallisation from the polyester backing foil. The
adhesive is either pre-cured just beforehand in order to have some degree of residual tack (the original dry
lamination process, using cationic ultraviolet cured adhesives), or it is cured through the foil just before
the foil is pulled away (wet lamination process, which is more common today). Cold foiling is a faster
process than hot foiling and is now being integrated into flexographic and screen printing machines in
order to carry out both processes at the same time [1].
A few suppliers provide paper-backed heat transfer foils used for application of multi-colour images onto
moulded containers using heated backing rollers. The low pressures required facilitate the decoration
of flexible blow-moulded substrates. Where a greater degree of register precision is required, such as in
flat hit (platen, reciprocating) application systems onto moulded parts, laminated or poly-coated paper
may be used for greater stability, but higher temperatures and more pressure are required.
The use of a polyester film backing allows the greatest positioning accuracy, and the smooth film surface
permits the highest printing, coating, or metallic quality. Cured coatings used to manufacture the foil
laminate also provide the highest resistance properties. Hot foil stamping (i.e., using a metallised or
coated film, image produced with a heated relief silicone or metal plate), or heat transfer printing (i.e.,
image and coating are pre-printed onto the foil, the die is flat or cylindrical) are slower processes than
those previously described and require more heat, but they provide the best results in terms of quality
(a laser induced transfer process from foil developed by LEONHARD KURZ is described in Part D,
Section 21).
For flat-hit (platen, reciprocating) processes, a relief die can be contoured to the form of the substrate
surface provided no there is no risk of foil wrinkling. In a rotary mode, for peripheral decoration, the
simplest example is an internally or externally heated silicone-covered banding wheel equipped with a
counterweight in order to regulate pressure. High speed decoration for small round bottles or closures
can now achieve over 7,000 parts/h [2], (see Figure 18.1). For complex shapes in rotation and printing
127
detail, computer numerical control, controlled movements were developed by CER and PERMANENT
LABEL over 25 years ago, thus avoiding the need for expensive non-adjustable substrate-specific
mechanical cams. Additional mechanical movements provide the possibility of transferring images to
highly tapered, i.e., conical, substrates. Plates are usually flat, and the substrate is rotated against the
plate or treated in a series of indexed flat hits. Many rotary machines can also be adapted to transfer
labels (Part D, Section 20).
Figure 18.1
Ultimax F hot stamping machine for high speed decoration of mascara bottles.
Reproduced with permission from CER SA, Oyonnax, France. ©2014, CER SA
Even with the cushioning effect of a relief silicone die the hot foil process is highly pressure sensitive so
as not to have voids (lack of contact) or excessive squash (too much contact). Process tolerance can to
some extent be improved by using dual durometer dies (hard skin on a soft underbelly, e.g., 90° Shore
A over 70-80°) and also using mechanically engraved masters to produce a steep relief profile on die
characters, e.g., a 20-30° angle instead of 40-60° produced with chemical etching. However, effects can
still be noticed if combined substrate, die, and machine tolerance vary more than +/-0.2 mm. The need
for precision means that mould cavity cores have to be well stabilised and accurately centred, dies and
any recycled die bases maintained completely flat, and decorating machines robust and precision-built
as well as micro-adjustable on the fly. In this respect, heat transfer printing results in more uniform quality
since there is no issue of squash encountered with relief dies. The precision challenge when considering
relief printing plates leads some machine manufactures to minimise the numbers of mandrels on a
machine. The pressure sensitivity of hot foil stamping has meant that multi-holder machines were often
found to be ill-suited to high quality decoration. A patent taken out by MACHINES DUBUIT [3] claims to
resolve this issue.
Other important considerations for hot transfer versions are:
• The limitations on speed required by heat recuperation of silicone dies (silicone is usually required in
order to absorb variation in rigid plastic substrates);
• The need for the foil to cool before release, and therefore have careful control of tension and slack;
128
• The release properties of the foil itself (without producing flakes); and
• Foil register methods for heat transfer decoration.
Transfer onto hard and cured surfaces is also a challenge and may require some form of pre-treatment,
reduction of slip additive and reduced crosslinking in any coating pre-applied to the substrate, or even a
specially applied softer basecoat (see US20110277646A1 [4] in Part D, Section 18.4). Combined, these
issues usually limit decoration to a peripheral speed on plastic substrates of 15-30 m/min. Hard metallic
dies require tighter tolerances and inevitably result in some degree of embossing, although they can be
satisfactorily used on flexible moulded substrates such as tubes, where additional cushioning can be
provided by the holding mandrel. Temperature is important; at higher speeds, e.g., 5,000 substrates an
hour or higher, even a 1 °C shift in ambient temperature can sometimes statistically affect the transfer
quality. A typical die face temperature is 200-250 °C (temperature setting of the heating block behind
the die will be higher as it is influenced by the degree of hardness - silicone is thermally insulating, losing
about 5 °C per 0.1 mm thickness, and iron oxide added for hardness, improves conductivity).
When decorating blow-moulded containers with polyester foils, the pressures required usually demand
inflation of the container. Sometimes this is carried out in a special mould tailored to the shape of the
container so that adequate inflation pressures can be reached without risk of permanent deformation or
bursting. In these cases the foil is threaded through slots in the mould.
In what is referred to as thermal transfer printing, or digital thermal transfer marking, plate costs are
avoided and images can be instantly changed on-the-fly. A pigmented hot melt coating is transferred by
heat and pressure applied to a thermal ribbon from a selectively electronically heated array (for example,
150-250 lines/cm, i.e., 150-250 resistors/cm) according to the image to be transferred. Whereas this
process is usually used for marking labels, it has been developed for metallic decorating on web, and
a version for decorating 3D objects was developed a few years ago in Italy. In this, the heating head
(250 lines/cm) is used to selectively transfer a metallic image to an intermediate release foil which is then
pressed against the substrate using a silicone roller [5].
Water slide decals are typically screen printed images supplied on a backing paper. They can be removed
(slid) when the binding adhesive layer between the two is wetted and softened. This process is usually
used manually and is frequently employed in the toy industry and on complex surfaces in countries with
low-cost labour.
The majority of patents can be located by searches including any of the IPC codes B41F (Printing Machines
or Presses), B41J (Typewriters; Selective Printing Mechanisms, i.e., Mechanisms Printing Otherwise than
from a Forme; Correction of Typographical Errors) or B29C (Shaping or Joining of Plastics; Shaping of
Substances in a Plastic State, in General; After-Treatment of the Shaped Products, e.g., Repairing).
Recent innovations in foil transfer have been Digitube Transfer Technology from MOSS for 1,200 dots
per inch heat transfers developed in collaboration with web digital printing manufacturer XEIKON. This
transfers pre-printed images onto rigid moulded tubs and containers [6]; ISIMAT has teamed up with
LEONHARD KURZ to introduce in-line cold foiling for tubes. A speed of 100/min is claimed [1]; A patent
has been applied for; at K 2013, LEONHARD KURZ displayed its 3D tactile films for hot stamping and
in-mould decoration [7]; also at K2013, LEONHARD KURZ demonstrated its 3DHS process for decorating
slight to moderate 3D substrates by first in-line forming the metallic hot stamping foil to the shape of the
part (Figure 18.2) [8].
129
Figure 18.2
3DHS® Process for 3D hot stamping, showing principle for air vent covers.
Reproduced with permission from Leonhard Kurz Stiftung & Co KG, Fuerth, Germany.
©2014, Leonhard Kurz Stiftung & Co KG
18.3 Patent Trends
Table 18.3
3D, tactile and depth effects Cold foiling in relief
Metallic or reflective effects Brushed effect together with laser engraving
Surface quality improvement Basecoat application prior to foil transfer • Hot soft silicone application pad to
conform with surface • Use of a backing roller to reduce bubbles and wrinkles
On the whole foil transfer processes, as opposed to foils themselves (covered in Part B, Section 6) are
well established and subject to relatively little innovation today for new decorative effects. Table 18.3
shows the themes of patents listed in this chapter.
Innovators with 3 or more patents are listed in Table 18.4.
Table 18.4
Rank Applicant Number if patents %
1 CER 3 18
130
18.3.2 Items of Particular Interest US20130047871A1 Feb 28th 2013.

BECKWOOD
Tactile effects with cold foil decoration using a Decorating a conical substrate.
thick adhesive layer.
ES399283T3 Mar 27th 2013.
CER
Use of a linear camera for positioning a decoration.
US20130156955A1 Jun 20th 2013.
None observed. PROCTER AND GAMBLE
Decorating substrates with asymmetric edges.
EP1908590B1 Jul 3rd 2013.

18.4 Listed Patent Literature 2011-2103 (for
DUBUIT
Decorating elliptical or cylindrical substrates.
US20130169730A1 Jul 4th 2013.

18.4.1 Three-dimensional, Tactile and BEIFA
Depth Effects Decorating non-cylindrical substrates.
US20130174752A1 Jul 11th 2013

A system and method for cold foil relief
Foil guiding device.
production.
WO2011110956A3 Jan 19th 2012.
SCODIX LTD 18.4.3 Metallic Effects
A method for producing relief images using the cold
foil transfer technique.
Method for manufacturing plastic identifier
by adopting gold stamping and laser etching
18.4.2 Definition, Detail and Contrast technology.
CN101727774B Aug 28th 2013.
Mechanical innovations related foil transfer TONGDA XIAMEN TECH CO LTD
machines. A combination of hot stamping with brushed-effect

metallic foil and laser engraving to produce a plastic tag.
BRPI1001602A2 Aug 16th 2011.
CER
A machine for conical substrates. 18.4.4 Surface Quality Improvement
US8074568B2 Dec 13th 2011.
CER Plateless transfer printing film, device
Improved narrow foil tension control at high speed. with colored pattern and the method of
EP1924437B1 Jun 6th 2012.
US20110155007A1 Jun 30th 2011.
MADAG
CLEVO CO
A rotating curved die avoids vibrations caused by
In order to avoid bubbles and creasing that can occur
reciprocation.
in a single transfer process, a digitally-printed image
US20120160404A1 Jun 28th 2012. on a transfer film is pressed onto a substrate using a
DUBUIT roller and optional silicone film to espouse the contours
A precision multi-mandrel concept. of the surface, assisted by hot air.
EP2484524A1 Aug 8th 2012.
CERVE Automatic facility and automatic method for
Use of a backing roller and flexible heated silicone decorating items made of rough or refined
membrane. glass or of plastic with raised patterns.
WO2011121222A1 Oct 6th 2011.
US20120235328A1 Sep 20th 2012
VERRERIES DU COURVAL
Pressurised supercritical CO2 used to cause transfer
from a film. An automated system for applying a basecoat, partially
curing the basecoat, and then hot stamping prior to
final cure of the basecoat.
131
Device for hot-marking articles in crude

or finished glass or in plastic material by
tampography.
US20110277646A1 Nov 17th 2011.
VERRERIES DU COURVAL
A soft silicone pad is used instead of a roller in order to
facilitate transfer of a heat transfer image to a complex
surface. The pad is preheated by contacting with a hot
plate immediately prior to transfer.
References
1. H. Gavin, In-Line Foiling, ISIMAT.

http://www.abividro.org.br/wp-content/uploads/2014/03/15harald_gavin1.pdf {Accessed June 2014}
2. Ultimax F – Hot Stamping Machine for Mascara Bottles, CER.

http://www.itwsbifr.com/products/hotstampheattransferequipment/ultimax/ultimaxf.aspx
3. J-L. Dubuit and F. Dumenil, inventors; Machines Dubuit, assignee; EP1518675B1 2012.
4. M. Auger, R. Binet and J. Benoit, inventors; Verreries Du Courval, assignee; US20110277646A1,

2011.
5. Coditherm, Matthews Marking.

http://www.matthewsmarking.com/product/thermal-transfer-overprint/coditherm/ {Accessed June
2014}
6. Italy’s MOSS SRL Will Show for the First Time in the U.S. its New Digitube Transfer Technology
for Decorating Cosmetic Containers, Plastics Technology, 2012, 58, 3, 85.
7. Designs You Can Touch Tactile Surfaces Are on the Up for Automotive Interiors, K Show.
http://www.k-tradefair.com/cipp/md_k/custom/pub/content,lang,2/oid,23275/ticket,g_u_e_s_t/~/
Designs_You_Can_Touch_Tactile_surfaces_are_on_the_up_for_automotive_interiors.html
8. K. Laird in Decoration and Functionality for 3D Geometries in Single Molding Process, K Show,
Düsseldorf, Germany, 2013.
http://k.plasticstoday.com {Accessed June 2014}
132
19 Inkjet and Droplet Printing
Table 19.1
19.1 Background
Inkjet printing involves the projection of up to hundreds of thousands of small droplets of ink or coating
per second by employing continuous feed or drop-on-demand (DOD) technologies. The process can be
carried out up to a few millimetres from the substrate (or transfer blanket) surface, although a gap of no
more than 1-2 mm is preferable for drop placement accuracy and thereby print quality. Large distances
need to be compensated for by jetting larger droplets (US20110211017A1 [1]) or special techniques to
direct the droplets (WO2012027540A1 [2]). The slight off-contact means fewer mechanical demands on
equipment and tolerances can be made less stringent in the off-contact dimension. For plastic substrates,
UV curing is usually employed, often with light-emitting diode (LED) curing devices. Print heads are
designed to print downwards or sideways. Table 19.1 indicates that there is a growing focus relevant to
moulded substrates, with the number of patents nearly doubling over the three year period examined.
Among DOD technologies there is the simpler and more condensed thermal technique for generating
droplets or bubbles, or the piezoelectric principle more commonly encountered in this field. In each
variant, continuous, thermal DOD and piezoelectric DOD, there are several technical approaches, each
developed and favoured by different companies [3]. The use of lasers to cause jetting in the AURENTUM
process is referred to in Part D, Section 21.
OPTOMEC provides its Aerosol Jet process, which is also used for selectively depositing functional
materials and has similarities to inkjet printing. Aerosol jet printing has been proposed for making
flexographic printing plates [4].
The advantage of these processes is that they are plateless, and therefore printed image change can be
instantaneous at no cost or downtime. An early digital application was the Tonejet process [5]. Companies
hitherto involved in dry offset or flexographic printing on cylindrical objects, such as HINTERKOPF, ISIMAT
or POLYTYPE, or those involved in pad or screen printing such as COMEC/PAD PRINT MACHINERY
OF VERMONT, DUBUIT, KAMMANN, or MORLOCK, are now also presenting digital printing solutions.
Companies previously involved in inkjet printing of flat substrates, such as TAPEMATIC (see Figure 19.1),
have developed machines for 3D objects. Some solutions allow for computer numerical control (CNC)
movements for irregularly shaped objects. KHS is offering an inkjet bottle printing machine claimed to
be capable of 36,000 prints/h with the appropriate number of stations.
133
Figure 19.1
TAPEMATIC CPrint cylindrical digital printer.
Reproduced with permission from TAPEMATIC SPA, Ornago, Italy. ©2014, TAPEMATIC SPA
A specific characteristic of inkjet printing machines, unlike other printing technologies used for plastics
printing, is that the original equipment manufacturer typically purchases the printing device itself from
one of about 10-20 specialist companies.
Key process considerations are droplet size, droplet velocity, and the rate at which droplets are generated.
Ink viscosity is typically in the range of 10-50 mPa.s, i.e., similar to screen printing. When the head is
smaller than the substrate width, e.g., on a wide format flatbed machine, printing of ‘swaths’ takes place
in single pass or multi-pass mode, and positioning accuracy is critical. Typical droplet size may be 10-
50 picolitres (pl), 10 pl machines are becoming more common, and typically yield a droplet of up to about
100 μm in diameter if flattened to 1 μm thickness. Although print quality is often expressed by dots per
inch (dpi) capability, droplet behaviour and other factors render such quantifications relatively limited;
flexographic printing, at say 180 dpi, can still render a better overall print quality than an inkjet specified
at a several times higher dpi.
A key consideration for print quality, tonal reproduction and smoothness, is the degree of ink spreading
that occurs before drying and curing. It will in part be influenced by the surface energy of the impermeable
substrate. Excessive spreading will result in loss of definition, whereas inadequate spreading will produce
a rougher finish. Pinning, i.e., the use of a partial cure immediately after deposition, can be used to
prevent ink dots from over-spreading and to control print smoothness. Surface energy can typically be
manipulated using plasma treatment.
Four machine configurations are typically encountered (see Table 19.2):
134
1. Flatbed printers, often large format, in which a multiple-colour head moves in X and Y directions,
typically with onboard pretreatment and UV curing. Suitable machines are designed with head
adjustment in order to take thick substrates, e.g., up to 100 mm or more.
2. Conveyor machines, where an array of fixed heads print downwards or sideways onto passing
substrates, e.g., the upper surfaces of plastic cards or the sides of bottles.
3. Machines where printing heads are moved in order to comply with three-dimensional (3D) surfaces,
e.g., using robotics.
4. Machines designed for handling objects in a 3D configuration, e.g., cylindrical parts, where the
substrate has to be rotated in front of a fixed printing head, maintaining a constant distance.
The first two solutions, which are suitable for use with near flat substrates, are more common.
Table 19.2
Versions of inkjet printer
Description Comments
1 Flatbed, moving head machines Decorating near-flat substrates or an array of near-flat substrates
2 Conveyor/single pass machines, Near-flat substrates or parts of substrates move under, or to the side
fixed heads of, an array of fixed heads
3 Machines for the decoration of 3D Robotically or CNC controlled printing heads
substrates, moving heads
4 Machines for the decoration of 3D This is an emerging technology, requiring that the curved substrate
substrates, fixed heads and rotating be rotated under an inkjet head and introducing the challenge that
substrate successive colours be tightly registered with each other
CNC: Computer numerically controlled
The process can be used for printing fine detail, multi-coloured photographic quality images, or simply for
coating or creating 3D relief effects. As examples of coating, a white basecoat may be required for hiding
coloured substrates prior to CMYK process colour printing, and a protective topcoat may be desired
after printing, so this technology has the advantage of both printing and coating. These operations will
require a separate machine pass or in-line machine head with its own curing. Although ink misting can
be an issue at high speeds, and is presently subject of several patent applications (e.g., from HEWLETT
PACKARD, KHS, KINPO ELECTRONICS, MIMAKI and SEIKO EPSON), the close proximity of the inkjet
head substantially reduces overspray when compared with conventional spray coating [6]. Another
significant advantage of this technology is that digital control allows the localised adjustment of contrast,
colour intensity and film thickness on-the-fly.
A limitation of inkjet printing, as with flat screen printing and rotary decorating processes, relates to the
use of straight print heads; the technique can absorb only small lateral variations in substrate flatness.
For this reason, inkjet printing stands to share the market for decorating moulded plastics with other
more flexible processes, most notably pad printing. For printing non-planar shapes such as dishware,
an indirect inkjet process has been proposed, using a pad to press a fresh inkjet image pre-printed onto
a flexible intermediate carrier in order to conform to the irregular substrate surface [7].
Because of nozzle clogging issues, metallic inkjet inks have been slow to be used. This has now changed,
most notably with the arrival of inks e.g., from ECKART. Solvent-based inks give a brighter metallic look
than zero-solvent UV-cured inks, and mirror-like effects can be obtained using very small flake sizes in
the order of 1 μm, although such inks remain expensive.
135
A majority of patent documents are covered by any of the IPC codes B41J (Typewriters; Selective Printing
Mechanisms, i.e., Mechanisms Printing Otherwise than from a Forme; Correction of Typographical Errors)
or B05D (Processes for Applying Liquids or other Fluent Materials to Surfaces, in General). Most inkjet
innovation today, to the tune of several patent applications per day, is focused on jetting devices, types
of ink feed [e.g., mono-direction (single-ended) or recirculating (cross-flow)], digital controls, substrate
control for flexible substrates. Patent applications for machines or devices for printing 3D substrates
have been applied for by applicants listed in Table 19.3. Methods for improving register control or head
positioning have been applied for by ATLANTIC ZEISER, KHS, MACHINES DUBUIT, TILL and others.
Table 19.3
Recent patents for inkjet printers for 3D objects or surfaces
Patent no. Date Assignee
1 US20110012961A1 20 January 2011
th HON HAI PRECISION INDUSTRY
2 WO2011009536A1 27th January 2011 TILL
3 WO2011018191A1 17 February 2011
th TILL
4 WO2011024313A1 3rd March 2011 MIMAKI ENGINEERING
5 US7910184 22 March 2011
nd PLASTIPAK PACKAGING
6 US20110115849A1 19th May 2011 MIMAKI ENGINEERING
7 WO2011072764A1 23rd June 2011 TILL
8 US20110179959A1 28th July 2011 KHS
9 WO2011095865A2 11th August 2011 None given
10 WO2011132694A1 27th October 2011 MIMAKI ENGINEERING
11 WO2011144278A1 24th November 2011 KHS GMBH
12 WO2011147485A1 1st December 2011 ERREVI
13 US8070244 6th December 2011 MACHINES DUBUIT
14 WO2011154628A1 15th December 2011 None given
15 WO2012012793A2 26 January 2012
th PLASTIPAK PACKAGING
16 WO2012022746A1 23rd February 2012 TILL
17 WO2012093077A1 12th July 2012 TILL
18 EP2179853B1 1st August 2012 TAPEMATIC
19 US20120200626A1 9th August 2012 EXATEC
20 US8256854 4 September 2012
th KHS
21 WO2012131478A2 4 October 2012
th MARTINENGHI
22 WO2012130981A1 4th October 2012 ARKEMA FRANCE
23 US20120255450A1 11 October 2012
th None given
24 US20120274695A1 1st November 2012 INX INTERNATIONAL INK COMPANY
25 WO2012147695A1 1 November 2012
st TOYO SEIKAN KAISHA
26 HK1156283A1 4th January 2013 PLASTIPAK PACKAGING
27 WO2013065966A1 10th May 2013 DREAMJETKOREA
28 WO2013077112A1 30th May 2013 KAWASAKI SPECIAL PRINTING
29 EP2611591A2 10 July 2013
th KHS
30 WO2013107958A1 25th July 2013 None given
31 US20130193022A1 1 August 2013
st PLASTIPAK PACKAGING
32 WO2013143668A1 3rd October 2013 KHS
33 WO2013143659A1 3 October 2013
rd HEIDELBERGER DRUCKMASCHINEN
34 US20130269551A1 17th October 2013 TILL
35 WO2013170888A1 21st November 2013 POLYTYPE
36 US20130307892A1 21st November 2013 ENJET
37 US20130314460A1 28 November 2013
th EXATEC
38 US20130342592A1 26th December 2013 APPLE
136
19.2.1 Conveyor/Single Pass Machines
PAD PRINT MACHINERY OF VERMONT has introduced a new multi-colour inkjet printer for bottle caps
[8]; PAD PRINT MACHINERY OF VERMONT has also developed a low-cost high-resolution eight-colour
single pass inkjet printer [9].
19.2.2 Flatbed Machines
Recent developments in this field have included new flatbed machines for thick substrates from AGFA
GRAPHICS (Anapurna M2540FB, Jeti 3020 Titan) [10]; ROLAND DGA (LEJ-640, Versa-UV LEF-12) [11];
POLYTYPE (Virtu Quantum) [12]; FUJIFILM and INCA DIGITAL [13]; INKCUPS (Xjet) [14]; EFI (VUTEk
HS100 Pro) [15] and DIRECT COLOR SYSTEMS (DCS) (1024UVHS) [16]; INKCUPS has introduced a
proprietary head lift system for the MIMAKI UJF-3042 UV LED flatbed inkjet printer [17]; the Vuecoat
machine manufactured by PHILLIPS is designed for selectively depositing a clearcoat [18]; FUJIFILM
has used their Acuity line of inkjet printers to produce 3D effects [19]; Eagle UV LED flatbed printers
from DPI DG PRINTING can handle substrates up to 25 cm deep by up to 300 × 1,000 mm [20]; DURST
has introduced 10 pl Variodrop printing technology for its P10 series 1,000 × 1,000 dpi UV, wide format
flatbed printers for improved greyscale printing on substrates up to 40 mm thick. Output speeds offered,
range from 205-240 m2/h depending on the model [21]; DURST demonstrated its Rho IP engine A2 or A3
format at K 2013 for 10 pl 4 to 8-colour UV printing at 1,000 × 800 dpi substrates up to 70 mm. Output
for A2 format is claimed to be 1 min (21 m2/h) [22]; the new 3.2 m large format POLYTYPE NQ32 UV 10
to 30 pl printer aims at the 40-80 boards/h market [23]; ROLAND DGA announced its LEF-20 UV and
LEF-12 flatbed printers for UV inkjet printing up to 100 mm thick objects, including white coat, CMYK and
matte or gloss varnishing [24]; the INCA Onset S40i large format flatbed UV inkjet printer for substrates
up to 50 mm thick is capable of applying a double white basecoat as well as CMYK. CMYK speed is up
to 560 m2/h [25].
19.2.3 Inks and Effects (see Part B, Section 7)
There is an increasing availability of metallic inks for inkjets, e.g., Jetfluid from ECKART [26]; ROLAND
DG has used UV-curable inks to produce structured surfaces [27].
19.2.4 Machines for Three-dimensional Objects
The GMC D-HDT machine prints containers at a resolution up to 1,200 × 1,200 dpi at a rate of 450-
650 parts/h [28]; with its Innoprint process, KHS offers 1,080 × 1,080 dpi 5-colour UV-cured digital
printing on polyethylene terephthalate (PET) bottles at up to 36,000 bottles/h [29]; TILL has designed
inkjet machines for printing onto 3D substrates at up to a length of 190 mm. Printing is carried out on 1
to 8-colour SmartPrint modules. Depending on the number of modules, output speed can range from
500-36,000 substrates/h [30]; at K 2013, KAMMANN demonstrated a new UV CNC printer with two
screen printing stations and one CMYK 1,080 dpi inkjet station for short run work. Output is claimed to
be 150 parts/h [31]; DUBUIT demonstrated its new 9150 inkjet machine for bottles and containers at
SGIA EXPO 2013 [32]; HINTERKOPF demonstrated its new 1,200 dpi digital printer for up to 240 tubes/
min at K 2013 [33]. ARBURG has partnered with FPT ROBOTIC to produce robotic inkjet printing at the
moulding press using their InkBOT process, which is capable of printing 600 dpi [34].
137
19.2.5 Printing Heads
An article described the XAAR 1001 1,000 dpi inkjet print head for printing containers [35].
19.2.6 Products
YETPACK has integrated 800 dpi inkjet printing for cosmetics tubes [36].
19.3 Patent Trends
Table 19.4
3D, tactile and depth effects Braille • Embossed metallised look • Lenticular patterns • Textured and relief effects
Definition, detail and contrast Closed loop print quality management • Contrast improvement • Detail
improvement • Droplet bleed, spread and coalescence reduction • Droplet
placement accuracy improvement • On-the-fly localised print quality modification •
Pinning to improve detail • Swath line reduction
Gloss and matte effects Gloss and matte zones • Gloss level control through controlled pinning • Gloss level
control though formulation and heat control • Matte effects
Metallic or reflective effects Increasing metallic dot density to improve lustre • Metallic nanoparticles or
micronised particles in inks • Second surface decoration • Substrate transition areas
disguised with overprinted effect inks
Surface quality improvement Basecoat and/or topcoat application to improve appearance • Coating with inkjet
• Gloss banding reduction • Ink delivery compensation for conical substrates •
Matting reduction from UV curing • Smoothing inks or coatings with gas jet or
ultrasonics
Table 19.4 shows the themes of patents listed in Section 19.4. Inkjet technology is the most frequent
subject of innovation among all the decorative processes carried out outside the mould. The potential
to platelessly apply both images and coatings of varying thickness gives this process considerable
advantages. In the patent selection in Part D, Section 19.4 some applications intended for flexible film
substrates are included because of the potential interest for using this technique for 3D moulded objects.
The most frequently innovating companies for decorative effects are listed in Table 19.5.
Table 19.5
1 ELECTRONICS FOR IMAGING 5 10
2 SERICOL 3 6
Inkjetting metallic nanoparticles or micronised particles to obtain a bright metallic effect; localised image
manipulation on-the-fly; and, the use of inkjet printing applied before vacuum metallisation in order to
obtain an embossed effect.
138
Textured effects through ink delivery variation; applying smooth topcoats using inkjets; UV pinning
techniques to control bleed, surface texture and matteness.
19.4 Listed Patent Literature 2011-2103 (for TAPEMATIC
search phrases see Part A, Section 2) A method for inkjet printing an image onto a substrate
prior to metallising in order to obtain an embossed
effect.
Depth Effects Method for producing a panel having a
decorative finish and a three-dimensional
Method and device for generating a three structure.
dimensional surface structure on a work piece. WO2012007230A1 Jan 19th 2012.
WO2011064075A2 Jun 3rd 2011. FRITZ EGGER GMBH & CO OG
THEODOR HYMMEN HOLDING GMBH A 3D finish for flat panels.

The use of a combination inkjet and ultraviolet curing
to produce a textured surface. Braille ink-jet printing apparatus and printing
method thereof.
Decorative surface structure of synthetic resin WO2012163212A1 Dec 6th 2012.
molded article, method for producing the BEIJING MEIKEYI CO LTD
same and automobile interior part. A Braille inkjet printing machine.

US20110177303A1 Jul 21st 2011.
The flattening effect of coating relief patterns in Lenticular print three dimensional image
plastic surfaces is avoided by applying relief patterns display device and method of fabricing the
after coating, using ultraviolet-cured ink jet in one or same.
more passes. The result is a controllable 3D tactile WO2013048615A1 Mar 4th 2013.
effect. HENKEL CORPORATION
Direct inkjet printing of a ultraviolet-curable resin onto
Method and apparatus for producing 3D a substrate to form a lenticular pattern. (See also
surfaces. WO2013048614A1)
WO2011138441A1 Oct 11th 2011.
SUEDDEKOR GMBH Container with printed surface contour and
Stacked inkjet printing is used to create a 3D tactile printing method.
surface. US20130056482A1 Mar 7th 2013.
KRONES AG
System for printing 3D semiconductor A coloured container moulded with a relief pattern is
products. also decorated using inkjet, screen or pad printing in
US8087755 Jan 3rd 2012. order to increase the aesthetic effect of the relief.
SILVERBROOK RESEARCH PTY LTD
Digital additive manufacturing method for producing Method for manufacturing braille-printed
‘voxels’ (3D pixels) using inkjet. matter using a printer.
WO2013042876A1 Mar 28th 2013.
High-pressure melamine resin decorative DILLI
plates. A digital printer is used to superpose Braille onto a

US8097328 Jan 17th 2012. printed image.
DAI NIPPON PRINTING CO LTD
An embossed look is achieved by overcoating zones In-line integrated raised printing.
printed with a matte ink. WO2013066382A1 May 10th 2013.
HEWLETT-PACKARD DEVELOPMENT COMPANY LP
Method for producing stoppers for vessels. Creating raised characters in inkjet printing. (See also
EP2407315 Jan 18th 2012. WO2013066289A1)
139
Method for treating the surface of objects. Surface decoration method and electronic
WO2013182280A2 Dec 12th 2013. device.
EISENMANN AG US20130089714A1 Apr 11th 2013.
A patterning robot is used to apply a personalised layer SANYO ELECTRIC CO LTD
on a substrate in a spray coating line. The layer can be A pattern is printed in ultraviolet-ink onto a substrate in
in relief and applied by inkjet. order to provide contrast with the substrate.
Method for printing substrate using inkjet

printer, involves adapting adjustable variables
of printer during actual printing of substrate
High definition printing with waterborne inks according to external parameters.
on non-porous substrates. DE11013683B4 Jun 13th 2013.
US8025918 Sep 27th 2011. ATLANTIC ZEISER GMBH
RHODIA INC A camera is used to provide feedback for automatically
Ink-bleed problems of water-based inks on plastic adjusting inkjet printing parameters.
substrates are avoided and high definition obtained by
coating the substrate with a silyl coating that provides Method and apparatus to eject drops having
a high contact angle that prevents spreading. straight trajectories.
US8480196 Jul 9th 2013.
Printing device and density correction method. FUJIFILM DIMATIX INC
WO2011121810A1 Oct 6th 2011. A method for ensuring straight drop direction in inkjet
DAINIPPON SCREEN MFG. CO LTD printing.
A system for adjusting print quality on the run during
inkjet printing. Method and arrangement for printing a three-
dimensional surface.
Jet directionality control using printhead WO2013143668A1 Oct 3rd 2013.
nozzle. KHS GMBH
US8091983 Jan 10th 2012. A method for compensating for varying differential
EASTMAN KODAK COMPANY speeds while inkjet printing conical containers.
A device for improving drop placement accuracy on a
continuous inkjet printer. Staggered ultra-violet curing systems,
structures and processes for inkjet printing.
Inkjet ink and intermediate transfer medium WO2013165394A1 Nov 7th 2013.
for inkjet printing. ELECTRONICS FOR IMAGING, INC
US20120105525A1 May 3rd 2012 A device for variably pinning ultraviolet inks prior to
A method for avoiding coalescence of adjacent ink full cure.
drops onto a transfer medium in an indirect (offset)
inkjetting process, in order to improve final quality.
Method of inkjet printing.
WO2012110815A1 Aug 23rd 2012. Decorating material.
SERICOL LIMITED US7931954 Apr 26th 2011.
A clear ultraviolet lacquer/ink is applied in multi-pass DAI NIPPON PRINTING CO LTD
mode (instead of single swath) in order to assure This claims to be an improvement on existing
evenness of application, and bleeding of any inks techniques mentioned, designed to produce in fine
printed beforehand is avoided by limiting the time detail gloss and matte zones in a gloss ultraviolet-
interval between application and ultraviolet curing. curable coating. A low-lustre pattern is printed where
low-gloss appearance is required prior to ultraviolet
Method of inkjet printing. overcoating.
WO2012110814A1 Aug 23rd 2012.
SERICOL LIMITED Method of controlling gloss in UV curable
Inkjet film thickness is regulated in order to avoid swath overcoat compositions.
lines in the image. US8043665 Oct 25th 2011.
140
XEROX CORPORATION 19.4.4 Metallic or Reflective Effects

Digital print gloss is controlled by applying an overcoat
and using varying amount of wax in the coating and
Metallic ink jet printing system for graphics
heat prior to ultraviolet curing.
applications.
US7891799 Feb 22nd 2011.
Inkjet printing apparatus and inkjet printing ELECTRONICS FOR IMAGING INC
method. A metallic effect obtained with inkjet inks containing
US20120050369A1 Mar 1st 2012.
metallic nanoparticles applied over a basecoat and
CANON KABUSHIKI KAISHA
protected by a topcoat.
A solution for inkjet printing a matter text differentially
inlaid into a glossy photographic print that avoids
Special effect glazing.
producing haze.
US20110268931A1 Nov 3rd 2011.
EXATEC LLC
Ink jet UV pinning for control of gloss. Special effect decoration is used to enhance transitions
US20130050368A1 Feb 28th 2013.
between adjacent automobile components.
EFI
A pre-cure is used to prevent ink dots from spreading
Method for printing metal-tone printed matter
or balling so as to improve gloss control.
and metal-tone printed matter.
WO2012111242A1 Aug 29th 2012.
Differential ultraviolet curing using external MIMAKI ENGINEERING CO LTD
optical elements. A solvent-borne metallic ink is first printed onto a
WO2013043732A1 Mar 28th 2013.
smooth film and then transferred from the smooth film
PHOSEON TECHNOLOGY INC
to a substrate. The substrate benefits from the quality
A patterned sheet is placed in front of a ultraviolet
of the initial second-surface decoration applied to the
light-emitting diode system following an inkjet printing
smooth film.
device in order to alter the cure rate so as to influence
gloss of the final product.
Metal nanoparticle compositions for reflective
features.
Ink jet printer and printing method for printing US20130099179A1 Apr 25th 2013.
an image having matt and glossy image areas. CABOT CORPORATION
WO2013056292A1 Apr 25th 2013.
A method for inkjetting a reflective layer using
DURST PHOTOTECHNIK DIGITAL TECHNOLOGY GMBH
nanoparticles.
A method for inkjet printing matte and gloss print
areas without the need of separate inks or levels of
Printing device and printing method.
ultraviolet cure.
US20130155149A1 Jun 20th 2013.
SEIKO EPSON CORPORATION
Gloss-controllable, radiation-curable inkjet ink. Inkjet dots in metallic ink are placed closer to each
US20130222499A1 Aug 29th 2013.
other when compared with other colours in order to
CONG LIANHUI
accentuate lustre effect.
Pinning energy (applied before full ultraviolet-cure) is
varied in order to alter gloss of an inkjet print
Method for UV inkjet printer to generate
irregular transparent matte particle surface Coating and the production thereof by means
and completed printing object thereof. of ink jet printing methods.
US20130278672A1 Oct 24th 2013. EP2358541A1 Aug 24th 2011.
TSAI CHEN-CHIEN MANKIEWICZ GEBR & CO
A method for producing a matte finish using inkjet Single or two-component inkjet clear coatings are used
printing. to protect inkjet-applied decoration in water, solvent,
or ultraviolet based inks.
141
Method for making device housing, and device Systems and methods for leveling inks.
housing. US20120321816A1 Dec 20th 2012.
US2011151212A1 Jun 23rd 2011. XEROX CORPORATION
SHENZHEN FUTAIHONG PREC IND CO Ultrasonics are used in order to level out phase-change
A paintjet process is used to decorate a substrate followed inkjet inks (ultraviolet curable gel inks which become
by an optional protective ultraviolet-cured topcoat. fluid when heated).
Material application method. Coating method and coating apparatus.

US8187668 May 29th 2012. US20130089668A1 Apr 11th 2013.
SEIKO EPSON CORPORATION A method for evenly coating a flat surface using inkjet
An inkjet coating device for applying thick layers technology, where the final film is smoothed by a gas jet.
of coating, for example compensating where
subsequent solvent loss results in thinning of the Printing system for application of a patterned
deposited layer. clear layer for reducing gloss banding.
WO2013078297A1 May 30th 2013.
Method and apparatus for the application of ELECTRONICS FOR IMAGING INC
plastics coatings. Gloss variation issues with ultraviolet inks are resolved
EP2183057B1 Jun 6th 2012. by overprinting with a clearcoat.
SCHMID RHYNER AG
A device for smoothing an inkjet-applied varnish layer Plastic containers with a base coat thereon.
on an essentially flat substrate whereby the coating area US8522989 Sep 3rd 2013.
may be partial. Instead of doctor blades, air knives, or PLASTIPAK PACKAGING INC
rollers, which would cause the coating to spread, or A plastic container is digitally printed with a basecoat
using ultrasonics, a gas stream is used. followed by a pattern layer.
Printing method. Reduced gloss banding through low ink

US2012157561A1 Jun 21st 2012. volume deposition per print pass.
SERICOL LIMITED US20130250001A1 Sep 26th 2013.
A combination of ultraviolet-light emitting diode ELECTRONICS FOR IMAGING INC
and xenon or krypton flash lamp is used to cure an A method for reducing gloss banding or ‘tyre tracking’
inkjet ink without causing surface matting and ozone encountered with interlaced images flatbed inkjet
characteristic of mercury vapour lamps. printers involves spacing the inkjet nozzles so that ink
droplets do not interact.
Multiple layer coating and manufacturing
method for same.
WO2012133667A1 Oct 4th 2012.
DAI NIPPON TORYO CO LTD
Ultraviolet-cured inkjet decoration is sandwiched
between a basecoat and topcoat.
References
1. Y. Maruoka, T. Sekiya and D. Kawashima, inventors; Toyoda Gosei Co Ltd., assignee;

US20110211017A1, 2011.
2. K-C. Kwok, inventors; Illinois Tool Works Inc., assignee; WO2012027540A12012.
3. J. Ducrée, Microfluidics – Ink-Jet Technology, Dublin City University, Dublin, Ireland, 2012.
http://www.dcu.ie {Accessed June 2014}
4. L. Vanmaele, inventor; Agfa Graphics NV, assignee; WO2013045349A1, 2013.
5. Leading the Way in Digital Printing, Tonejet.

http://www.tonejet.com {Accessed June 2014}
142
6. F. Herre, H-G. Fritz and S. Wesselky, inventors; no assignee; US20110262622A1, 2011.
7. J. Donohoe, M.J. Sullivan, R.J. Lugen and K.A. Kirk, inventors; J. Donohoe, M.J. Sullivan, R.J.
Lugen and K.A. Kirk, assignees; US20130224445A1, 2013.
8. Bottle Caps and Molded Closures, Engineered Printing Solutions.

http://www.epsvt.com/productapplication/index.cfm?appID=25&proID=35 {Accessed June 2014}
Auxiliaries at NPE: New Solutions from Material Preparation To Post-Mold Operations, Plastics
9.
Technology.
http://www.ptonline.com/articles/auxiliaries-at-npe-new-solutions-from-material-preparation-to-
post-mold-operations {Accessed June 2014}
10. Anapurna M2540 FB, Afga Graphics NV. http://www.agfa.com {Accessed June 2014}
Roland SGIA Exhibit Features a New Generation of UV and Metallic Printers, Expert Guest Speakers
11.
and Live Vehicle Wrap Demonstrations, Roland.
http://www.rolanddga.com/company/pr_detail.asp?id=391&yr= {Accessed June 2014}
12. Upgraded Wide-Format Inkjet Printers, Industrial and Speciality Printing.

http://www.industrial-printing.net {Accessed June 2014}
13. Fujifilm and Inca Digital Launch the Inca Onset S40i at DRUPA 2012, Inca Digital.
http://www.incadigital.com {Accessed June 2014}
14. Inkjet Printer Videos, Inkcups Now. http://www.inkcups.com {Accessed June 2014}
15. Wide-Format UV Inkjet Printer, Screen Web.

http://www.screenweb.com {Accessed June 2014}
New High-Speed, Small-Format UV LED Flatbed Printer Features Inline Printing with TEXTUR3D™
16.
On Board, Direct Color Systems.
http://www.directcolorsystems.com/news/1210-UVHS.php {Accessed June 2014}
17. Printing on Paper Cubes with the Mimaki UJF-3042 UV LED Inkjet Printer, Inkcups Now Blog.
http://www.inkcups.com/blog/mimaki-printers-applications/inkjet-printing-on-paper-cubes/
18. Selective Abrasion Coating Saves Steps in Manufacturing Process, Design News.
http://www.designnews.com {Accessed June 2014}
19. ‘How To’ Textured Inks, Ink World.

http://www.inkworldmagazine.com {Accessed June 2014}
20. SSE Worldwide to Launch Eagle Range at FESPA, Screen Process and Digital Imaging.
http://www.spdi-online.com {Accessed June 2014}
21. DURST’s Latest Imaging Breakthrough: 10-Picoliter Variodrop Technology Refines Grayscale,
Overall Image Quality, What They Think?
http://whattheythink.com. {Accessed June 2014}
22. Rho IP, Durst.

http://www.durst.it/en/index.php/industrial_printing/product_glass/rho-ip {Accessed June 2014}
23. Polytype America Introduces the New Polytype NQ32 3.2 Meter 3-in-1 UV Production Printer,
Wifag Polytype.
http://www.wifag-polytype.com {Accessed June 2014}
143
24. VersaUV® LEF Series of Benchtop UV Flatbed Printers, Roland.

http://www.rolanddga.com {Accessed June 2014}
25. Fujifilm and Inca Digital Launch the Latest INCA Onset S40i+, Screen Process and Digital Imaging.
26. Brilliance by ECKART, Packaging Europe.

http://www.packagingeurope.com {Accessed June 2014}
27. M. Swinnen, Specialist Printing Worldwide, 2012, 3, 62.
28. Direct Digital Printing, Macplas.

http://www.macplas.it {Accessed June 2014}
29. Maximum Flexibility through Direct Digital PET Bottle Printing, KHS Corpoplast.
http://www.khscorpoplast.de {Accessed June 2014}
30. High speed inkjet printing on glass containers, Glassman Events.

http://www.glassmanevents.com/south-america/conference {Accessed June 2014}
31. Kammann K1 Digital, KBA-Kammann GmbH.

http://www.kammann.com {Accessed June 2014}
32. Digital Machine 9150, Machines Dubuit.

http://www.machinesdubuit.com/en/machines/type9150_digitale.html {Accessed June 2014}
33. Digital Printer Type D240, Hinterkopf.

http://www.hinterkopf.de {Accessed June 2014}
34. Six-axis Robots – Reliable Handling of Tasks, Atburg.

http://www.arburg.com/en/gb/media-centre/videos/products/six-axis-robots {Accessed June
2014}
35. XAAR Printheads at The Heart Of New Direct-to-Shape Packaging Decoration Systems, Screen
Process and Digital Imaging.
YETPACK LTD., a Polish Manufacturer, Has Introduced a New Kind of Cosmetic Tubes Decorated
36.
by Perfect Digital Printing.
https://www.facebook.com/pages/YETpack-Sp-z-oo/203476083059667?fref=nf. {Accessed June
2014}
144
20 Labelling, Sleeving and Form Over Part
Table 20.1
20.1 Background
A wide range of equipment exists to apply labels or sleeves to moulded substrates, especially bottles.
These even include machines primarily designed for heat transfer, hot foil stamping, and screen printing
decoration, whereby printing or decorating heads are removed in order to accommodate labelling devices
(e.g., CER or MADAG). Labels are manufactured from paper, polymer, or laminated materials. They may
be self-adhesive and mounted on a carrier, have adhesive backing that has to be activated (e.g., by heat,
moisture and so on), or require the application of adhesive at the same time as their placement. Sleeving
from a tubular material does not require adhesive application, as shrinking binds the sleeve to the substrate.
The considerable advantage of labels and sleeves is that they are printed flat, thus allowing very high
quality and versatile reproduction processes to be employed (digital, flexographic, gravure, offset or screen
printing, hot or cold foil stamping, embossing, metallisation, varnishing and so on, and in-line combinations
of either). Digital printing significantly reduces the cost of short runs. In packaging applications, labels
can be easily applied after filling, thereby avoiding the need to warehouse multiple stock keeping units
until the last minute.
Labels present other possibilities. Recent advances in intelligent or smart solutions in flat printing (printed
electronics, colour change materials and so on) increase the potential interest in labels. Labels can now
be made to talk or play music (Part B, Section 6). Labels can also be formulated to change colour or
reflectivity according to environmental conditions or migrating substances from food (Part B, Section 4).
Labels can be laminated or coated in order to provide better resistance properties. Barriers to migration
and various other desirable properties such as anti-fingerprinting can also be incorporated, as well as
the ability to be post-marked, e.g., by laser.
In what has been referred to as Form Over Part Technology [1], a film is vacuum thermoformed over a
part after moulding without employing a mould. It is included here in view of its closeness to labelling
and sleeving (note that the same principle is proposed for sublimation printing of shaped objects - see
Part D, Section 28).
Innovation in this field concentrates on developing improved labelling devices and methods of adhesion,
and is mostly covered by any of IPC codes B29C (Shaping or Joining of Plastics; Shaping of Substances
in a Plastic State, in General; After-Treatment of the Shaped Products, e.g., Repairing), B32B (Layered
Products, i.e., Products Built-Up of Strata of Flat or Non-Flat, e.g., Cellular or Honeycomb, Form), B44C
(Producing Decorative Effects) or B65C (Labelling or Tagging Machines, Apparatus, or Processes).
Frequently named equipment innovators during the three year study include AVERY DENNISON, GRUPO
CONVERMEX, ILLINOIS TOOL WORKS, KHS, KRONES, NULABEL TECHNOLOGIES and SACMI VERONA.
145
Table 20.1 shows that the majority of innovation in decorative effects during the period examined has
concerned 3D, tactile and depth effects.
Among recently publicised innovations, SACMI developed a rotary Opera 500 45T RFST high speed
labeller for bottles that uses laser welding of roll-fed film [2], (see also Figure 20.1).
Figure 20.1
Sacmi formsleeve+ labeller for creating and applying sleeves with natural liquid bonding solutions followed
by heat shrinking.
Reproduced with permission from Sacmi Verona SPA, Mozzecane, Italy. ©2014, Sacmi Verona SPA
20.3 Patent Trends
Table 20.2
3D, tactile and depth effects Foaming agents to create tactile effects in sleeves or labels • Form over part
for depth, relief or tactile effects • Tactile or natural material application
Interference effects Interference label film
Metallic and reflective effects Form over part application to produce a metallic finish
Surface quality improvement Bottle seam avoidance for labels • Label damage reduction • Reducing
bubbles during labelling • Shrink-fit sleeve
Table 20.2 shows the themes of patents listed in this chapter. Most innovation in this area has focused
on the labels themselves (Part B, Section 6). No innovators with three or more patents were uncovered
during the three year period examined.
146
20.3.2 Items of Particular Interest Method for coating a core of an arbitrary

shape by thermoforming, automatic machine
The use of a heat-activated expanding layer in a for the implementation thereof and finished
shrink sleeve capable of creating tactile effects product obtained by such a method.
during shrinking. WO2011117487A1 Sep 29th 2011.
VERGNE, PASCAL
A method for enrobing a 3D object with a vacuum-
20.3.3 Principal Trends thermoformed skin without having to resort to creating
a mould cavity.
Form over part techniques in order to provide 3D,
tactile and depth, or metallic effects on substrates. Post molding application of an extruded film
to an injection molded part.
US8062451 Nov 22nd 2011.
20.4 Listed Patent Literature 2011-2103 (for DELTA ENGINEERED PLASTICS
search phrases see Part A, Section 2) A vacuum forming process is used to apply a decorated
film to a moulded part.
Depth Effects Production method of a molded article.
US8080124 Dec 20th 2011.
YAMAHA HATSUDOKI KABUSHIKI KAISHA
Method and device for applying decorative A decorative sheet is vacuum formed onto a substrate
body. without image deformation due to a metallic ‘spread
WO2011071091A1 June 6th 2011.
supressing member’ in the sheet.
HONDA MOTOR CO LTD
Applying a decorative body to a substrate by vacuum
Production process of plastic leather-coated
forming.
spectacle case.
CN102178386B Nov 7th 2012.
Shrink sleeve for an article closure. XINHE XINXIN BOX CO LTD
US20110177267A9 Jun 21st 2011.
A method for adhering a plastic leather material to a
MULTI-COLOR CORPORATION
moulding.
A foaming agent is used in a heat-activated expanding
layer in a shrink sleeve in order to create a 3D tactile
effect and conform well with any features in the 20.4.2 Interference Effects
substrate.
Decorated plastic package.
Decorating method and decorating apparatus. US8586158 Nov 19th 2013.
JP2011126263A Jun 30th 2011. TOYO SEIKAN KAISHA LTD
NAVITAS CO LTD A thin interference film is laminated to the exterior of
A substrate is vacuum enshrouded with a decorated a natural polyethylene terephthalate bottle in order to
film and steam used to fuse the film to the substrate. impart colour. The colour of the film can be easily locally
modified using a laser.
Wrapped three-dimensional shaped article
and process for its production.
US20110229681A1 Sep 22nd 2011.
20.4.3 Metallic and Reflective Effects
Costly die change parts for 3D decorations are avoided
by partially adhering relief components to the base Structure integrated by vacuum pressure
substrate and applying a decorative film by vacuum forming or vacuum forming, and
contact bonding. manufacturing method thereof.
WO2013003428A2 Jan 3rd 2013.
Resin film coating method and coating device. 3M INNOVATIVE PROPERTIES COMPANY
WO2011114484A1 Sep 29th 2011. A vacuum forming/filming method for producing a
TOYOTA JIDOSHA KABUSHIKI KAISHA metallised object.
A method for vacuum-forming a film over a relief
surface.
147
20.4.4 Surface Quality Improvement Multiple step forming and labeling process.
WO2013025699A1 Feb 21st 2013.
AVERY DENNISON CORPORATION
Oral care implement and method of
decorating. Methods for labelling thermoformed or blow-moulded
US7941924 May 17th 2011. substrates prior to the final forming stage without
COLGATE-PALMOLIVE COMPANY
causing label damage.
A shrink-fit, cling fit, or otherwise held sleeve or cover in
a decorated thin material is placed over a 3D moulding. Detection system and inspection method for
bottle seam and embossing alignment.
Method and device for labeling containers, US20130120746A1 May 16th 2013.
KHS GMBH
labeled container and self-adhesive label
therefor, and method and device for producing A detection device to avoid applying a label to a bottle
such a label. seam.
WO2011085790A3 Sep 13th 2012.
RWR PATENTVERWALTUNG GBR
A method for bubble-free applying labels that can be
subsequently removed for recycling purposes.
References
1. D. Northrop in Proceedings of the SPE Decorating TopCon Conference, Franklin, TN, USA, 2010.
2. San Benedetto, Scorzè plant, Goes for SACMI-RFST Technology, SACMI.

http://www.sacmi.com {Accessed June 2014}
148
21 Laser and Irradiative Marking, Engraving or Transfer
Table 21.1
21.1 Background
High powered light can be used to induce a chemical and/or physical change in a polymer substrate
surface. The change will result in various levels of contrast, colour, and definition depending on the type of
energy source, power, and concentration, as well as the choice of materials incorporated into the polymer.
The substrate may be a polymer, a blend with additives, or it may be pre-coated (i.e., with a reactive
multi-layer film or coating materials). The source of energy is most commonly a laser beam because of
the exceptionally high power density that can be achieved without excessive energy requirements or
substrate damage. Materials for such applications are covered in Part B, Section 4. The focus of patents
listed in this chapter with respect to decorative effects is shown in Table 21.1.
The particular advantage of laser energy is that its direction and intensity is in most cases digitally controlled
(i.e., plateless), non-contact, and does not require inks or drying, pretreatment or curing processes
associated with other decoration methods. Exceptions to the first two criteria are: a) if masks are used,
or b) if the laser is used to transfer media from a foil in contact with the substrate.
Table 21.2
Most common laser types used for marking of plastics
Laser type Description
CO2 gas laser Wavelength = 10,600 nm (far-IR). More heat generation.
Etches plastic surface. Faster. Typical power level used 10-25
W. Beams are pulsed, but energy level is not peaked
Nd:YAG (solid state crystal or diode pumped laser) Wavelength = 1,064 nm (near-IR). Less heating. Higher
resolution. Best for foaming and colour-change effects. Typical
power levels used 100 W
IR: Infrared
Nd:YAG: Neodymium doped yttrium aluminium garnet
Substrate marking using a laser is the most common process, usually employing either CO2 lasers (typically
around 50 W) emitting at a wavelength of 10,600 nm (far-IR), or Nd:YAG solid state or diode pumped
lasers (typically 100 W) emitting at 1,064 nm (near-IR) (see Table 21.1). The more recent diode pumped
versions are more compact and energy efficient than the solid state ones and require less maintenance.
Because beam divergence is proportional to wavelength, some more precise marking applications involve,
for example, green and UV excimer lasers, but the use of 1,064-1,070 nm remains predominant, with
149
increasing usage of ytterbium fibre (1,070 nm) and neodymium vanadate (1,064 nm). Fibre lasers offer a
number of improvements in construction and potential beam output [1]. Nd:YAG and shorter wave lasers
create less heating than CO2, and their output is more easily absorbed by a wider range of materials.
The most common marking system consists of laser, beam expander, computer-controlled galvanometer
double mirror deflection system for beam steering, i.e., vector marking, and finally a focusing lens.
Laser beams are narrow, typically around 100 μm, with a power level of 103-104 W/cm2. The choice of
laser type, power level and frequency, together with substrate polymer selection and additives [2] including
pigments, will determine the type of reaction described in Table 21.3. Most discovery in this area is entirely
empirical; a sample test grid of laser applied current (amps) versus pulse frequency is created in order
to determine the effects obtained and the optimum process window. When specific colours are sought,
only limited matching is usually possible. Additives incorporated into plastic substrates, in order to more
efficiently convert beam energy into heat energy, include mica, fillers such as clay or talc, or metal salts,
and are the subject of continuing innovation (Part B, Section 4).
Table 21.3
Different effects of laser treatment
Effect Comments
1 Carbonisation Higher frequencies are used in order to heat the surface more. The
polymer surface is carbonised, thereby creating good contrast on light
coloured substrates
2 Foaming Light scattering in the foamed surface layer produces a whitening
effect of relatively poor wear resistance, but providing good contrast on
darker backgrounds
3 Colour change, fading and internal Pigments or dyes incorporated into the polymer substrate either
blackening change colour, fade, or are destroyed. The result in bulk material can
be less sharp than with foaming or engraving
4 Engraving, ablation In laser ablation, a thin surface layer, for example a topcoat or
metallisation, is removed in order to expose a second layer or substrate
of different colour. Lasers are also used for selective plating techniques
(Sections 25 and 29)
5 Activation An additive in the polymer substrate is exposed and activated by
laser in order to selectively enable electroless plating (e.g., laser direct
structuring, below, and Section 25)
6 Transfer In a contact process, the coating on a foil normally in contact with the
substrate surface is transferred and fused with the substrate (e.g.,
Laser Colour Transfer process, below)
In a non-contact process, the laser beam causes a film of wet ink to
sputter towards a substrate (e.g., LaserSonic process, below)
Marking definition can be as fine as 25 μm in certain cases. Focal distance may be around 300 mm,
and the physical operating window (marking field) size 150 × 150 mm. To improve output and coverage,
beam splitting is possible in order to process more than one area at a time. Key laser parameters are
shown in Table 21.4.
150
Table 21.4
Key laser parameters
Parameter Description
Beam travel speed (mm/s) Typically 300-1,000 mm/s. A higher frequency allows higher speeds while maintaining
overlap in order to ensure continuous coverage over an area
Focal distance (mm) A lower focal length permits a finer and more energetic spot. Typically 200-400 mm
Frequency (kHz) 1-50 kHz. Created by pulsing. Optimum pulse time is 5-50 ns. Higher frequency
results in higher contrast and less etching
Marking field (mm) Up to 1,000 mm, but usually 100-250 mm. Heads can be doubled in order to increase
coverage (option of beam splitting or beam switching)
Power (W) Laser beam power is indicated by amps. In pulsed systems, peak pulse may be
higher
Spot diameter (μm) Typically 100 μm, range 30-500 μm. Increases with focal distance. A smaller spot
implies longer process time for coverage of a given surface area of substrate. Other
parameters refer to beam quality
Spot energy Up to 1013 W/cm2. Typically 103-104 W/cm2
Wavelength (nm) Fixed according to laser type. Shorter wavelength allows finer detail and less heating
effect. Beam divergence is proportional to wavelength
In laser direct structuring (LDS), commonly used for selectively plating electrical circuits onto 3D surfaces,
additives incorporated into the substrate polymer become exposed and activated by laser treatment. The
resulting surface roughening allows metal to be deposited with good adhesion in an electroless plating
step. This process can be used as an alternative to multi-material moulding in order to determine where
plating is to take place (Part D, Section 25 on plating), but the result is usually not cosmetic.
In a contact process, a laser beam can be directed at a transfer foil carrying a dried ink or coating. MERCK
and LEONHARD KURZ have developed the laser colour transfer process as a means for digitally marking
parts with a decoration said to be more resistant than conventional foils or inks [3].
There are also other applications for lasers which are likely to encroach further into mainstream plastics
decoration in the future. The LaserSonic process (developed by BASF, AURENTUM and machine
manufacturer SCHMID) is a non-contact plateless printing process alternative to inkjet and is able
to use standard printing inks. The laser beam, directed at an inked drum or belt running in a closed
circuit, causes the ink to sputter towards a passing substrate. Web print speeds of up to 120 m/min
at 240 dpcm (dots per centimetre) are envisaged [4]. The process is currently being used to metallise solar
cells as an alternative to screen printing. Other technologies mentioned elsewhere (and in contexts not
necessarily at present related to polymer substrates) include laser induced deposition, laser direct writing
and laser transfer film.
Recent equipment and process innovation patents have been seen from companies that include ALLTEC,
COHERENT, EXITECH, IPG PHOTONICS, LASEROP, KONINKLIJKE PHILIPS, MACSA, RAYDIANCE,
ROFIN-BAASEL, SHENZHEN JPT and VARDEX.
Fibre lasers are reported to be used in an increasing number of marking applications [1]. Developments
also include improved additives for providing better contrast in coatings or substrates (Part B, Section 4
covering laser-sensitive additives). New equipment includes an on-the-fly marking system from
TAMPOPRINT [5]; FOBA introduced its Point and Shoot system for accurately positioning laser marking
151
onto substrates [6]. For laser-produced effects, SOLEV announced its proprietary Ultra-Finesse decoration
process for metallised and lacquered surfaces [7]; TRI-STAR has developed a cold laser that can mark
highly temperature-sensitive substrates [8]; FRAUNHOFER ILT is working with industry partners in order
to economically produce functional surfaces on temperature-sensitive substrates in-line and without the
need for vacuum deposition. Their process uses wet chemical coating and laser functionalisation [9]; and
ROFIN has introduced picosecond lasers for precise marking and ablation allowing higher power to be
used on temperature-sensitive substrates [10].
Among other recently publicised innovations, the A*STAR SINGAPORE INSTITUTE OF MANUFACTURING
TECHNOLOGY has used a laser to create a template to microstructure a coated surface in order to create
a superhydrophobic (easy-to-clean) effect [11].
21.3 Patent Trends
Table 21.5
3D, tactile and depth effects Lenticular effects • Localised foaming • Natural material texture effects • Relief
patterns in a metallising basecoat • Use of lasers to structure the surface of a bottle
Colour effects Inkless colour printing • Multi-colour effects • Selectively binding an ink or coating
to a substrate • Selectively marking a colour layer • Selective masking prior to laser
exposure to change colour • Selective pigment fading
Definition, detail and contrast Bleeding or efflorescence reduction • Improved ablation quality improvement
through laser repetition rate • Laser colour transfer • Overlap improvement • Post
in-mould label marking • Selective marking inside or outside surfaces of substrates
Gloss and matte effects Selective matting • Surface etching of coatings • Surface wrinkling using excimer
UV
Metallic or reflective effects Laser direct writing with a metallic contact film
Olfactory effects Substrate heating used for odour reduction after laser marking
Surface quality improvement Optimising wavelength to reduce substrate damage • Reduced under-layer damage
• Residue removal using laser overlapping
Table 21.5 shows the themes of patents listed in this chapter. Much innovation involves the use of lasers
to mark or selectively ablate substrate surfaces. Several patent applications listed in Part D, Section
21.4 refer to the use of laser energy in order to create tactile surfaces. The use of lasers for multi-colour
effects can be considered to be important for their future expansion into more decorative applications.
Notable among the inkless printing solutions in this respect are US7897320B2 [12], WO2011089447A1
[13], WO2013014436A1 [14] and WO2013068729A1 [15].
In non-laser irradiative applications, the use of excimer UV energy to provide matte effects in coatings
by surface micro-folding has been a subject of interest for several years, and is the subject of a selective
process discussed in EP2418019A1 [16]. The downside is that an oxygen depleted atmosphere is
required, requiring enclosure techniques designed to reduce gas wastage that would occur because of
movement of 3D objects.
The most prominent innovating companies are listed in Table 21.6.
152
Table 21.6
1 DATALASE 3 10
Creating a relief pattern on a metallising basecoat prior to metallising; inkless printing techniques directly
to substrates.
Use of lasers to produce colour or multi-colour effects.
21.4 Listed Patent Literature 2011-2103 (for Laser-induced plastic foaming.

search phrases see Part A, Section 2) US20130065979A1 Mar 14th 2013.
CHEMISCHE FABRIK BUDENHEIM KG
A method for locally foaming a plastic substrate, ink,
21.4.1 Three-dimensional, Tactile and or coating using a laser.
Depth Effects

Methods of forming graphics on a substrate
and laser active coatings.
WO2011031468A1 Mar 3rd 2011. Inkless printing apparatus.
MASONITE CORPORATION WO2011089447A1 Jul 21st 2011.
Natural effects, e.g., imitation wood, created on coated DATALASE LTD
substrates. Laser radiation or other source of two or more distinct
wavelengths is used in order to achieve multi-colour
Laser modified plastic container. images on a substrate containing colour-change
US20110089135A1 Apr 21st 2011 additives. A first wavelength (e.g., infrared or near-
A laser is used to structurally modify, and therefore infrared) is used to activate the colour change additive
re-enforce, thin-walled polyethylene terephthalate and a second wavelength (e.g., ultraviolet) to effect the
containers in order to reduce their deformation during colour change.
filling or transport. The same device can be used to
replace the need for labels. Method and device for producing colour
images by way of a UV laser on pigmented
Method for realizing metal embossing effect substrates, and products produced as a result.
on plastic-rubber base material. WO2012062505A1 May 18th 2012.
CN102133835A Jul 27th 2011. U-NICA TECHNOLOGY AG
SUZHOU MITAC PRECiSION TECHNOLOGY CO LTD Multi-colour effect by using a laser to selectively fade
A laser is used to create a relief pattern on a metallising colour pigments incorporated into the substrate.
basecoat prior to metallising and topcoating.
Decorating, labeling and/or tagging
Method for producing objects with a defined component surfaces, comprises applying
structured surface. coloring layer on component surface and
US20120104637A1 May 3rd 2012. curing, applying clear coat layer over coloring
3D INTERNATIONAL EUROPE GMBH layer and curing clear coat, and modifying
A low-cost method for producing a lenticular surface selected area of coloring layer.
for 3D imaging using ultraviolet curable liquids and DE102010054837A1 Jun 21st 2012.
selective laser exposure or masking. RITZI LACKIERTECHNIK GMBH
153
A decoration method in which a plastic substrate Use of a laser to mark coatings applied to the outside
is painted and dried and then topcoated and with a or an intermediate face of a perfume bottle.
clear coating which is cured, and then the substrate
is subjected to laser marking which only affects the Plastic shell with ink-free pattern and its
colour layer. manufacturing method thereof.
US2011097540A1 Apr 28th 2011.
Polymer laser marking. QUANTA COMP INC
WO2012115824A3 Oct 18th 2012. A laser is used to engrave an image on a film applied
FERRO CORPORATION to an object by in-mould roller.
A laser-sensitive water-based coating for a polymer
surface whereby the pigment of the irradiated portion Sealing of inscriptions on plastics.
becomes encapsulated into the polymer surface, and US20110117335A1 May 19th 2011
excess coating is subsequently washed away. One method for laser decorating plastics is to place
a coloured media on the plastic surface and expose
Method for activating colorant associated with to a laser beam. Such media are highly loaded with
an article. pigment or dye, and tend to bleed or effloresce once
WO2012177692A1 Dec 27th 2012. so treated. This invention claims to resolve this problem
THE PROCTER & GAMBLE COMPANY by applying a translucent sealing polymer protective
The use of masks in order to selectively activate layer in the same manner.
colorants in, or applied to, an article using
electromagnetic radiation. Packaging for a cosmetic product comprising
a hollow body having a localized coating-
An inkless printing method. free pattern in a portion of a layer of a laser-
WO2013014436A1 Jan 31st 2013. removable coating.
DATALASE LTD WO2011117515A1 Sep 29th 2011.
A method for marking a substrate in more than SOCIETE LOTOISE D’EVAPORATION (SOLEV)
one colour using two-stage focused high energy Laser engraving of an image inside a container. (See
electromagnetic radiation. The first wavelength causes also WO2011131911A1)
an initial colour change, and a second high-power beam
effects a second colour change. Laser marking method.
US20120013699A1 Jan 19th 2012.
Method of forming an image on a substrate. SHIZUOKA PREFECTURE
WO2013068729A1 May 16th 2013. A coloured dye or pigment is vacuum deposited from
DATALASE LTD an off-contact transfer paper and a laser subsequently
A method for obtaining multi-colour images in, for used to selectively blend it with the plastic substrate
example, a multi-layer laminate using a laser. material in order to form a well-defined image. Excess
colouring material is removed by washing.
Process for producing a laser-marked
laminate and use of a laminate for laser Laser marking of an interior cavity of a
marking. securing means of a substance-container.
EP1852270B1 Sep 25th 2013. US20120111865A1 May 10th 2012.
TECHNO POLYMER CO LTD TELESIS TECHNOLOGIES INC
A laminate which is laser marked in two or more A method for permanently marking the inside of a
different tones by employing two or more laser lights container cap.
with different energies.
Housing for electronic device and method for
US20120168339A1 Jul 5th 2012.
HON HAI PRECISION INDUSTRY CO LTD
Method for decorating perfume bottle, and A laser is used to produce a decorative image after
decorating device. in-mould labelling, thereby avoiding problems of ink
US20110039038A1 Feb 17th 2011. washing out during the moulding process.
SHISEIDO INTERNATIONAL FRANCE
154
Enhanced quality of laser ablation by 21.4.5 Metallic or Reflective Effects

controlling laser repetition rate.
US8344286 Jan 1st 2013.
Method and apparatus for deposition.
INTERNATIONAL BUSINESS MACHINES CORPORATION
WO2011154747A1 Dec 15th 2011.
Laser repetition rate is manipulated in order to improve DZP TECHNOLOGIES LIMITED
ablation quality. A method for laser direct writing onto a substrate using
a near-infrared laser and a laser-transparent media
Staggered laser-etch line graphic system, support placed close to the substrate. Metal can be
method and articles of manufacture. deposited.
US20130337238A1 Dec 19th 2013.
ECHELON LASER SYSTEMS LP
A method of reducing the visibility of image overlaps 21.4.6 Olfactory Effects
where each laser image is smaller than the total surface
to be printed. Odor reduction in laser processed material
with curl reduction.
WO2013170160A1 Nov 14th 2013.
PRECO INC
Post-heating is used to remove odour from laser
Method for manufacturing decorative molding, marking.
and decorative molding obtained by the
method.
JP2011000797A Jan 6th 2011. 21.4.7 Surface Quality Improvement
KEY TRANDING CO LTD
A method for selectively matting exterior areas of Method and apparatus for optimally laser
a substrate involves incorporating additives in the marking articles.
polymer and irradiating with a laser. WO2013074105A1 May 23rd 2013.
ELECTRO SCIENTIFIC INDUSTRIES INC
Method for manufacturing decorative An improved method for laser ablating a coating without
component, and method for decorating damaging the under-layer.
component.
JP2011147969A Aug 4th 2011. Method for marking components using
TRINITY IND CO LTD overlapping and then barely overlapping laser
A substrate is printed or coated with a coloured layer pulses.
followed by a protective clearcoat. The clearcoat only WO2013149747A1 Oct 10th 2013.
is laser etched in order to provide optical enhancement. SCHAEFFLER TECHNOLOGIES AG & CO KG
An overlapping method for laser marking in order to
Method for partial matting of UV varnishing remove residue.
layers.
EP2418019A1 Feb 15th 2012. Laser marking of polymer materials.
HUECK FOLIEN GMBH US20130279527A1 Oct 24th 2013.
A masking process exposes a wet ultraviolet-curable ADVALUE PHOTONICS INC
film to excimer radiation in a partially controlled A method for laser marking transparent polymer substrates
atmosphere order to promote a selective matting effect involves using a wavelength of around 2 microns in order
through micro-folding of the lacquer surface. to correspond with the absorption characteristics of the
polymer, and modifying the substrate surface without
destroying it or substantially degrading it.
155
References
1. T. Hoult, Fiber Lasers Technical Digest, Industrial Laser Solutions.

http://www.industrial-lasers.com {Accessed June 2014}
2. S.R. Sabreen, Laser marking plastics, Industrial Laser Solutions.

http://www.industrial-lasers.com/articles/print/volume-23/issue-1/features/application-report/
laser-marking-plastics.html {Accessed June 2014}
3. New Labeling Technology for Plastic Parts, Leonhard Kurz Stiftung & Co KG.
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0457083/$FILE/C35C95EE1F98783AC125765000457083.pdf {Accessed June 2014}
4. Future Technology – LaserSonic, Aurentum.

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5. Laser Marking ‘On-the-Fly!’, Actuell & Informed News, 2012, 9, 1.

http://www.tampoprint.pl/tampo2/en/aktuell_informiert_en/pdf_en/news_9_2012_mof_multi_web_
en.pdf {Accessed June 2014}
6. FOBA Point & Shoot – Camera System for Direct Mark Positioning, Alltec GmbH.
http://www.youtube.com/watch?v=0Uys1NikfjI {Accessed June 2014}
7. S. Pitman, Solev Launches New Decorative Laser Finish for Packaging, Cosmetics Design-Europe.
http://www.cosmeticsdesign-europe.com {Accessed June 2014}
8. Cold Laser™ Series Marking System, Tri-Star Technologies.

http://tri-star-technologies.com {Accessed June 2014}
9. Combining Wet-Chemical Coating Processes with Laser Functionalizing, European Coatings.

10. Short Pulsed Lasers, Rofin.

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11. Researchers Develop Fabrication Method for Superhydrophobic Surfaces, European Coatings, Inc.
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12. N.J. Rogers, C. Lamb and A.N. Jarvis, inventors; The Procter & Gamble Company, assignee,
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13. J. Cridland, A. Jarvis, M. Walker and C. Wyres, inventors; DATALASE, assignee; WO2011089447A1,
2011.
14. J. Cridland, inventor; DATALASE, assignee; WO2013014436A1, 2013.
15. A.N. Jarvis, C.A. Wyres, W. Green and M.R Walker, inventors; DATALASE, assignee; WO2013068729A1,
2013.
16. G. Brandstetter, G. Aigner and H. Käferböck, inventors; HUECK FOLIEN GMBH, assignee;
EP2418019A1, 2012.
156
22 Liquid Coating Techniques
Table 22.1
22.1 Background
In mainstream decorative applications on moulded 3D substrates, liquid coating techniques are typically
used to apply a clear liquid coating or a coloured or metallic paint to a substrate in order improve and/
or alter its appearance and protect it from abrasion or chemical attack. On occasions the coating is
also designed to provide some other function such as antimicrobial, anti-reflective, antistatic, barrier
to permeation, easy-to-clean, self-cleaning or self-healing properties. There are many different coating
processes, and these are summarised in Table 22.2. Table 22.1 shows that the most frequent target of
innovation lies in the field of surface quality improvement, i.e., to improve the appearance and durability
of the polymer substrate.
A common challenge for many of these processes, which mostly use low viscosity products to ensure
good flow-out and quality finish, is edge effects due to excessive build-up and surface tension effects.
For this reason, for the finest finishes, coating thicknesses in such cases tend to be kept low, e.g.,
under 20 μm.
A second challenge is to obtain the required low viscosity. This has, historically, been enabled by the use
of solvents which also help good substrate wetting. For safety and environmental reasons solvents are
being increasingly replaced by aqueous solutions, or the use of liquid coating resins is optionally further
aided by heating. If the viscosity remains higher, a thicker film is required in order to improve the surface
finish and to avoid orange peel, but the risk of edge effects is then greater.
In some cases a third challenge is to selectively coat a surface. For a major evolution in possibilities in
this respect, refer to Part D, Section 19 on inkjet printing.
A challenge for all these processes is the eventual presence of contaminants on the substrate surface
or dust in the air. Coating operations are therefore usually conducted in a Class 10,000 [1] or ISO 7 [2]
environment with prior deionisation, dust removal, and sometimes degreasing operations. In recent years
in-line CO2 snow cleaning has been successfully deployed, particularly for the automotive industry, but
such cleaning methods are hampered by the cost of the compressed air and the raw material as well as
by the problem of noise. Several patents have appeared on process improvements [3, 4].
157
Table 22.2
Common liquid coating processes for 3D objects
Process Description
1 Curtain coating The substrate is advanced while a thin film of liquid coating is poured onto it from a slot die
above. It is, therefore, a process best adapted to flat or near-flat objects
2 Dip coating Substrates are immersed in a bath of low viscosity coating and then very slowly removed.
The process is used, for example, for applying organic hardcoats to lenses and device
screens. The challenges are: a) to avoid the last drop that tends to remain after full
withdrawal of the substrate from the bath, and b) to control solvent loss
3 Doming A technique that uses high viscosity products. Used most notably as a decorative effect,
for example for key holders and badges. A viscous 100% solids coating is applied to the
substrate using an out-of-contact syringe (or in some cases a transfer pin) and leaves
a domed surface. Top recesses in moulded substrates have also been filled using this
technique in order to achieve an aesthetic optical effect that may cover a decoration or
embossed image
4 Drum coating In a highly efficient and low-cost process substrates are tumbled in an enclosed drum while
introducing a coating by drip feed or spray. The process is used for applying a functional
coating to parts, such as slip or lubricant, as well as a for decorative painting, where transfer
efficiencies are considerably higher than spray painting, thereby reducing materials costs.
The multiple contact between substrates implies that the final paint finish is not smooth
or specular, but cosmetically pleasing tactile matte or satin effects can be achieved. The
process can be used, for example, for coating pen bodies or handles, as well as substrates
difficult to hold individually during a spray process
5 Flow coating Substrates are rotated as they move in a solvent-laden atmosphere while a low viscosity
coating is poured onto them. As with dip coating, control of solvent loss is a challenge
6 Roller coating This technique is typically used for varnishing flat or cylindrical surfaces using a rubber
transfer roller in contact with the substrate. It is employed, for example, in-line with dry offset
or flexographic printing. A smooth stainless steel roller or engraved anilox rotates half-
immersed in a bath of low viscosity coating while either a second smooth steel roller or a
doctor blade respectively ensures even metering of the coating to the rubber roller
7 Spin coating A flat square, oblong or typically round substrate, such as an optical disc or lens, is spun at
high speed (several thousand rpm) while liquid coating is poured onto its centre. The liquid
spreads out due to centrifugal force. The coating film thickness can be well-controlled
8 Spray coating A low viscosity paint or coating is atomised, usually using compressed air, a spinning head,
or ultrasonics, towards a stationary or rotating and moving substrate, typically 50 to 200
mm away. Smaller substrates may be sprayed on chain-on-edge conveyors. Electrostatic
assist can be used in certain cases to improve transfer efficiency
Drum coating (see Figure 22.1) has seen a recent surge in activity, notably in processes provided by
SPECIAL COATINGS and WALTHER TROWAL, both in Germany. Several thousand small substrates, e.g.,
handles or closures, can be coated in a cycle time that may be in the order of one hour during which a
slow spray gradually coats the parts which are tumbling in warm air. Water or solvent-based air-drying
coatings or paints are used. Coatings are formulated to dry upon contact, and catalysed versions are
available. Metallic effects are common, and the process is virtually labour-free. The enclosed drum
ensures very efficient coating usage.
158
Figure 22.1
SC-Coater® for low-cost drum coating, e.g., for quality metallic paint finishes.
Reproduced with permission from Special Coatings GmbH & CO KG, Gilching, Germany.
©2014, Special Coatings GmbH & CO KG
Spray coating is the most common liquid coating process. As with dip, curtain and flow coating, it can be
responsible for an exceptionally high quality finish, and is often faster to carry out. The sprayed coating
may be colourless, contain matting pigments, or coloured or metallic pigments or dyes. The spray system
may be manual or automatic, and the substrates coated with fixed or moving spray guns. The substrate
itself can be fixed or moving, with or without rotation. An automatic spray coating line may be equipped
to apply and dry/cure successfully two to three or more coats with or without intermediate drying and
curing, all in-line.
Spray coating tactile effects in the form of relief finishes can be achieved by incorporating granulate
either in the spray or applying it afterwards before drying and curing (Part D, Section 26), or by reducing
atomisation through pressure reduction or disk or bell rotation speed in order to substantially increase
the droplet size.
Substrates may be partially masked, e.g., with features included in their holders or using a manually
removable label. In some spray processes, a mechanical electroformed mask is brought into contact
with the substrate prior to spraying, and then solvent washed prior to re-use.
Other than inkjet devices, small spray guns, ultrasonic heads, or other special devices exist for selective
deposition, for example, onto circuit boards. NORDSON ASYMTEK produces an example of such a new
system.
Feeding of the coating may be from a pot or container fixed to the spray head, via a line fed from a
separate pressure pot, a continuously recirculating system driven by a pneumatic or mechanical pump,
or a one-way feed driven by a mechanical gear or peristaltic pump. Recycling systems ensure improved
homogeneity of temperature and pigment dispersion.
Atomisation may be achieved using compressed air surrounding a nozzle (pneumatic spraying), forcing
a product through a nozzle using high pressure (airless spraying), a spinning disc or bell, or ultrasonically
159
activated nozzles. On a 3D substrate, more than one such device may be required if the guns or heads
are fixed. The effect of rotating substrates in front of spray heads can cause challenges; on a complex
shape, for example a rectangle, the spraying operation with fixed guns may require two or more spray
posts with alternating clockwise and anti-clockwise substrate rotation to maximise homogeneity of the
coating surface and avoid localised orange peel or sagging.
After any evaporation of solvents or water, the final coating may have a thickness ranging from a few
microns to low tens of microns. A typical dried, pigmented or clear organic coat, may have a film thickness
ranging from 5-20 μm. Drying and any curing may be carried out separately, or on the same conveyor (to
avoid the opportunity for any intervening pollution). Drying alternatives, to remove any water or solvent
present in the formulation, are: a) ambient air, b) hot air, c) long, medium, or short wave infrared (IR;
medium wave is most efficient because of the absorption characteristics of the coating and substrate).
A coating may be designed to dry only, without curing, and therefore yield lower resistance properties.
Curing results in polymerisation of the coating, provided suitable reactive materials are present. Alternative
energy sources are typically: a) ambient air; b) hot air; c) long, medium, or short wave IR; or d) UV, or
electron-beam (EB) curing. Solvent or water evaporation may take from 30 seconds to several minutes,
depending on the formulation (light or heavy solvents), and curing from several seconds (UV) to more
than 30 minutes (heat-cure, depending on the formulation). Solvent build-up in drying zones is avoided
by introducing and circulating a portion of fresh air in order to ensure that the solvent concentration
remains below 20-25% of the lower explosion limit value for the solvent, usually a figure in the order of
1% by weight per drying volume. Extraction vents are kept low since solvent vapour is heavier than air.
A key cost feature in spray coating is overspray. This can vary from 30% to more than 90% depending on
the type of spray device and setting, how close it is set to the substrate, and substrate size and spacing.
Overspray increases if finer spray is produced with high-pressure compressed air. Spray is also lost if
substrates are smaller than the spray jet, and the spraying is continuous with substrates spaced apart from
each other as they move past. Gun setup is always an important factor, and invariably coating consumption
can be reduced by 30% or more if a more careful setup is carried out. Best practices include spraying close
to the substrate (e.g., <100 mm), using narrow jets, and, where output speed requirements allow, indexing
any conveyor in order not to spray between or beyond parts, or using following gun devices. Important
economies can be made by employing an atomising process that produces a lazy jet, such as ultrasonic
or spinning bell heads, and, if possible, with electrostatic assist and minimum compressed air used for
shaping the jet. Most spray heads used are pneumatic guns, and adequate quality can often be achieved by
reducing pressures, using guns referred to as high-volume-low-pressure (HVLP) of even very low pressure.
However, the use of compressed air in order to atomise inevitably encourages overspray. Electrostatic bells,
which consist of a small head that typically spins at between 40,000 and 60,000 rpm, use shaping air to
direct the spray jet, and this too must be judiciously employed. However, provided electrostatic attraction
can be used, transfer efficiencies can be at least doubled in relation to pneumatic devices.
For electrostatic spraying, there are several methods to provide conductivity in order to reduce overspray:
a) a conductive prep-coat that grounds the substrate to its conductive holder; b) conductive additives
incorporated into the substrate polymer; and c) using a metallic part holder inside or behind a substrate.
Electrostatic spraying requires maintenance of larger distances between the substrates and the metallic
spray booth walls and conveyor.
Ultrasonic spraying is another alternative generally reserved for highly diluted coatings, but throughputs are
low thereby requiring many heads. Atomised particle size is relatively high (e.g., 30 μm) and the technique
is not usually encountered in decorative spraying on plastics. Airless spraying, in which atomisation is
achieved using high pressure to the product and nozzle, is a widely employed technique in non-decorative
paint applications and has also recently been used in this field.
160
So-called 100% solids coatings, which are usually UV-curable and contain reactive liquid resins, can be
recycled by passing the extracted overspray across baffles and allowing the accumulated liquid to flow
down into a vessel for re-filtration and reuse. The same practice can be used for solvent-borne versions,
making up for any lost solvent. This practice is restricted to non-pigmented coatings.
Traditionally spray coating has been carried out separately to moulding, often in different plants and
on high-speed conveyors running at up to 15-20 m/min for smaller substrates, with all the incumbent
issues of surface damage and pollution intervening. In order to reduce costs as well as improve control of
substrate surface quality, in-line spray coating is becoming more common, with robotic transfer directly
from the mould, and linear speeds in the order of 10 times less in order to match moulding output. An
added advantage in better controlling the substrate surface by being in-line is that solvent usage, used
to improve substrate wetting, can be reduced or entirely dispensed with.
The emerging, more common scenarios for spray coating are therefore as follows:
1. Spray coating in-line or in synchronisation with moulding, automatic loading, small footprint machine.
2. Slower indexing lines, spray stops and starts only when the substrate is present.
3. 100% UV-cured coatings with overspray recycling where possible.
4. Electrostatic assist for spray transfer efficiency.
This overall subject is largely covered by any of IPC codes B05D (Processes for Applying Liquids or Other
Fluent Materials to Surfaces, in General), B05B (Spraying Apparatus; Atomising Apparatus; Nozzles) or B05C
(Apparatus for Applying Liquids or Other Fluent Materials to Surfaces, in General), and coatings formulations
are covered in Part B, Section 7. Other than the scenarios mentioned previously, innovation has focused
on handling systems; spray booth design and materials, improved controls and design for rotary atomisers
and pneumatic spray guns and their feed systems (e.g., from ANEST IWATA, ILLINOIS TOOL WORKS,
RANSBURG and TOYOTA), as well as spraying of multiple component or multi-coat applications. Two recent
Chinese patents talk of spraying in a vacuum chamber in order to control emissions [5, 6].
22.2.1 Materials
Lucon® PS-6080EX from LG CHEM is an acrylonitrile-butadiene-styrene (ABS) containing carbon

nanotubes that does not require a paint primer for electrostatic spraying. Antistatic grades of polycarbonate
(PC), PC/ABS, metallocene polypropylene oxide/polyphenylene oxide and poly(p-phenylene sulfide) are
also available [7].
22.2.2 Miscellaneous
New compressed air cleaning and heating systems are available from MARTECH SERVICES CO. [8]; at
K 2013, WANDRES showed its brush and microfibre (Microfaser) cleaning sword systems for removing
dust and fingerprints from substrates [9]. A low-emission burn-off oven for metal holders is available from
ACE EQUIPMENT [10]; and a spray pattern sensor mat has been developed by PRESSURE PROFILE
SYSTEMS [11].
161
22.2.3 Processes
The SURREY MATERIALS INSTITUTE, BP INSTITUTE and AKZO NOBEL have developed IR Radiation-
Assisted Evaporative Lithography using a shadow mask, in order to create patterns in coatings [12].
22.2.4 Spray Booths
DÜRR introduced its EcoDryScrubber paint booth system [13].
22.2.5 Spray and Coating Feed Equipment
New equipment developments include the following: The NORDSON Trilogy™ electrostatic spray gun
producing 93 kV [14]; quick-change guns from REITER [15]; flowmeters from CORIOLIS [16]; the Accubell
electrostatic spray gun for aqueous coatings from SAMES [17]; the Quattro airless spray gun from
NORDSON [18]; AirPro pneumatic guns for various air pressures from GRACO [19]; medium pressure
guns from WALTHER PILOT [20]. NORDSON ASYMTEK has won a Global Technology Award for its
NexJet precision coating system and Genius Jet Cartridge [21]; WALTHER PILOT has produced a new
WA 900 with HVLP Plus nozzle technology for more efficient coating consumption than HVLP [22]; and
WALTHER PILOT has described the advantages in combining recirculation with pressure tanks, including
providing a more regular spray [23].
22.3 Patent Trends
Table 22.3
3D, tactile and depth effects Crack patterns • Flow patterns • Partial mixing • Relief patterns • Second surface
effects
Colour effects Antique look • Application control using a robot • Colour gradients • Disguising
overlap edges between two colours
Gloss and matte effects Gloss level control in multi-layer applications • High pigment loaded matte basecoat
to control matteness • Surface wrinkling using UV exposure
Metallic or reflective effects Controlled evaporation • Half mirror reduction process • Improved metallic effect
from application method • Improved multi-coat effects • Silver reduction • Specular
level control
Selective coating deposition Masking solutions
Surface quality improvement Bubble reduction • Disguising substrate join lines • Drip control • Dynamic spray
control • Electrostatic voltage control • Film surface quality improvement • Film
thickness control • Improved multi-coat application • Paint edge control or removal
• Pinning techniques to reduce film defects • Popping reduction • Spray fan control
• Spray shaping air temperature control • Substrate preheating and low bake
temperatures to improve film quality
Table 22.3 shows the different themes presented by the patents mentioned in this chapter. Principal
trends are listed in Table 22.4. The predominating subject is spray coating in relation to other application
techniques, and Table 22.5 analyses the focus within this subject area.
162
Table 22.4
Repartition of application techniques for liquid organic coatings
1 Spraying 15 52
2 Dip 5 17
3 Curtain 3 10
4 Spin 3 10
5 Roller and contact methods 2 7
6 Flow 1 3
Tactile and 3D effects are proposed that use physical methods such as varying thickness, locally applied
solvent, compressed air, or using surface tension effects by pulling away a plate contacting the wet
coating. Colour gradients are proposed by manipulating coating feed, locally airbrushing colours, masking
techniques, or robotically moving spray heads. Matte manipulation is proposed by using a matting agent,
multi-layer applications, or the use of excimer UV to provoke surface wrinkling.
Various techniques are proposed for metallic effects. Traditionally they can be improved by applying
multiple thin layers of low viscosity paint containing metallic flake pigment, preferably produced by vacuum
metallising, in order to ensure flat pigment orientation [24], and several innovations here fall along the same
lines. However, arguably the most important innovation here is the new more benign chemistry introduced
into silver reduction spraying by Jet Metal Technologies (US20110155444A1 [25]). Continuous bright metallic
films are produced by a low-investment spray process, although the use of more costly silver is involved and
substrates must be able to undergo copious rinsing without any features that may provoke water retention.
As in vacuum metallisation, a basecoat and topcoat are normally required, and for smaller substrates such
as closures and small bottles, these are sprayed, dried and cured in-line on the same conveyor.
Table 22.5
Focus in spray coating technique
Rank Trend Number of patents
1 Multi-layer coating 16
2 Electrostatic spraying 8
3 Multiple component spraying 1
(Non-specified) (12)
Innovation in surface quality improvement, the largest subject of focus here, has included techniques to
remove edge effects, e.g., in dip or curtain coating; improved spray devices or their controls and feed
mechanism; improved formulations for multi-layer coating; the use of UV pinning to prevent surface
defects appearing (EP2419223A1 [26] and WO2013146730A1 [27]).
Table 22.6
1 BASF 4 7
2 DUPONT 3 5
3 KANSAI PAINT 3 5
163
Improved fan and temperature control in electrostatic devices; pinning techniques to reduce defects; and
silver reduction for metallic effect.
Improvements in electrostatic spraying techniques.
22.4 Listed Patent Literature 2011-2103 (for Injection preform having pattern on surface
search phrases see Part A, Section 2) thereof and method of manufacturing the
same.
US20120088077A1 Apr 4th 2012.
22.4.1 Three-dimensional, Tactile and SAMSUNG ELECTRONICS CO LTD
Depth Effects A translucent injection moulded substrate with a
second-surface sprayed crack pattern.
System for applying varnishes with relief.
ES2350546BA Jan 25th 2011 Pattern coating method using surface tension
An application roller for a varnish or paint contains relief and density, and apparatus thereof.
forms that allow deposition of thicker areas of coating WO2013018956A1 Feb 7th 2013.
in one pass. KIM CHANG KUN
A method for forming relief patterns on a surface
Lacquer pattern production method, lacquer without using solvents using a contact plate which is
pattern formed by using the method, and removed before curing.
lacquer pattern display method.
US20110154701A1 Jun 30th 2011.
DUCO CO LTD
Flow patterns are induced in a lacquer film by locally
applying solvent before the coating is dried. Crack Process for producing two-tone coated
patterns are also introduced by adding a protein substrates.
containing drying agent into the lacquer film before US7943197 May 17th 2011.
drying, and further aesthetic effect can be achieved by E I DU PONT DE NEMOURS AND COMPANY
adding thin gold foil. A visible overlapping zone or perceptible edge between
two colours is avoided by spraying colour 1 beyond
the required area, masking, and then spraying colour
Process for making decorative crack pattern
2, removing the mask and applying a top clearcoat
on object and digital camera with decorative
before curing clearcoat and colour 2 at the same time.
pattern.
WO2011124081A1 Oct 13th 2011.
AIGO DIGITAL TECHNOLOGY CO LTD Production of color coatings gradients,
A ultraviolet-curable coating providing a crack pattern application methods and uses therefor.
after spraying, baking and ultraviolet curing. US7979226 Jun 12th 2011
A computer is used in conjunction with mixing/blending
equipment in order to vary spray coating composition
Method of forming multi-layered patterned
in order to obtain colour gradient coatings.
coating film.
US8071170 Dec 6th 2011.
KANSAI PAINT CO LTD Process for archaizing surfaces of plastic
A multi-layered patterned coating film with 3D effect is nameplate.
achieved by wet-on-wet spraying of a 3-coat thermally CN101923806B Dec 21st 2011.
cured solvent or water-borne system. The second coat is BOFENG WANG
applied in different colours using 2-4 nozzles, and its solids A combined moulding and spraying process providing
content once applied is high enough to cause only partial an antique look to plastic wine labels.
merging with the basecoat so that a pattern is obtained.
164
Device for gradient color coating of plastic shell. Method for producing homogeneously matte
CN202113980 Jan 18th 2012. coatings by means of radiation hardening.
STARSEIKI ELECTRICAL APPLIANCE PRODUCTS HANGZHOU WO2013092521A1 Jun 27th 2013.
CO LTD BAYER MATERIALSCIENCE AG
A robotic method for varying spray film thickness across A solution for creating matte finish in 100% ultraviolet-
a substrate. curable solids coatings over 20 microns by surface
wrinkling.
Manufacturing a container with solid colored
coating, comprises providing bottle for
containing cosmetic product, applying fluid 22.4.4 Metallic or Reflective Effects
dye solution on part of the bottle, and forming
solid colored coating of dye solution applied Coating film formation process and coated
on the bottle. article.
FR2945757B1 Jan 11th 2013. EP1482014B1 Jan 5th 2011.
L’OREAL HONDA
A dip coating process for decorating bottles. Controlled evaporation in a multi-coat sprayed
application is applied in order to improve metallic
Smart phone and plastic part surface gradient effect.
color decoration layer making method.
CN102922939A Feb 13th 2013. Half mirror and process for producing same.
CHITWING MOULD INDUSTRY DONGGUAN CO LTD US20110141568A1 Jun 16th 2011.
A colour gradient effect is achieved using an airbrush OMRON CORPORATION
technique on an applied coloured ink. The ink is A controlled chemical reduction process by various
protected by basecoat and topcoat layers. application means is proposed that allows the creation
of a semi-translucent mirror in tin, indium, nickel, gold,
22.4.3 Gloss and Matte Effects palladium, or silver.
Method of forming metallic tone glitter paint

Method for producing a film with a matt surface.
films and painted objects.
DE102012104513A1 Nov 29th 2012.
US7981529 Jun 19th 2011.
SUEDDEKOR GMBH
BASF COATINGS JAPAN LTD
A method for producing well-cured scratch-resistant
clear or coloured matte 100% solids coatings involves A high chroma sprayed metallic paint with a clear
first monochromatic ultraviolet exposure in order to topcoat.
wrinkle the surface, followed by electron beam curing
in order to achieve through-cure. Coating method.
US20110159197A1 Jun 30th 2011
Process for producing multi-layer coating. Improved metallic effect and transfer efficiency are
US20130040149A1 Feb 14th 2013. obtained by more flexible manipulation of the spray
E I DU PONT DE NEMOURS AND COMPANY pattern of an electrostatic bell.
A method for wet-on-wet spray coating two or more
layers and controlling gloss level. Electroless method for in-line metallization
of substrates by spraying them, with
Basecoat/clearcoat coating. prior surface treatment and device for
US20130052454A1 Feb 28th 2013 implementing the method.
A method for obtaining a sprayed matte coating with US20110155444A1 Jun 30th 2011.
good performance characteristics entails applying a STREMSDOERFER
sprayed basecoat with high pigment ratio. A silver reduction spraying process.
Low gloss metallic color coating. Method for forming multi-layer coating film.
WO2013013236A3 Apr 11th 2013. WO2012002569A1 Jan 5th 2012.
E I DU PONT DE NEMOURS AND COMPANY KANSAI PAINT CO
A method for controlling the matteness of a sprayed A 3-coat 1-bake spraying process using aqueous
metallic coating. coatings without intermediate drying is achieved by
165
employing a hydrophobic solvent in the intermediate Selective high gloss is achieved using a 2-coat
coating layer that contains the effect pigment. application and, using a mask, selectively polishing in
order to obtain gloss areas.
Method for producing a multi-coat colour and/
or effect paint system, the colour-forming
coating composition comprising a ketone for
reducing the pinhole count.
DE10025768A1 Jan 5th 2012. Lacquer film product for applying a seamless
BASF COATINGS GMBH surface over an object embedded in a carrier
A sprayed basecoat-topcoat aqueous system with element, comprises a transparent area, which
improved quality after a single drying step. is arrangeable over the object, a transparent
film layer, and a transparent cover layer.
Method of producing a polished metal effect DE102009032815 Jan 20th 2011.
DAIMLER AG
finish on a vehicle.
US8512802 Aug 20th 2013. A method for hiding join lines in a spray coated
AXALTA COATING SYSTEMS IP CO LLC
substrate that has an embedded label or appliqué.
Multiple spray applications of thin metallic coats in
order to improve metallic appearance are avoided Rotary atomizer and coating pattern control
by applying an aqueous metallic pigment-free black method.
basecoat to hide substrate defects and colour, and US20110014387A1 Jan 20th 2011.
then a single aqueous metallic layer. Both layers contain Improved fan control for a rotary spray device.
aqueous microgels and sheet silicate to avoid mixing
of the layers before full heat drying and curing. Circuit for displaying the relative voltage at the
output electrode of an electrostatically aided
Methods for tailoring the properties of a coating material atomizer.
reflective coating. CN101970125A Feb 9th 2011.
WO2013158345A1 Oct 24th 2013. A device for indicating voltage on a pneumatic
GE LIGHTING SOLUTIONS LLC electrostatic spray gun.
A two-stage curing process of a sprayed reflective
coating is used, whereby the first stage is carried out Method of curtain coating.
at a lower temperature in order to control the level of US7943200 May 17th 2011.
pigment migration to the surface, i.e., the degree to RICOH COMPANY LTD
which the reflector will provide non-specular reflection. A nozzle is used to blow off excess coating found at
the edge of a curtain coating.
22.4.5 Selective Coating Deposition Coating device and coating method having a
constant directing air temperature.
Masking material for jig for coating. US20110159196A1 Jun 30th 2011.
US20110203521A1 Aug 25th 2011. Improved temperature control of shaping air used in an
NAGOYA OIL CHEMICAL CO LTD electrostatic bell spray atomiser is proposed in order
A paint mask material blend is proposed that facilitates to eliminate adiabatic effects and to better control
easy cleaning between spray painting operations. deposition quality.
Device and method for applying paints. Application method and application device.
US20120231174A1 Sep 13th 2012. WO2011102201A1 Aug 25th 2011.
GM GLOBAL TECHNOLOGY OPERATIONS LLC TOKYO ELECTRON LIMITED
A device that avoids the need to employ paint masking A coating is applied by capillary force to a rotating
where multi-coloured sprayed finishes are required. substrate followed by spin coating to level out the
coating.
Method for surface treating plastic products
and plastic products made thereby. Method of dip-coating a lens.
US20130288028A1 Oct 31st 2013. WO2011123132A1 Oct 6th 2011.
FIH (HONG KONG) LIMITED ESSILOR INTERNATIONAL (COMPAGNIE GENERALE D’OPTIQUE)
166
Thickness variation normally encountered in dip coating Lateral edge guide for curtain coating method.
a lens is avoided by rotating the lens. EP2412446A1 Feb 1st 2012.
POLYTYPE CONVERTING SA
Dip coating apparatus. An improved method for edge control in curtain coating
WO2011129764A1 Oct 20th 2011. of flat substrates.
CAL-COMP TECHNOLOGY PTE LTD
Problems of uneven edge application and drip Process and apparatus for coating with
contaminating equipment parts in a conventional dip reduced defects.
coating process for discs are resolved by using upper EP2419223A1 Feb 22nd 2012.
and lower angled support frames that cause dripping 3M INNOVATIVE PROPERTIES COMPANY
from a single point. Surface defects in a solvent-borne ultraviolet-cured
coating are reduced by employing a partial initial curing
Chromophoric or effect-generating multi-layer (pinning) prior to complete solvent evaporation.
paint coatings having pigment-free coats
of paint as filler substitute, the production Method of dip-coating a segmented multi-
thereof and use thereof. focal lens.
US20110274896A1 Nov 10th 2011. WO2012080775A1 Jun 6th 2012.
BASF COATINGS GMBH ESSILOR INTERNATIONAL (COMPAGNIE GENERALE
A clear basecoat is used in a 3-coat sprayed system D’OPTIQUE)
over a rough surface to provide enhanced appearance A device and method for dip coating multi-facetted
and performance and replace a 4 to 5-coat solution. lenses and avoiding drip lines at facet edges.
Method for producing color giving and/or Coating method and coating system having
effect giving lacquer coatings. dynamic adaptation of the atomizer rotational
EP1315778B2 Nov 16th 2011. speed and the high voltage.
BASF COATINGS GMBH US20120219700A1 Aug 30th 2012.
Popping problems encountered when thick applications An electrostatic bell spraying system that allows
of sprayed aqueous paint or coating are applied and dynamic adjustment of spray parameters, for example
dried are avoided by selecting coating resins that have for robotically spraying changing surfaces.
a certain degree of water permeability.
System and Process for Coating an Object.
Method and apparatus for control of layer US20120301671A1 Nov 29th 2012.
thicknesses. ADVENIRA ENTERPRISES INC
US8062705 Nov 22nd 2011. A system for automatically dip coating 3D substrates.
SINGULUS TECHNOLOGIES AG (See also US20120301670A1)
A temperature gradient is applied in order to reduce
film thickness radial variation in spin coating. Coating method and coating device with a
compensation for asymmetries of the spray jet.
Method for coating molded articles. WO2013041184A1 Mar 28th 2013.
US20110293948A1 Dec 1st 2011. DÜRR SYSTEMS GMBH
A low-temperature 3-coat-1-bake solution for sprayed A method for compensating the problem of asymmetry
water-based paints and coatings that resolves problems of a spray jet from an electrostatic bell for 3D surfaces.
associated with under-cure and water retention.
Method of spin coating.
Method for flood coating a polymeric material. EP1967283B1 Apr 10th 2013.
EP2394747A1 Dec 14th 2011. TOKUYAMA CORPORATION
SAINT-GOBAIN GLASS FRANCE A method for rapidly applying a coating in a spin coating
A method for applying a primer and hardcoat by curtain operation without provoking bubbles.
coating uses angling and an air jet in order to avoid
typical problems of film thickness irregularity and drips. Method of forming multi-component
(See also EP2394746A1) composite coating compositions on
substrates using compact processes.
US20130095316A1 Apr 18th 2013.
167
PPG INDUSTRIES OHIO INC Process for formation of multi-layered coating

A thermally-cured sprayed multi-layer coating requiring film.
a single bake and presenting good flow-out and wetting US8568833 Oct 29th 2013.
properties. KANSAI PAINT CO LTD
A 3-coat 1-bake process requiring heat-cure preferably
Spraying method. at between 120-160 °C that ensures smoothness and
CN102091686B Jul 31st 2013. chipping resistance.
HONGFUJIN PREC IND SHENZHEN
A substrate preheating regime at high and low temperatures Method for forming multi-layer coating film.
improves sprayed film quality and reduces baking time. WO2013175925A1 Nov 28th 2013.
HONDA MOTOR CO LTD
Device and method for applying a liquid A polypropylene substrate is successively sprayed
coating to a surface. with a conductive primer, followed by an electrostatic
EP1872864B1 Sep 11th 2013. application of an adhesion primer and then a
MANKIEWICZ GEBR & CO (GMBH & CO KG) clearcoat.
A multi-jet nozzle system for avoiding paint dripping.
Production method for film with coating.

WO2013146730A1 Oct 3rd 2013.
FUJIFILM CORPORATION
An initial ultraviolet cure is used to ‘pin’ the coating in
a web coating device in order to avoid craters.
References
1. Federal Standard 209E, Airborne Particulate Cleanliness Classes in Cleanrooms and Clean Zones,
1992.
2. ISO 14644-1, Cleanrooms and Associated Controlled Environments - Part 1: Classification of Air
Cleanliness, 1999.
3. A. Michalske and D. Kleinelümern, inventors; Venjakob Maschinenbau GmbH & Co., assignee;
DE102009058211B4, 2013.
4. H. Vogl, S. Züfle, U. Trillitzsch and B.B. Barry, inventors; Rehau Ag + Co, assignee; WO2013149713A1,
2013.
5. T. Zhehao, inventor; T. Zhehao, assignee; CN101530841B, 2011.
6. T. Zhehao, inventor; Dongguan Baijin Hardware & Plastic Co Ltd., assignee; CN101966499B,
2012.
7. CHINAPLAS 2013: Carbon Nanotube ABS Compound Delivers Enhanced Paintability, Plastics Today.
8. System Works with Existing Compressor to Clean, Heat Atomizing Air, PF Products Finishing.
9. Industrial Surface Cleaning/Cleaning of Parts, Wandres GmbH.

http://www.wandres.com {Accessed June 2014}
10. Oven Cleans with Low Nitrogen Oxide Emissions, PF Products Finishing.
http;//www.pfonline.com {Accessed June 2014}
168
11. Spray Pattern Sensor System, Pressure Profile Systems.

http://www.pressureprofile.com {Accessed June 2014}
12. IR Radiative Heating Creates Topographic Hard Films, European Coatings.

13. BMW Awards DÜRR with its Supplier Innovation Award for EcoDryScrubber Paint Booth System,
SpecialChem.
http://www.specialchem4coatings.com {Accessed June 2014}
14. Nordson Trilogy Electrostatic Spray Gun Provides the Highest Kilovolts (kV) Available for Liquid
Painting Application; Maximizes Transfer Efficiency and Control, Nordson.
http://www.nordson.com {Accessed June 2014}
15. AGR – New Automatic Guns from Reiter on the Hannover Fair, Reiter.
http://www.reiter-oft.de {Accessed June 2014}
16. Flow measurement – Product Overview for Applications in Liquids, Gases and Steam, Endress+Hauser.
http://www.uk.endress.com/en/products/flow {Accessed June 2014}
17. The New Solution for Waterbased Products Accubell 709 EVO was on Display at SURCAR Show,
Kremlin Rexson Sames.
http://www.kremlinrexson-sames.com {Accessed June 2014}
18. Automatic Spray Gun Improves Finish Quality in Airless Painting, PF Products Finishing.
19. Automatic Air Spray Gun Designed for Precision Finishing, Graco.
http://www.graco.com/gb/en.html {Accessed June 2014}
20. Optimised Medium-Pressure Spraying Technology, Walther Pilot.

http://www.walther-pilot.de {Accessed June 2014}
21. G.P. Thomas, Nordson Asymtek Honored for its Select Coat SC-280 Precision Film Coater, Nordson.
http://www.azom.com/news.aspx?newsID=32995 {Accessed June 2014}
22. New Line of Automatic Spray Guns, Walther Pilot.

23. Non-Damaging and Pulsation-Free, Walther Pilot.

24. A. Afshar, inventor; A. Afshar, assignee; US7846510, 2010.
25. S. Stremsdoerfer, inventor; no assignee; US20110155444A1, 2011.
26. W.B. Kolb, P. Price and W.R. Dudley, inventors; 3M Innovative Properties Company, assignee;
EP2419223A1, 2012.
27. S. Kuniyasu, inventor; Fujifilm Corporation, assignee; WO2013146730A1, 2013.
169
23 Pad Printing
Table 23.1
2 Surface improvement 0 0 1 1
23.1 Background
Pad printing, sometimes referred to by the brand name TAMPOPRINT, involves the transfer of a solvent-based
liquid ink from a recessed and doctored flat plate (typically of up to 60-70 lines/cm with an etch depth of
15-30 μm) to a substrate using a highly compressible silicone pad. The simple reciprocating process is ideal
for decorating three-dimensional objects with flat or shaped surfaces. Machines can have multiple heads
in order to enable multi-colour printing and/or accelerate the output by decorating several substrates at a
time. Table 23.1 shows the patent activity related to decorative effects detected during the period examined.
Rotary pad printing, in which a smooth cylindrical pad is fed ink from a doctored cylindrical anilox bearing
the recessed image, is suited to high-speed decoration of cylindrical or flat substrates in a way which is
very close to the flexographic printing processes.
In the more common reciprocating process, the flat plate is either made of a photopolymer or steel. The
advantage of the former, although service life is shorter, is that it can be readily made in-house and is
cheaper. The ink is housed in a closed reversed cup with a sharp steel or ceramic doctoring rim in contact
with the plate. When the cup recedes towards the back of the machine and away from the engraved
image, the pad descends to pick up the ink from the image, rises, transverses, and descends onto the
substrate in an inverted ‘U’ type motion.
The large silicone pad typically has a hardness of 6-20 Shore A, i.e., it is highly deformable, and able to
address irregular surfaces or a significant portion of a facing curved or spherical surface. The pad tends
to be pointed in shape, either in a conical or elongated form, and is normally at least 50% larger than
the artwork to be printed. The tip is positioned to land about 5 mm from the edge of the print area. The
purpose of the pointed pad shape is that a progressively increasing contact during the descent avoids
air bubbles. The pad softness is in part aided by the addition of silicon oil to the silicone rubber. Pads
can be rejuvenated by applying fresh silicone oil. US7870823 [1], and WO2011108034A1 [2], discuss
of multi-layer pads, whereby a harder silicone is used for image transfer. US20120031289A1 [3], and
US20120222573A1 [4], discloses a replaceable top layer for a pad. US20120222574A1 [5], describes a
pad design with a hollow centre, which gives more flexibility in order to cover more of the surface of a
spherical object, for example.
Because of the low viscosities used for inks, the final film thickness is limited, and in extreme cases,
such as printing white on black, it may be necessary to double cycle in order to obtain adequate print
opacity. Ink viscosity is in the order of 20-50 Pa-s, i.e., between glycerol (1.5 Pa-s.) and toothpaste (20
Pa-s.). Solvent loss from the ink film ensures that the ink tacks up while on the silicone pad, and therefore
subsequently more or less wholly transfers to the substrate.
Inks are ambient air dried, hot-air dried, or sometimes UV cured for improved resistance. Air dried versions
are often catalysed, i.e., are two component (2K) systems. Because of tack-up, inks can be wet-on-wet
170
printed without the need for intermediate forced drying. UV inks used less, and because they are based on
liquid resins, they require less solvent. If metallic inks, containing pigments produced by physical vapour
deposition (PVD), are second-surface printed onto translucent gloss substrates such as polycarbonate
or polymethyl methacrylate (PMMA), bright metallic effects can be obtained. Because of the thin ink film,
and therefore flat lay of metallic pigments, brighter metallic finishes are possible than, for example, screen
printing, where much thicker films are deposited, even using first surface printing.
Traces of remaining ink or dust, if any, are removed from the pad after several prints by a programmable
automatic cleaning step using advancing tacky tape. Mechanically or electromechanically controlled
machine movements are preferred to pneumatic ones so that machine cycling remains constant. The
process is capable of good quality multi-colour halftone printing. Other features being proposed by
suppliers are automatic optical plate and substrate holder registration during setup. Recent patent
applications also mention:
• Avoiding the need for cleaning cups by supplying ink in pre-filled cups [6], cups with replaceable
liners [7];
• Facilitating cleaning of cups using a non-stick coating [8]; and
• Being able to adjust ink viscosity in the cup on-the-fly [9].
Prime issues to contend with in pad printing are: a) ink opacity, b) ink stability because of uncontrolled
solvent loss, and c) the pad becoming contaminated with dust.
Most patent documents here can be found searching any of the IPC codes B41F (Printing Machines or
Presses), B41K (Stamps; Stamping or Numbering Apparatus or Devices) or B29C (Shaping or Joining of
Plastics; Shaping of Substances in a Plastic State, in General; After-Treatment of the Shaped Products,
e.g., Repairing). Prominent patent applicants for equipment developments are ITW, ITW MORLOCK,
and TAMPOPRINT, as well as SHUHOU for pads. One patent application [10] provides for the use of UV
curing inks.
There are variants to the process described. In one invention, the pad has been replaced by a flat flexible
membrane vacuum enshrouded over the substrate to be decorated (the membrane being pre-printed using
screen or inkjet); a recent patent application by LG CHEM [11] talks of using a relief plate to remove ink
from a cylindrical fully-inked printing blanket prior to printing from the blanket. Another patent, mentioned
in Part D, Section 19, uses a pad to transfer an inkjet image to an irregularly shaped surface [12].
Recent developments include the disc plate from TAMPOPRINT with up to twelve 250 mm motifs on the
same plate [13]; printing of cylindrical parts at up to 50,000 parts/h from TAMPOPRINT [14]; the Speed
40-2 head from TAMPOPRINT, capable of up to 9,000 impressions/h [15]; water-cooled rotary wheels
from TAMPOPRINT [16]; and a two-axis servo-driven printer from PAD PRINT MACHINERY of VERMONT
[17]. TAMPOPRINT has introduced a laser system for engraving polymer clichés with a resolution of
100 lines/cm [18].
23.3 Patent Trends
Table 23.2 shows the themes of patents listed in Section 23.4.
171
Table 23.2
Definition, detail and contrast Camera register control
Surface quality improvement Multiple pads for complex shapes
23.4 Listed Patent Literature 2011-2103 (for 23.4.2 Surface Improvement

Method and a machine for decorating bottles
Pad printing machine. by indirect pad printing using a shell.
US20110023738A1 Feb 3rd 2011. US20130298788A1 Nov 14th 2013.
ITW MORLOCK GMBH SGD
A camera is used to ensure rapid and continuous Pad printing pads are shaped to conform to a shaped
register on a multi-stage pad printing machine. bottle in order to more accurately transfer ink to required
areas including edges.
Pad printing machine.
US20110100241A1 May 5th 2011.
ITW MORLOCK GMBH
A multi-colour pad printing machine with automatic
register through camera control of printing plate
position.
References
1. R. Cameron, inventor; no assignee; US7870823, 2011.
2. K. Muraoka, inventor; Shuhou, assignee; WO2011108034A1, 2011.
3. J. Cheng, inventor; no assignee; US20120031289A1, 2012.
4. H-C. Wu, inventor; FIH (HONG KONG), assignee; US20120222573A1, 2012.
5. N. Inoue and T. Ohira, Bridgestone Sports, assignee; US20120222574A1, 2012.
6. S. Peterson, C. Schaafsma, S. Knappik and C. Williamson, inventors; Illinois Tool Works Inc.,
assignee; WO2013148926A1, 2013.
7. T. Kucaba, D. Pulvino and R. Hitchcock, inventors; Illinois Tool Works Inc., assignee; US20130118368A1,
2013.
8. J. Cheng, inventor; J. Cheng, assignee; US20130025489A1, 2013.
9. W.M. Ho, inventor; Kent Engineering (Gao Yao) Co. Ltd., assignee; US20130008329A1, 2013.
10. M. Ohnishi, inventor; Mimaki Engineering Co., Ltd., assignee; WO2011065338A1, 2011.
11. S.K. Chun, I-S. Hwang, J.Y. Hwang, J.Y. Kim, B.M. Koo, S.H. Lee, J. Seong and Y.G. Son, inventors;
LG Chem., Ltd., assignee; WO2012138138A2, 2012.
12. J. Donohoe, M.J. Sullivan, R.J. Lugen and K.A. Kirk, inventors; J. Donohoe, M.J. Sullivan, R.J.
Lugen and K.A. Kirk, assignee; US20130224445A1, 2013.
172
13. At FAKUMA 2011 in Friedrichshafen, We are Presenting a New Printing Plate Solution: the Disc
Plate, Packaging Europe.
http://www.tampoprint.de {Accessed June 2014}
14. Printing of Cylindrical Parts with an Output of up to 50,000 Parts per Hour, Tampo Print.
15. Built-in tampon printing machine, Tampo Print.

http://www.tampoprint.de/en/produkte_en/tampondruckmaschinen_en/standards_en/speed_en/
speed_40_2_a_en.html {Accessed June 2014}
16. Water Cooled Rotary Wheels from Tampo Print, European Plastics News.
17. Two Axis Servo-Driven Pad Printer, Engineered Printing Solutions.

http://www.epsvt.com/company/pressRelease.cfm?preID=59 {Accessed June 2014}
18. ‘Intaglio’ Cliché Laser, Aktuell & Informed News, 2013, No.10.
173
24 Pigment Orientation Techniques

Table 24.1
24.1 Background
In a process first patented in the 1960s, a magnet is used to orientate special flake pigments (Part B,
Section 4) in an ink or coating while still wet. By engraving designs into the face of a magnet or magnetic
rubber sheet, and placing it no more than 1-2 mm from the surface of a wet ink or coating, a three-
dimensional (3D) effect image can be produced within a few seconds. On conveyor devices, the magnet
must accurately follow the substrate while the orientation is taking place, but a simpler version of this
principle is to embed the magnets into the part holder so that a precise register is easily maintained
throughout the drying process. In the latter case, the magnetic field traverses the thickness of the moulded
part, which ideally should also be no more than 1-2 mm. It is important that inks and coatings remain open
(i.e., do not dry or become viscous) for the time required. This technique is mostly used in the security
printing field but has been also employed for plastics decoration. A low to medium (e.g., 0.015-0.030 T)
rather than a high magnetic force (e.g., >0.1 T) is used to provide a full 3D effect by virtue of a gradual
shift in flake orientation from near flat towards a more upright position. The coating must then be dried
rapidly in order to avoid the flakes losing their new orientation. The technique can be used in conjunction
with any process using wet inks or coatings, and is more beneficial with those that produce thicker films
(inkjet, screen, spray). Formulation with the right pigments and drying characteristics is important. The
pigments used are dark, and supplied by companies such as BASF, ECKART, MERCK and others.
Other attempts to orientate pigments have included embossing, as covered by several patent documents
listed in Part D, Section 24.4. Another method developed a few years ago for a cosmetics closure involved
moulding substrates which incorporated a pearlescent pigment and with a shallow relief pattern on their
surface. After polishing away the relief pattern to give a smooth surface, the corresponding pigment
orientation adjacent to the raised zones achieved during the moulding showed as an impressive 3D effect.
Parts were then spray coated with a clear lacquer to provide a uniform surface finish.
Recent publicised innovation includes magnetic solutions for pigment orientation produced by BARLOG
PLASTICS [1].
24.3 Patent Trends
Table 24.2
3D, tactile and depth effects Embossing to re-orientate pigments in inks or coatings • Magnetic flake
orientation in inks or coatings
Colour effects Structural colour from magnetically controlled nanoparticles
174
Table 24.1 indicates a spate of activity in 2012. Most developments are related to security printing but are
mentioned next because of a possible generic interest that may be applicable to 3D plastic substrates.
In US8354145 [2] it is proposed a magnet be integrated into in the substrate as opposed to employing
an external magnetic component.
Embossing wet coatings containing flake pigments; and the use of an internal magnet in the substrate
to control pigment orientation.
Magnetic orientation techniques.
24.4 Listed Patent Literature 2011-2103 (for Magnetic orienting and printing.
search phrases see Part A, Section 2) US20120055355A1 Mar 8th 2012.
CHINA BANKNOTE SICPA SECURITY INK CO LTD
A mechanically controlled multiple magnet array
controls pigment orientation during the printing stroke
Depth Effects
in a screen printing operation for security documents.
Articles having metalizing and holographic

Processing method of pattern with
effects.
stereoscopic vision effect on plane or arc
WO2011116036A2 Sep 22nd 2011.
surface.
THE GILLETTE COMPANY
CN101417277B May 23rd 2012.
A liquid acrylic coating containing suspended aluminium
flakes is applied over a decorated object and pressed TAI YING PAINT IND CO LTD
with an embossed casting film prior to ultraviolet curing. The use of magnetically sensitive pigments to create
a 3D effect.
Device and method for magnetically
transferring indicia to a coating composition Process for creating three-dimensional
applied to a substrate. patterns in coatings.
US20110290129A1 Dec 1st 2011. WO2012079674A1 Jun 21st 2012.
KBS-GIORI SA MERCK PATENT GMBH
An improved method for obtaining a 3D effect using A 3D effect is achieved by embossing a wet coating
magnetically oriented pigments in an ink film whereby containing platelet-type pigments with a relief plate.
the magnetic engraved plate contains a layer of high
magnetic permeability.
Optically variable security element.
CN101903183B Jul 4th 2012.
3D tumbler structure.
GIESECKE & DEVRIENT GMBH
US20120000922A1 Jan 5th 2012.
An anti-counterfeit solution involving effect pigments
Magnets are used to create patterns in a metallic paint
and magnetically orientating pigments.
layer that is sandwiched between two mouldings.
Security element comprising oriented A method for producing 3-D printed images.
magnetic pigments. WO2012007563A3 Jul 19th 2012.
WO2012025206A2 Mar 1st 2012. SUN CHEMICAL BV
GIESECKE & DEVRIENT GMBH A non-magnetic method for producing 3D images
Magnetic pigment orientation is combined with involves pressing a dried varnish into a softer dried
embossed features to give added security. undercoat in order to re-orientate pigment platelets.
175
Method for the creation of color effect images. achieved by integrating a magnet into the substrate.
US8263191 Sep 11th 2012.
LEONHARD KURZ STIFTUNG & CO KG Method for producing three-dimensional
Equipment for producing magnetic orientation of patterns in liquid-crystalline coatings.
pigments in a carrier film. WO2013185872A1 Dec 19th 2013.
MERCK PATENT GMBH
Apparatus for orienting magnetic flakes. An embossing process is used to create 3D patterns
AU2007200128B2 Oct 11th 2012. in liquid-crystalline coatings before curing.
JDSU
A rotary tool for facilitating the orientation of magnetic
pigments on flat carriers.
Method of applying a pattern to a substrate. Method of generating structural color.

US8354145 Jan 15th 2013. US20120064309A1 Mar 15th 2012.
AKZO NOBEL COATINGS INTERNATIONAL BV SNU R&DB FOUNDATION
Magnetic pigment orientation in a wet coating is A magnetic field is used to create a structural colour
from nanoparticles in a ultraviolet-curable medium.
References
1. 3D Effect decoration for Plastics, Premium Beauty News.

http://www.premiumbeautynews.com/en/3D-effect-decoration-for-plastics,2037?checklang=1
2. T.E.L. De Rydt and L. Goubet, inventors; Akzo Nobel Coatings International BV, assignee;
US8354145, 2013.
176
25 Plating, Electroplating and Chemical Deposition
Table 25.1
25.1 Background
The decorative electroplating of plastics is a process that is normally used to produce >20-30 μm thick
high quality finishes, often completed with a flash of real gold or chrome as final colour layer. The process
is carried out in a series of chemical baths. Substrates, predominantly moulded in a special grade of
acrylonitrile-butadiene-styrene (ABS), are loaded onto plastic-coated metallic racks with protruding
electrically conducting pins to hold them and create a cathodic surface. Because the process time can
be long, output is assured by using large racks holding hundreds of parts at a time. To counter slower
steps in the multiple stage process, duplicate chemical baths are employed. The traditional process first
of all roughens the substrate surface in order to ensure mechanical keying of the plating layer, and then
renders the surface conductive for electroplating. The basic phases are as follows (excluding intermediate
multiple rinsing operations):
1. Chemical attack, traditionally achieved using sulfochromic acid [which yields toxic hexavalent chromium
(CrVI)], creates a roughness to ensure anchoring of the metal layers.
2. Activation using colloidal palladium.
3. Exposing the palladium, which will catalyse nickel from a chemical bath.
4. Chemical deposition of nickel in order to render the substrate surface conducting.
5. A thick electrolytic deposition of brilliant copper, which is auto-levelling.
6. A layer of matte or bright nickel to protect the copper from oxidising.
7. A final flash coat of chrome, gold, other metal or alloy to provide the final colour.
A plating bath will contain metal salts, ionic additives to improve conductivity, products to improve throwing
power, levellers, brighteners and wetting agents. A poor throwing power implies uneven deposition, e.g.,
less deposition in recessed areas or parts of substrates farther away from the anodes.
A rectifier provides direct current (DC) for electro-deposition from metal anodes placed in the bath. The
amount of deposition depends on current and time. An important feature of the process is current density.
This can vary across a rack of 3D substrates and requires special rack configurations and diverting
members in order to draw the current evenly. Software exists to optimise rack resign.
177
The higher overall film thickness and good levelling properties of the copper bath give plating an advantage
over vacuum metallisation, which relies on spray coating a basecoat film of typically less than half the
thickness. However, the plated film still remains relatively thin, and the moulding quality must, therefore,
be adequate. Weld and parting lines, traces of uneven shrinkage, sink marks, flash, splay and other
surface defects are to be avoided. Gates should be located in non-critical areas and parts should be free
of contaminants such as grease, oil, and traces of outgassing.
A number of design considerations also help determine the final quality. Tops, sides and angles should
be radiused where possible. Wall thicknesses should be even, avoiding steps or internal ribs that might
result in uneven shrinkage and resulting witness marks that will be visually accentuated by the bright
metallic finish.
A distinguishing feature of the plating process is that the insides of moulded substrates are also coated.
In some cases air entrapment can be an issue, and of course parts need to be drainable after immersion
in different baths in order to avoid carry-over from one bath to the next. Reduction of internal dimensions
has to be accounted for with respect to subsequent assembly operations.
An important potential of this process lies in selective plating, e.g., moulding a substrate in two separate
materials (two-shot moulding) such as ABS (plateable) and copolyester (non-plateable). This allows
substrates to have selected plated areas. Alternative approaches include selectively pre-printing a non-
plateable ink which may be subsequently removed by washing, or using laser direct structuring (LDS)
before plating to selectively roughen the surface and expose the plating additives incorporated into the
polymer. LDS provides a rough surface and matte finish and is, therefore, not usually encountered in
applications for cosmetic appearance. Table 25.1 shows that selective deposition has been the most
frequent subject of innovation over the three year period studied, and that focus has been increasing.
The main challenges faced by using plating are:
• Even deposition, especially across racks of parts, but also when individual parts have extended
protrusions;
• Part deformation as a result of heat from baths and pressure applied by holding pins;
• Surface defects such as deposits, discoloration (excess or lack of top layer deposition);
• Witness marks left by holders;
• The use of sulfochromic chemistry which involves toxic CrVI (Table 25.2); and
• The use of cyanide in some plating solutions to improve throwing power.
For thinner films, electroless plating can be used. This provides more even films, but is much slower, and
the resulting thinner film does not hide as well any substrate deficiency.
178
Table 25.2
Recently proposed alternative solutions to sulfochromic (CrVI) chemistry
Patent no. Date Assignee
EP2274459A2 19th January 2011 ISPA
JP2011031503A2 17th February 2011 ACHILLES CORP
US20110135949A1 9th June 2011 EI DU PONT DE NEMOURS
US20110226629A1 22nd September 2011 JET METAL TECHNOLOGIES
US20110256413A1 20th October 2011 PEGASTECH
US8052858 8th November 2011 TOYOTA JIDOSHA KK
US2012073978A1 29th March 2012 BASF
EP2270256A3 4th April 2012 HITACHI MAXELL
WO2013048635A1 4th April 2013 MACDERMID ACUMEN
CN101970719B 10th July 2013 HITACHI MAXELL
WO2013112268A2 1st August 2013 MACDERMID ACUMEN
US20130209689A1 15th August 2013 MACDERMID
WO2013135864A1 19th September 2013 ATOTECH DEUTSCHLAND
EP2657367A1 30th October 2013 ENTHONE
US8603352 10th December 2013 ROHM AND HAAS ELECTRONICS MATERIALS
WO2013182590A1 12th December 2013 ATOTECH DEUTSCHLAND
The use of real gold renders this process more expensive than vacuum deposition methods, where
alternative gold-coloured materials, pigments or dyes can be used. For some time, therefore, gold-colour
electroplated products such as sanitary ware (e.g., taps and showerheads) have been finished using a
vacuum metallising step, typically employing reactive sputtering or cathodic arc deposition to deposit a
top layer of gold-coloured ceramic (Part D, Section 29).
Common IPC codes are any of C23C (Coating Metallic Material; Coating Material with Metallic Material;
Surface Treatment of Metallic Material by Diffusion into the Surface, by Chemical Conversion or
Substitution; Coating by Vacuum Evaporation, by Sputtering, by Ion Implantation or by Chemical Vapour
Deposition, in General), C25D (Processes for the Electrolytic or Electrophoretic Production of Coatings;
Electroforming Joining Workpieces by Electrolysis; Apparatus Thereof) or B05D (Processes for Applying
Liquids or Other Fluent Materials to Surfaces, in General). Recent process innovation has focused on
alternative substrate materials, CrVI replacement for toxicity and environmental reasons (Table 25.2), and
selective plating primarily using LDS techniques. Process innovators include ATOTECH DEUTSCHLAND,
BYD, GOLDSCHMIDT, HITACHI MAXELL, MACDERMID, MACDERMID ACUMEN, ROHM AND HAAS
ELECTRONIC MATERIALS and UMICORE GALVANOTECHNIK.
Publicised innovations include a process that offers surface activation, e.g., from INCERTEC, in order to
avoid using sulfochromic chemistry [1]. INTEGRAN announced its patented polymer activation process
for electroplating – the Nanovate™ NP structural plating process [2].
179
25.3 Patent Trends
Table 25.3
3D, tactile and depth effects Textured substrate surface prior to plating
Colour effects Bright black plating
Gloss and matte effects Laser-etched copper layer • Matte electrolytes • Pre-etching the substrate
Metallic or reflective effects Brass • Bronze • Dark chromium • Nickel-metal finishes • Non-reactive
sputtered gold colour top layer • Reduced etch depth and subsequent metal
deposition thickness • Silver replacement using platinum and rhodium
Selective coating deposition Laser etching after plating • Laser treatment to expose additives in substrate
• Multi-material moulding • Pre-applying plating rejecting or accepting
organic films • Spray painting a metallic paint followed by laser exposure of
the metal • Stamping followed by selective masking and etching • Ultrasonic
assist during plating of multi-material substrates
Table 25.3 shows the different themes of patents listed in this chapter. As mentioned previously, the key
innovative decorative feature here relates to developments in selective plating. Table 25.4 compares the
different techniques covered in this area.
Table 25.4
Repartition of recent patents related to selective plating
1 Selective laser treatment of the substrate and laser direct structuring 15 50
2 Multi-shot moulding 8 27
3 Pre-printed refusing or accepting ink 5 17
4 Laser removal after electroplating 1 3
5 Others 1 3
A number of patents relate to expanding the range of novel metallic effects varying in degrees of gloss
and metallic colour. Colours proposed include a bright silver effect, brass, dark chrome, black, bronze,
and various effects obtained using nickel.
Table 25.5
1 BYD 9 19
2 ATOTECH DEUTSCHLAND 3 6
3 UMICORE GALVOTECHNIK 3 6
Laser treatment of substrates for selective plating; non-reactive sputtering to replace a gold topcoat;
various colour effects, including black, brass, bronze, and dark chromium.
180
Selective metallisation techniques, in particular laser treatment prior to plating.
25.4 Listed Patent Literature 2011-2103 (for BSH BOSCH UND SIEMENS HAUSGERAETE GMBH
search phrases see Part A, Section 2) An injection moulded substrate is etched and chrome
plated in order to present a brushed metallic effect.
25.4.1 Three-dimensional, Tactile and Method for producing matt copper deposits.
Depth Effects WO2013110373A2 Aug 1st 2013.
ATOTECH DEUTSCHLAND GMBH
Method for producing a plastics part and A method for plating matt copper.
household appliance having such a plastics part.
WO2012156236A2 Nov 22nd 2012.
BSH BOSCH SIEMENS HAUSGERAETE
A plastic substrate receives a textured surface either
by using an engraved cavity or a post etching process Decorative surface finish and method of
prior to chrome electroplating. forming same.
WO2011025753A1 Mar 3rd 2011.
LACKS INDUSTRIES
A durable alternative to electroplating, vacuum
deposition, or silver reduction, in order to produce a
Electrolyte and method for depositing decorative
metallic effect. Raw parts receive only a light etch in
and technical layers of black ruthenium.
order to permit reduction of metal film thickness without
US8211286 Jul 3rd 2012.
sacrificing surface quality. The sequential layers are
UMICORE GALVOTECHNIK GMBH
electroless nickel and/or copper plated, followed by
An oxidation-resistant and mechanically stable bright
electroless silver and an organic protective clearcoat
black finish for electroplating.
applied, for example, by electrostatic spraying.
Blackening treatment solution for black Cr-Co

Process for the deposition of platinum-
alloy plating film.
rhodium layers having improved whiteness.
WO2013168528A1 Nov 14th 2013.
US20110308959A1 Dec 22nd 2011.
OKUNO CHEMICAL INDUSTRIES CO LTD
UMICORE GALVANOTECHNIK GMBH
A method for improving the blackness of a plated Cr-
A solution for replacing silver plating using platinum
Co film.
and rhodium to produce an unexpectedly bright
finish.
Material and process for electrochemical
Plastic surface processing method. deposition of nanolaminated brass alloys.
CN101613862B Sep 27th 2011. WO2012012789A1 Jan 26th 2012.
SHENZHEN FUTAIHONG PREC IND CO MODUMETAL LLC
An intermediate copper layer is laser-etched in order A thick electrodeposited brass coating onto plastic.
to create matte zones.
Dark colored chromium based
Electrolyte and process for depositing a matt electrodeposits.
metal layer. US20120111731A1 May 10th 2012.
US20120298519A1 Nov 29th 2012. MACDERMID ACUMEN INC
ENTHONE INC Darker electroplated coatings obtained from trivalent
An electrolyte that produces a matte metallic finish. chromium.
Method for producing a plastics part and Copper-tin electrolyte and method for
household appliance having such a plastics part. depositing bronze layers.
WO2012156236A3 Jun 20th 2013. US8211285 Jul 3rd 2012.
181
UMICORE GALVANOTECHNIK GMBH exposed to laser radiation in order to convert it into a

A copper-tin non-toxic electrolyte for electroplating a metallic element in order that subsequent electroplating
bronze finish. or electroless plating can occur.
Electroplating bath and method for producing Method for metallising objects which have at
dark chromium layers. least two different plastics on the surface.
WO2012150198A2 Nov 8th 2012. WO2011098428A1 Aug 18th 2011.
ATOTECH DEUTSCHLAND GMBH ATOTECH DEUTSCHLAND GMBH
Cosmetically acceptable dark gloss chromium plating Ultrasonic treatment is carried out between the electroless
from trivalent chromium. noble metal deposition and electrolytic metallisation in
order to avoid metallising one plastic of a multi-shot
Method for depositing a nickel-metal layer. injected substrate, for example in acrylonitrile-butadiene-
WO2012001134A3 Feb 21st 2013. styrene (1st plastic) and acrylonitrile-butadiene-styrene/
SCHAUENBURG RUHRKUNSTSTOFF GMBH polycarbonate (2nd plastic).
Obtaining different colours by plating with nickel-metal.
Surface metalizing method, method for
Electrodeposition of chromium from trivalent preparing plastic article and plastic article
chromium using modulated electric fields. made therefrom.
US20130220819A1 Aug 29th 2013. EP2367967A1 Sep 28th 2011.
FARADAY TECHNOLOGY INC BYD CO LTD
A method for electroplating chromium metal from A method for selectively plating plastic substrates using
trivalent chromium, thereby avoiding hexavalent an incorporated additive and laser treatment prior to
chromium. plating.
Gold or silver metallized plastic product free Providing a plastic substrate with a metallic
of any gold and silver element and method for pattern.
manufacturing it. US20110240350A1 Oct 6th 2011.
US20130288071A1 Oct 31st 2013.
NEDERLANDSE ORGANISATIE VOOR TOEGEPAST-
ALBÉA SERVICES
NATUURWETEN-SCHAPPELIJKONDERZOEK TNO
A method for achieving gold colour, for example, in
A process designed for electrical circuits on plastics
electroplating involves sputtering a copper/aluminium
that entails stamping the plastic and then metallising
top layer in order to avoid the cost of real gold.
the recesses using plating instead of metallising and
then selectively etching or alternatively screen printing
25.4.5 Selective Coating Deposition the image.
Plastic product and preparation method Methods for Plating Plastic Articles.
thereof. US20110303644A1 Dec 15th 2011.
CN102071412A May 25th 2011. ARLINGTON PLATING COMPANY
BYD CO LTD A selective plating method that employs laser direct

A selective plating method which employs substrates structuring.
containing catalysts and using a laser to treat the
areas to be plated. (See also CN102071424A and Plastic product and preparation method for
CN102071423A) same.
CN102418091A Apr 18th 2012.
Surface metallizing method, method for BYD CO LTD
preparing plastic article and plastic article Polymers containing chemical plating catalyst
made therefrom. precursors are irradiated in order to provide selective
WO2011072506A1 Jun 23rd 2011. deposition.
BYD COMPANY LIMITED
A selective metallising process that provides better Method of fabricating a part decorated with
adhesion onto plastic with lower energy requirements relief.
than electroless plating is proposed. An electroless US20120100305A1 Apr 26th 2012.
plating promoter incorporated into the plastic is ETA SA MANUFACTURE HORLOGERE SUISSE
182
A simplified method for selectively metal plating a NATIONAL DEFENSE UNIVERSITY

plastic substrate whereby after moulding a laser is used The substrate is printed with an ink comprising catalytic
to selectively treat areas to be plated prior to metallising metals that allow selective metallising using electroless
and then electroplating in the wanted areas. plating.
Methods of multi-shot injection molding and Resin substrate having metal film pattern
durable polymeric assemblies made therefrom. formed thereon.
WO2012083007A2 Jun 21st 2012. WO2012165168A1 Dec 6th 2012.
SRG GLOBAL INC SEIREN CO LTD
Substrates moulded in both plateable and non- A process for creating a patterned electroless nickel
plateable materials in order to produce selective image by pre-printing on a substrate followed by
metallisation. (See also WO2012083003A2) electroless copper.
Methods of multi-shot injection molding Plastic part with selective metallization and
and metal-plated polymeric articles made corresponding manufacturing process.
therefrom. WO2013001053A1 Jan 3rd 2013.
WO2012118875A2 Sep 7th 2012. VALEO SECURITE HABITACLE
SRG GLOBAL INC A modified polycarbonate/polyester material is used
A multi-shot injected substrate where one material is for selective electroplating.
plateable.
Preparation method of plastic product and
Transparent plastic film that can be plastic product.
electroplated for partial electroplating. CN102492940B Jan 9th 2013.
WO2012120007A1 Sep 13th 2012. BYD CO LTD
BAYER MATERIALSCIENCE AG A process for plating a polymer that includes selectively
An electroplateable film is partially electroplated, activating a catalyst compound incorporated into the
and then in-mould formed and back-moulded with plastic.
translucent resin in order to produce an object that
can be backlit. Preparation method of plastic product and
plastic product.
One-piece decorative trim bezel having plural CN102409319B Jan 9th 2013.
unpainted finishes. BYD CO LTD
US20120235436A1 Sep 20th 2012. Laser pretreatment of a plating accelerator incorporated
FORD GLOBAL TECHNOLOGIES LLC into the plastic.
A bi-injected substrate where one material is plateable.
Method for producing plastic product and
Method of manufacturing a decorated object plastic product.
using an electroplating process. CN102345123B Jan 30th 2013.
EP2522762A1 Nov 14th 2012. BYD CO LTD
ALBÉA SERVICES A plastic resin contains a plating enhancer which is
A selective plating process uses a combination of exposed by laser gasification.
plateable and non-plateable materials and over-
moulding to form uniquely distinct plated areas. Housing of portable electronic devices and
method for manufacturing the same.
Plastic electroplating product and preparation US20130048519A1 Feb 28th 2013.
method thereof. FIH (HONG KONG) LIMITED
CN102002744B Nov 21st 2012. In order to avoid wastage of metal and the need to
BYD selectively remove unwanted metal, a laser is used to
A selective plating process using an oil. selectively convert a metal oxide additive into metal in
order to provide a base for electroplating.
Method for forming a metal pattern on a
substrate.
US8323739 Dec 4th 2012.
183
Plastic product and manufacturing method Ink composition, method of metalizing surface
thereof. and article obtainable.
CN102950836A Mar 6th 2013. WO2013097729A1 Jul 4th 2013.
SHENZHEN FUTAIHONG PREC IND CO SHENZHEN BYD AUTO R&D COMPANY LIMITED
A selective metallisation is achieved by laser treatment A method for selectively plating a substrate using a
of a polymer with additives that render the treated areas pre-printed ink.
conductive for electroplating. After selective plating, the
plated surface is over-moulded for protection. Metal film material and method for
Decorative element, dashboard, and method US20130186672A1 Jul 25th 2013.
for manufacturing a decorative element. FUJIFILM CORPORATION
US20130059108A1 Mar 7th 2013. A method for selective plating involves printing an ink,
JOHNSON CONTROLS TECHNOLOGY COMPANY curing, applying a plating catalyst to the cured film and
Fit problems after electroplating are avoided by two- then plating.
stage injection moulding and selective chromium
plating achieved through the choice of different A process for application of metal.
polymers. WO2013167598A2 Nov 14th 2013.
CUPTRONIC TECHNOLOGY LTD
Aqueous activator solution and process for A method for metallising a polymer substrate that
electroless copper deposition on laser-direct consists of spraying, drying, using laser light to create
structured substrates. a pattern, washing in deionised water, and then metal
WO2013055786A1 Apr 18th 2013. plating the irradiated areas using copper or palladium
ENTHONE INC baths.
An activator solution for electroless copper deposition
onto laser direct structured substrates. Composite component made of plastic.
WO2013170912A1 Nov 21st 2013.
Thermoplastic composition for use in forming GERHARDI KUNSTSTOFFTECHNIK GMBH
a laser direct structured substrate. A moulding solution for selective plating, using
WO2013066663A2 May 10th 2013. polyamide 12 or cyclo-olefin-copolymer as the non-
TICONA LLC plateable surface.
A mouldable resin suitable for laser direct structuring in
order to create electrically conductive paths. Resin composition for laser direct structuring,
resin-molded article, and method for
Electroplating method and article made by manufacturing molded article with plated
same. layer.
US20130161195A1 Jun 27th 2013. WO2013183789A1 Dec 12th 2013.
FIH (HONG KONG) LIMITED MITSUBISHI ENGINEERING-PLASTICS CORPORATION
Plating of acrylonitrile-butadiene-styrene, A polycarbonate material blend suitable for laser direct
polycarbonate, or polyamide substrates is made structuring without compromising mechanical strength.
possible by spray painting the substrate with a metallic
paint and then laser etching the paint to expose the
metal prior to plating.
References
INCERTEC Introduces Surface Activation® Instead of Chromic/Sulfuric Etching for Plating Plastics,
1.
Omnexus.
2. Adhesion of Metals Plated onto Plastics, Integran.

http://www.integran.com {Accessed June 2014}
184
26 Powder or Particulate Coating
Table 26.1
26.1 Background
This section focuses on powder coating as well as on any other process that involves applying a dry
and unheated particulate material to a substrate. The flocking process is covered in Part D, Section 17.
In common powder coating techniques a dry powder is sprayed onto substrates or deposited from a
fluidised bed and its flow-out and film-forming is dependent on melting the powder in an oven. The spray
application process is usually electrostatic, relying on conductive polymers or prep-coats, or electrically
grounded part holders in order to attract the spray. Applied powder normally requires a relatively high
baking temperature in order to melt, and curing (crosslinking) is achieved by heat or UV light. UV-cured
coatings allow lower temperatures to be used, solely to melt the powder prior to photo-initiation. Powder
overspray can be recycled as long as it is kept uncontaminated and free of agglomerates. Given the
typical particle sizes used in powder coating and the need for flow-out, films are usually several times
thicker than those obtained with liquid coatings. As a result of this the films can be more prone to visual
defects such as orange peel and edge build-up, and so the application of this technology to plastics for
decorative purposes has been limited. Another significant restriction has been the requirement for high
temperatures >120-150 °C, thus limiting the process to so-called engineering polymers, filled materials
or composites. Low-temperature coatings claiming to require temperatures as low as 60 °C have recently
been proposed [1, 2]. Self-cleaning, thermochromic, photochromic, and photoluminescent powder
coatings have also been developed [3].
In recent developments in powder coating, colour changes in less than six minutes have been claimed by
MODEAN INDUSTRIES [4]; DSM participated in the Pegasus project which involved the use of powder
coatings for automotive coatings on plastic substrates [5]; INNOVOC SOLUTIONS has developed a
powder coating solution for plastic substrates resistant to 120 °C [6]; and the CHEMICAL COATERS
ASSOCIATION INTERNATIONAL published an updated 208 page training manual for powder coating
[7, 8].
185
26.3 Patent Trends
Table 26.2
3D, tactile and depth effects Powder or particulate application to an adhering substrate
Metallic or reflective effects Metallic topping materials • Retro-reflective particles
Selective coating deposition Masking techniques • Pre-decorated transfer sheet
Surface quality improvement Particle size range manipulation • Vibration
Particle size range manipulation to control finish; and vibration to control finish.
Applying metallic or non-metallic particulate materials to adhering surfaces.
26.4 Listed Patent Literature 2011-2103 (for 26.4.2 Metallic and Reflective Effects
System and method to apply topping materials
to print products.
WO2011077200A1 Jun 30th 2011.
Depth Effects
SCODIX LTD
Applying an adhesive using, for example, inkjet
Method and apparatus op increasing the process, then applying a topping material, e.g., glitter,
thickness of relief decorations, process and then curing the adhesive, and applying a protective
plant for relief decoration of surfaces. topcoat, if desired.
WO2011045694A1 Apr 21st 2011.
MENPHIS SPA Paint finish incorporating decorative effects.
As an improvement on the limited 3D relief capability US20120088080A1 Apr 4th 2012.
of heat transfer printing, 100-500 micron powder is Compressed air is used to disperse a polymeric/
post-applied in a fluidised bed to a tacky relief surface metallic powder across a painted substrate prior to
in order to augment the existing 3D relief. The result is topcoating.
then re-subjected to heat.
Method and system for forming a reflective
Method and system for applying particulate surface.
solids on a substrate. WO2012112993A2 Aug 23rd 2012.
US20120107497A1 May 3rd 2012. BATES, AARON P
KRONOTEC AG A method for applying a retro-reflective coating to a
A process designed for spray coating panels with a surface entails powder coating a base coat, applying
particulate embedded in a resin. retro-reflective particles followed by hydrophobic
nanoparticles.
Method for recording glitter image.

US20130083118A1 Apr 4th 2013.
SEIKO EPSON CORPORATION
186
An adhesive is applied over an ink using inkjet, and then Coating method.
a substrate with glitter is brought into contact with the EP2292338B1 Sep 18th 2013.
adhesive in order for the glitter to be transferred with BENTELER AUTOMOBILTECHNIK GMBH
the pigment orientation remaining more or less flat so A powder on liquid application where the powder is
as to maximise brightness. partially masked from being applied over the liquid
surface in a functional area of the component.
Process for applying a powder coating.
EP2337639B1 Mar 13th 2013. Electrostatic fluidised powder bed coating
AKZO NOBEL COATINGS INTERNATIONAL BV process.
A transfer sheet has a clear protective coating and a US7972660 Jul 5th 2011.
powder coating or simply an image in powder. The AKZO NOBEL COATINGS INTERNATIONAL BV
coating and powder are transferred to the substrate Coating rate, penetration, and film uniformity have been
by heating and the transfer sheet removed. improved in a tribo-charged electrostatic fluidised bed
process by selecting a particle size range.
System for coating at least partially at least
one object. A powder coating method.
WO2013075699A1 May 30th 2013 WO2011081871A1 July 7th 2011.
A device for selectively powder coating a substrate. E I DU PONT DE NEMOURS AND COMPANY
(See also WO2013075698A1) The orange peel effect characteristic of powder coating
is reduced by applying vibration to the substrate.
References
1. M.B. Kelly, O. Magnin and L. Granjou, inventors; no assignees; US20110028638A1, 2011.
2. L. Casadevall and E. Grau, inventors; Arkema Coatings Resins SAU, assignee; WO2012034901A1,
2012.
3. K. Biller, Back on the Fast Track, European Coatings Journal, 2013, 12, 74.
New Automatic Powder Coating Systems that Change Color in 6 Minutes or Less, Modean
4.
Industries.
http://modeanindustries.com/ {Accessed June 2014}
5. Meeting the Powder Coating Challenge, European Coatings.

http://www.european-coatings.com/layout/set/print/Raw-Materials-Technologies/Technologies/
Powder/Meeting-the-powder-coating-challenge {Accessed June 2014}
6. InnoVoc Solutions™ Technology Enables Powder Coating for Plastics, Composites and Other
Non-Metallic Substrates, Innovoc Solutions.
http://www.innovocsolutions.com/PR-02-16-2012.pdf {Accessed June 2014}
7. Powder Coating Manual Focusses on Practical Issues, European Coatings.

8. Powder Coating for Industrial Finishing Applications, 6th Edition, Ed., J. Gallagher, The Chemical
Coaters Association International, Taylor Mill, KY, USA, 2013.
187
27 Screen Printing
Table 27.1
27.1 Background
Flat screens are usually used for printing three-dimensional (3D) objects. Printing involves forcing paste
ink through a taut and selectively masked mesh (screen), woven in monofilament Nylon (for longer life)
or more often polyester (for greater stability), in order to leave a printed image on the substrate once
the mesh is lifted away. In the screen-making process, often carried out in-house, the image is created
by selectively blocking areas of the mesh with a dried emulsion using photographic or digital transfer
techniques. A screen print is usually distinguishable by using a loupe to look for traces of a mesh pattern
in printed areas and also checking for the characteristic relief associated with this process.
In the printing cycle, a small mass of ink (usually UV curable) is placed on the mesh and swept across
under pressure using a tilted sharp rubber squeegee (usually using a square or 45° end, and a material
hardness of about 75-85 Shore A). The pressure is used to press the mesh down 2-3 mm (the off-contact
distance) in order to be in full contact with the substrate and force the ink through the mesh. On the return
stroke, an out-of-contact metal, rubber or plastic flood return blade (flood bar) guides the remaining ink
back to its starting position. On some machines, in order to improve productivity, even the return stroke
is used to print.
There are basically two versions of this process: 1) the screen remains stationary, and the squeegee
moves across (for decorating flat objects), or 2) the squeegee remains stationary, and the screen moves
from side to side (for decorating 3D objects in rotation). In both cases it is important that the squeegee or
screen displacement speeds match the substrate movement so as to avoid ink slur, and this is achieved
through careful substrate stabilisation together with appropriate gears or servo-driven motors. Squeegee
descent onto the screen and lift-off are also important considerations, and space has to be allowed for
them on the substrate as non-printing areas. For better overlap quality, these movements have to be
precisely timed, and therefore, pneumatic controls are often avoided.
Computer numerical control (CNC) or servo-controlled substrate, screen, and squeegee movements for
shaped substrates in rotation have been available for over 15-20 years and are replacing non-adjustable
cam-controlled systems in order to facilitate quick-change and fine-tuning. Companies providing such
solutions include CER, DUBUIT, ISIMAT, KAMMANN, MADAG and OMSO. On multicolour machines each
ink colour is printed and cured in turn. The substrate register for multi-colour printing requires the use
of shaped holders or special features moulded into the substrate which will engage with locating pins.
Screen positioning (and the ability to make micro-adjustments), mesh tensioning, and precise substrate
and squeegee positioning control, are all critical for good registration between colours.
An important point to note is that, because it is flat, the screen cannot readily address surfaces curved at
90o to the direction of movement of the squeegee or screen. By loosening the mesh tension and slightly
188
curving the squeegee, this rule can, to a small extent, be deviated from, but print quality and screen wear
risk being compromised. Equally, when tapered substrates are printed, differing peripheral speeds of screen
and substrate surfaces in contact along the printing nip mean that some slur or image deformation occurs;
taper is usually limited to 10-20° without having to employ special mechanical compensatory movements.
The ink has a viscosity in the range of 20-100 Pa-s, i.e., a little thicker than toothpaste. In order not to
flow freely through the screen, the ink must be non-Newtonian, i.e., possess a measurable yield value,
which also serves to improve print sharpness. However, a conflict exists when solid print areas and fine
detail are combined in the same print step; a more free-flowing ink is required for the former, whereas an
image with fine detail requires less flow and in particular a more thixotropic ink. The need for thixotropy
has meant that this process has only been used to a limited extent for printing high gloss films of clear
varnishes. Flow-out can be encouraged using a relatively long delay between printing and UV curing,
and during this delay employing infrared heating to lower the viscosity of the coating. However, most
machines are built with UV curing units that follow closely after the print stroke.
Screens, which usually last for up to 50,000 prints or more, typically consist of a 150-180 per cm mesh
consisting of 34 μm thread. They are stretched taut up to 25 N/cm2 usually over a recyclable extruded metal
frame (mesh tension is measured with a tensiometer). The traditional rule is that the minimum emulsion
area must be at least three times the mesh diameter, implying a smallest dot size of 100 μm. The process
is, therefore, normally capable of printing detail up to a coarse halftone, i.e., 40-55 lines/cm with a tonal
range from 10-90%. The normal process is therefore limited in its ability to reproduce detail and soft tones.
Screens can be sub-divided parallel to the print direction in order to print different colours next to each
other (split screens). Because this involves creating a sealed partition, there is a limit to how close adjacent
coloured images can be placed to each other.
A harder and more pointed squeegee, coupled with finer meshes and higher tension, improves the
control of detail (image definition), but increases screen and squeegee wear. Softer squeegees can help
where lower viscosity inks and wider meshes are used for printing solid areas or ensuring coverage of
rougher surfaces. A squeegee is usually tilted at 10-30° to the vertical in order to retain some degree of
flexibility and limit wear. Rubber hardness is measured with a durometer. Squeegees can be recycled by
re-sharpening.
The strong point of screen printing lies in its ability to provide good ink build and accompanying gloss,
coverage and opacity. By adjustments in ink viscosity, mesh count, and especially emulsion thickness,
typical final film thicknesses are in the order of 7-10 μm (5-10 times thicker than flexographic, standard
inkjet, offset, or pad printing), but up to 30 μm or more are possible.
Machines are extremely varied in terms of mechanical conception, part handling, and number of stations.
The drive for flexibility has driven some companies to provide machines of more than 20 stations.
Other than printing fine detail, typical challenges of the screen printing process include:
• Allowing space on the substrate for process particularities; squeegee descent; any part holder
requirements that may impinge on print areas; printing into recessed areas; printing up to sharp edges;
and accommodating the screen frame.
• Printing over join lines or steps caused by split cavity mismatches.
• Printing acceptable bar codes oriented perpendicularly to the print direction unless slur can be avoided.
189
• Effects of static electricity, which may cause stringing around printed characters. This requires good
deionisation and can be helped by choice of ink formulation (including specific additives), viscosity,
and mesh type.
• Orange peel, caused by high viscosity or thixotropy, or insufficient flow-out time before UV curing.
• Metallic printing as bright as other printing processes that produce more favourable thinner films.
Even with physical vapour deposition produced pigments, metallic finishes are not particularly bright
unless second surface printed onto glossy transparent substrates such as polycarbonate or polymethyl
methacrylate. Mesh size must be adequate to accommodate the size of the metallic pigments.
• Ensuring adequate screen life (avoiding pinholes and emulsion breakdown) [1].
More specialist applications involve the use of steel meshes and techniques for high definition printing,
e.g., for solar cells, where line widths of 50-80 μm are required [2]. Automatic screen cleaning is also
employed in electronics applications (circuit boards) where thick air drying pastes are printed, and a
number of patent applications have appeared recently for different systems. Both these subjects are
outside the scope of this book.
IPC codes that cover a majority of patent documents are any of B05D (Processes for Applying Liquids
or other Fluent Materials to Surfaces, in General), B41F (Printing Machines or Presses), B41N (Printing
Plates or Foils; Materials for Surfaces used in Printing Machines for Printing, Inking, Damping, or the Like;
Preparing Such Surfaces for use or Conserving Them) and H05K (Printed Circuits; Casings or Constructional
Details of Electric Apparatus; Manufacture of Assemblages of Electrical Components). Recent equipment
innovators include APPLIED MATERIALS, DTG INTERNATIONAL, FUJI MACHINE, MACHINES DUBUIT,
NB TECHNOLOGIES, and PANASONIC. Most current innovation is for in-line electronics applications
on flat substrates.
27.2.1 Artwork and Screen-making
STORK PRINTS has developed randomised mesh in order to reduce Moiré effects [3]; IKONICS has
shown how to improve detail down to 50 μm [2]; Thermal print head technology is being used to make
screens [4]; and the VASTEX INTERNATIONAL E-2000 light-emitting diode (LED) exposing unit has been
introduced for high-definition screen-making [5].
27.2.2 Equipment for Moulded Substrates
OMSO has developed the servo-driven Servobottle for up to nine colours and using UV LED curing [6];
SYSTEMATIC AUTOMATION has developed a continuous motion printer for flat substrates [7]; CER has
developed their Quadrax-2-2M2N fully programmable quick-change machine for printing cylindrical or
shaped substrates at up to 3,000 parts/h [8], (see also Figure 27.1); KAMMANN has ventured into the
tube market with their K15 CNC 100/min machine [9].
190
Figure 27.1
Quadrax CNC Machine for shapes with screen printing head attached.
Reproduced with permission from CER SA, Oyonnax, France. ©2014, CER SA
27.2.3 Effects
COPE ALLMAN JAYCARE has developed screen printing in order to directly print Braille onto plastic
containers [10]; the Alpha line of products from the IKONICS CORPORATION is capable of producing
screens with a resolution of 25 μm or lower using stainless steel meshes (four times less than conventional
screen printing), aimed at specialist applications [11].
27.3 Patent Trends
Table 27.2
3D, tactile and depth effects Second surface printing
Definition, detail and contrast Curved squeegee • Tension control of fine screen meshes • Ultrasonics used to
encourage ink passage through fine meshes
Metallic or reflective effects Improved effect from reflective beads
Olfactory effects Scented ink
Techniques to develop finer detail printing for technical applications may eventually filter through to
decorative applications; the use of finer strands, ultrasonic energy to encourage ink passage, as mentioned
next, are two cases in point.
No innovators with three or more patents were uncovered during the three year period examined.
191
27.3.2 Items of Particular Interest DTG INTERNATIONAL GMBH

Improved transfer of very fine detail in screen printing
Curved squeegees and squeegee vibration. employs ultrasonic vibration to the squeegee.
Screen printing.
27.3.3 Principal Trends US20130098254A1 Apr 25th 2013.
ASHMORE, CLIVE
Techniques for printing finer detail. High frequency vibration is used to improve ink transfer
through a fine mesh.
27.4 Listed Patent Literature 2011-2103 (for Screen printing doctor blade and device for
search phrases see Part A, Section 2) screen printing.
WO2013068317A2 May 16th 2013.
THIEME GMBH & CO KG
27.4.1 Three-dimensional, Tactile and A squeegee for printing a surface curved at 900 to the
Depth Effects print direction.
Three-dimensional effect printing method and

electronic device treated using the method.
US20110268900A1 Nov 3rd 2011.
HON HAI PRECISION INDUSTRY CO LTD Screen print reflection transfer and process
A 3D effect is obtained by second-surface printing a for the manufacture thereof.
translucent material with a transparent textured layer US20110064912A1, Mar 17th 2011.
and then printing an opaque colour over the transparent Reflec 100 or Reflec 200 (from SERICOL) or similar
textured layer. The object is viewed from the substrate spherical translucent beads are known for producing
surface. reflective panels by being added to screen printed inks.
Moderate reflective properties encountered with such a
process are improved by allowing the beads to partially
27.4.2 Definition, Detail and Contrast stick out from the surface of the printed ink.
Screen printing screen.

US20110259218A1 Oct 27th 2011.
NB TECHNOLOGIES GMBH
A solution is proposed in order to preserve sufficient Method of manufacturing a product that
tension in a high-resolution screen (e.g., 5-micron contains a scented compound.
strands) for technical screen printing. US20110262715A1 Oct 27th 2011.
KA AROMA MARKETING OY
Screen printing head, method of screen Screen printing is used to apply thicker films of ink,
printing and printing blade. varnish, or adhesive containing a scented compound.
WO2011110795A3 Dec 15th 2011.
References
1. KIWO, KISSEL and WOLF GmbH, Specialist Printing Worldwide, 2012, 1, 20, and 2012, 2, 14.
2. M. Orr, High-Resolution Screenmaking for Industrial Applications, Industrial and Speciality Printing.
3. Stork Prints Introduces the Random Mesh 125 Screen, SPG Prints.
http://www.spgprints.com {Accessed June 2014}
4. J. Shutt, Specialist Printing Worldwide, 2012, 1, 10.
5. LED Exposing Units, Industrial and Speciality Printing.

192
6. SERVOBOTTLE, OMSO.
http://www.omso.it/index.php/en/news-and-events/servobottle/ {Accessed June 2014}
7. Screen Press for Conveyorized Manufacturing, Industrial and Speciality Printing.

8. Quadrax-2-2M2N, CER.
http://www.cer.tm.fr {Accessed June 2014}
9. Kammann Expands into the Printed Tubing Market, Observatorio del Plástico.
http://www.observatorioplastico.com/detalle_noticia.php?no_id=190875&seccion=automocion&id_
categoria=7003 {Accessed June 2014}
10. Cope Allman Jaycare Develops Process for Printing Braille Directly onto Plastic Containers, Web
Packaging.
http://www.webpackaging.com {Accessed June 2014}
11. IKONICS Corporation, Specialist Printing Worldwide, 2013, 3, 16.
193
28 Sublimation Printing, and Dye Infusion
Table 28.1
28.1 Background
Certain dyes pass directly to their vapour phase (sublimate) when they are heated. The vapour thus
produced is able to impregnate synthetic organic materials such as polyamide, polycarbonate, polybutylene
terephthalate, polyethylene terephthalate and polyoxymethylene. Widely used in the textile industry and for
label printing for decades, and also used for printing of photographs, this printing technology (otherwise
known as dye diffusion printing) is also applied to moulded plastics. The distinct advantage, when
compared with other decorating processes, is that impregnation of up to several hundred microns into
the substrate surface implies good resistance properties, making the decorated article a good candidate,
for resisting washing cycles or other abusive environments. For substrate surfaces that are not suitable
for sublimation, by virtue of their dark colour or chemistry, a dye-receptive coating must first be applied.
Dye chemistry is a specialised subject and there are a number of candidate types of dye theoretically
suitable for this process (e.g., acid, disperse or reactive dyes). Certain dyes are more suited to specific
polymers and degree of penetration, and resulting colour contrast, together with stability with minimal
fading or exudation, may vary.
There are several application methods. In a wet process, the dye is incorporated into an ink, which is
printed onto the substrate before heating in order to diffuse the dye. The remaining ink is subsequently
removed by washing. In dry processes, a transfer sheet or web, which may be rigid or flexible paper or
coated polymer, depending on process and application technique, is pre-printed with inks containing
suitable dyes using any of the common printing techniques. The sheet or web is placed in contact with
the substrate under heat and pressure.
There are several ways to carry out the dry operation. Examples include:
• In the same manner as hot foil stamping;
• Thermoforming a pre-printed sheet to the substrate for approximately 15 seconds;
• Using a silicone membrane vacuum formed to the shape of the substrate to maintain a transfer sheet
in contact;
• Placing the pre-printed sheet in a mould for an in-mould transfer process, together with a non-sticking
separating layer; and
• Immersing the substrate in a bath of a eutectic mix of molten metals (at 180 °C for 6 seconds), the
image pre-printed onto a light flexible tissue [1], or a hot fluidised bed [2].
194
Transfer has also been achieved with non-contact processes, e.g., for sensitive substrates (patents in
Part D, Section 28.4 from ALCAN PACKAGING BEAUTY and NIDEK).
Pre-printed sheet stability during storage can be an issue; dyes can migrate and cause marking of adjacent
sheets as well as gradual loss of definition. During a sublimation transfer process when enshrouding a
shape, sharp angles and vertical sidewalls may present challenges for good contact.
The minimum temperature required for sublimation is typically 180-210 °C. Since the process is slower
than other decoration processes, only certain plastics can be used without encountering issues of
deformation or surface damage. Heat can be provided by a heated backing, or by other means such as
a laser. Dyes are translucent and always coloured or black (white does not exist) and so the substrate
must be translucent or light in colour. At the lowest temperature, cycle time may be in the order of 15-
30 seconds; raising the temperature reduces the cycle time.
Dyes tend to fade under exposure to UV light (daylight), and so UV protection may require additives in
the substrate or even the application of a UV-resistant topcoat.
Dye infusion involves the absorption of a dye into a coated or uncoated substrate using an activator
that provides a vehicle for absorption without the need for sublimation. It can be used, for example, for
colouring 3D objects and, like sublimation, benefits from the dye remaining in the substrate as opposed
to on its surface, thereby imparting better resistance properties.
Recent publicised innovation has included the Sublideck 3DTM 3D imaging technology from OCTI TECH
and CR CLARKE [3]; NISSHA PRINTING exhibited its sublimation process for 3D shapes in Barcelona
in February 2013. Their process involves inkjet printing and vacuum forming in order to conform to the
part surface for sublimation [4].
28.3 Patent Trends
Table 28.2
3D, tactile and depth effects Depth look from multiple substrates • Soft substrate
Colour effects Non-contact sublimation • Thermal transfer through a temporary coating
applied to the substrate
Selective coating deposition Use of a relief pad for selective sublimation
No innovators with three or more patents were uncovered during the three year period examined.
195
28.4 Listed Patent Literature 2011-2103 (for Dyeing method and dye deposition apparatus.
search phrases see Part A, Section 2) US20120023684A1 Feb 2nd 2012.
NIDEK CO LTD
A laser beam is used to sublimate a dye to a surface
28.4.1 Three-dimensional, Tactile and which is slightly out of contact with the decorating media.
Depth Effects
Method for tinting an optical film by thermal
Method for manufacturing molded transfer printing.
resin articles implementing coloring by WO2012072520A1 Jun 7th 2012
impregnation. A sublimation process whereby a cellulose acetate
WO2012026764A2 Mar 1st 2012. butyrate-containing film is applied to the substrate and
INTARON CO LTD then sublimation dye is applied using a thermal transfer
Colour impregnation of a soft substrate. printer. The whole is heated in order to sublimate the
dye into the substrate before removing the cellulose
Method for sublimating an image onto a acetate butyrate film with solvent.
substrate.
US20130032049A1 Feb 7th 2013.
UNCOMMON LLC
A 3D depth look is achieved by sublimating an image
onto a suitably prepared translucent material and then Systems and methods for applying markings
a second image on a backing material. to an article.
US20110173762A1 Jul 21st 2011.
NIKE INC
28.4.2 Colour Effects A selective infusion dying process employing a relief
pad has been developed for marking objects.
Non-contact process for decorating dye-
permeable fibres of a cosmetic applicator.
US20110191966A1 EP2353879A1 Aug 11th 2011.
ALCAN PACKAGING BEAUTY SERVICES
A non-contact sublimation process is proposed for a
pre-formed cosmetics brush.
References
1. C.J. Noel, inventor; C.J. Noel, assignee; FR2881988A1, 2006.
2. L. Bedel, inventor; Elbe Technologies, assignee; WO2011124825A1, 2011.
3. Octi Tech Ltd., and CR Clarke & Co., Complete Exclusive Global Development Agreement on 3D
Imaging Technologies, Wide Format online.
http://www.wideformatonline.com/index.php/news/textile/4860-octi-tech-ltd-and-cr-clarke-co-
complete-exclusive-global-development-agreement-on-3d-imaging-technologies.html {Accessed
June 2014}
4. Exhibit 3D Dye Sublimation Products in ‘Mobile World Congress’, Nissha.

http://www.nissha.co.jp {Accessed June 2014}
196
29 Vacuum Deposition
Table 29.1
29.1 Background
Vacuum deposition of thin films is used in a wide range of quite different modern industrial fields. These
include architectural glass, numerous applications for electronic components, medical applications (bio-
compatibility, slip, hard coatings for prosthetics and so on), optical discs, lenses, reflectors and mirrors
(including anti-fingerprint, scratch and anti-reflection layers), solar cells, and especially the wear protection
of machine tools and dies. In these and many others, hundreds of different inorganic and organic materials
are deposited in either single or multiple layers.
Vacuum deposition is also a major process for moulded plastics substrates and subject to a considerable
amount of innovation covering a wide range of effects. Mainstream applications include decorative metallic
effects; several billion moulded substrates are metallised every year using large chambers of cycle times
up to 20-30 min for the packaging industry, and this certainly constitutes the largest activity on moulded
plastics. Other common applications include deposition of permeation barriers and abrasion resistant
coatings. Leading companies in various specialisations, including for in-line solutions for three-dimensional
(3D) objects, include HAUZER (e.g., Metalliner®); LEYBOLD OPTICS (e.g., DynaLine); OERLIKON (e.g.,
Inubia I); and VTD, but many other reputable companies also exist.
The film thicknesses deposited are usually low, in tens of nanometres rather than microns. There are
several reasons for this:
• Deposition rates are relatively low, and therefore thicker films hinder the cycle time;
• Because vaporised material finds itself in part being absorbed through pumping systems and coating
chamber walls and tooling, deposition is kept low in order to limit maintenance; and
• Longer cycle times usually entail heating of the substrate, which is particularly problematic for most plastics.
In traditional decorative metallising, metal film weights are usually intended to ensure opacity (i.e., around
30-50 nm in the case of aluminium, the most common decorative material). Where longer cycle times
have to be tolerated, e.g., in ceramic deposition, lower deposition power or an interrupted process are
used so as to avoid substrate heating. In such cases film thicknesses up to a few microns can be applied
in order to provide adequate performance of the final article.
There are many different deposition techniques and variants. The most common industrial physical
deposition processes are:
197
1. Thermal evaporation from filaments, boats or crucibles;
2. DC magnetron sputtering from flat ‘targets’ of material to be deposited; and
3. Cathodic arc evaporation from flat targets.
Deposition energy is substantially higher in the latter two processes, thereby providing better adhesion
to the substrate. The low pressure environment (vacuum) ensures a longer mean-free-path (MFP) before
molecular collision (thereby allowing use of larger chambers and more substrates), as well as a chemically
restricted atmosphere, for example at atmospheric pressure MFP is less than 0.1 μm, rising to around
6,000 μm at a pressure of 0.1 Pa. DC, or eventually microwave or radio frequency (RF) controlled plasma
together with an inert gas, usually argon, is employed in sputtering and cathodic arc processes. If ceramic
deposition is required (rather than pure metal or alloy) a controlled amount of a reactive gas such as nitrogen
or oxygen is also present. Ceramic coatings include gold coloured TiN and ZrN, and their high levels of
hardness remove any need for a translucent protective topcoat, especially at higher film thicknesses.
Plasma enhanced chemical vapour deposition (PECVD) is a low-temperature process in which a liquid
precursor is fed into the chamber in the presence of a plasma. In decorative applications on plastics,
PECVD can be used to apply a protective layer over a thin metal film, as well as easy-to-clean films,
to coated or uncoated substrates. Table 29.2 shows examples of materials deposited onto plastics for
decorative and common functional purposes.
Table 29.2
Common materials vacuum deposited onto plastic substrates*
Material Comments
Metals and alloys Decorative coatings (Al, Al/Cu, Ag, Au, Cr, SS, Ti and so on). Usually applied by
thermal evaporation (primarily Al) or direct current (DC) sputtering (all metals). Typical
film thickness is in the order of 50 nm and requires a post-vacuum (usually sprayed)
protective organic topcoat or in-chamber applied silica topcoat. Widely used in
the closures market, where the substrate usually also requires a gloss-enhancing
organic basecoat applied prior to metallising. Also used for mirrors and reflectors
Ceramics Hard decorative coatings in gold and other colours (TiN, ZrN and so on) usually
using reactive processes (sputtering or cathodic arc each with reactive gas present).
The gas flow controls the colour. These materials are applied at thicknesses of
hundreds of nanometres up to several microns, but do not require any further
protection. Deposition rates are much slower. Applications include as a final
topcoat for gold replacement on electroplated plastic products. The brittleness of
thick coatings on softer polymer substrates requires stacked layers of increasing
hardness in order to ensure adhesion
Oxides Scratch resistance (SiO2), permeation barrier (SiOx), or self-cleaning coatings
(TiO2), usually deposited from liquid precursor fed into the chamber coupled with a
plasma enhanced chemical vapour deposition (PECVD) process. SiO2 is used as an
alternative to an organic topcoat to protect metallised aluminium in less stringent
cases, for example for certain types of reflector. High refractive index materials such
as TiO2 and ZnS produce interference effects on coated polymer surfaces
Amorphous carbon (a-C:H) Alternative permeation barrier material, for example obtained from acetylene bled
into the chamber during a plasma process
Organic materials Gas and moisture barrier from evaporated Parylene, which has a barrier
performance equivalent to polyethylene terephthalate (PET). Other emerging
products include thin layers of adhesion primers, metallising basecoats, as well as
antibacterial and easy-to-clean films and so on
*Excluding anti-reflection coatings and other specialist applications
198
Sputtering is widely used for plastic substrates. Choice of sputtering target material is almost limitless, but
aluminium still dominates for decorative applications because of its low cost and high level of brightness
and neutral colour. Alternatives to aluminium include silver, or even indium (which may be used in the
very specific case of decorating substrates for use in electronic items, where a non-conductive vacuum
metallisation is required in order to avoid RF or EMI). Targets can last for tens of thousands of shots
(whereas filaments have to be reloaded with the deposition material at each cycle and replaced every
10-20 cycles).
A major milestone in industrial sputtering of 3D objects took place in the 1970s with an in-line multi-chamber
process for chromium deposition onto plastic parts developed for CHEVROLET. Multiple chambers allow
pump-down, any required pre-treatment, and breaking vacuum to be carried out at the same time as
deposition, thereby accelerating the process. One such line was later reused for depositing brass onto
moulded plastic picture frames. Other faster linear machines were eventually developed by companies
such as HARTEC, SIDRABE, VTD and many others. Around the year 2000, VACUMETAL and SIDRABE
developed an in-line sputtering system capable of transferring carrier bars between spray coating and
metallising [1]. A major turning point came in the 1990s when LEYBOLD developed a rotary device for
3D objects called the DynaMet. This technology, which had originated from CD-ROM manufacturing, has
today evolved into machines with less than a 10 second cycle time. The advantage of this technology
is that substrate transit time between chambers is reduced to a fraction of a second. Depending on the
model, targets are either placed above stationary substrates, or to the side of rotating substrates. One
of the first models, the SINGULUS 3DS, uniquely had side targets facing each other, thereby ensuring
good top and side coverage without the need for substrate rotation. Various other models have appeared
since, notably from MARCA COATING TECHNOLOGIES and TAPEMATIC.
Since spraying is a costly and wasteful process, various efforts have been made to avoid the use of
either organic basecoats or topcoats. Provided that the moulded substrate surface remains visually
perfect (it also requires in-line processing to avoid damage or exudation issues and provides instant
feedback to moulder), the basecoat can theoretically be avoided (Part A, Section 3.1.7 for further
comments on this). This has already been the case for CD-ROM and DVD manufacturing as well as for
automobile reflectors, using high-gloss polymers such as polycarbonate, polymethyl methacrylate and
polybutylene terephthalate (PBT). The use of heated cavities and rapid heat cycle moulding techniques
adds improvement possibilities for lower gloss materials (Part C, Section 13). Moulding in-line also
facilitates the maintenance of substrate surface wettability and thereby the avoidance of solvents
in coatings. With the possibility of using so-called zero-solvent or high solids UV cured coatings for
basecoats, overspray (which can account for more than 80% of coating consumption on smaller
substrates) can be easily captured and reused.
To suppress the need for an organic topcoat, PECVD can be used to deposit translucent silica topcoats.
Alternatively, ceramic deposition can be considered to replace both layers, although reactive deposition is
slow and requires compensation in the form of larger chambers in order to process more parts at a time,
as well as sophisticated equipment for reactive gas (and resulting colour) control. This latter process has
been used for nearly two decades to coat electroplated parts with gold colours. A third alternative is the
Cromatipic® process, developed by SIDASA, involving sputtering about 100-300 nm of chromium over a
UV-cured organic basecoat. In sufficient thickness chromium has the benefit of not requiring a protective
topcoat. HAUZER has more recently developed their Metalliner® for carrying out the entire operation in-
line. Table 29.3 shows common methods for applying metallic effects to plastics under vacuum.
199
Table 29.3
Optional decorative vacuum metallising processes for plastics
Process Description
1 Conventional batch metallising, High-output process carried out separately from moulding and running
usually by thermal evaporation several times faster. Vacuum deposition is usually by thermal evaporation in
(>50 years) large chambers with long cycle times and up to thousands of substrates.
Characterised by frequent changeovers. Often carried out in a separate
plant, days or weeks after moulding. UV-cured basecoats (10-15 μm)
and topcoats (5-10 μm) are usually applied by spray (80% overspray on
small parts). Colour is provided by dyes or pigments added to the organic
topcoat. Currently used in well over 95% of cases
2 Conventional batch metallising Sprayed topcoat is replaced by colourless in-chamber silica deposition.
with in-chamber topcoat Used for lower resistance requirements with low film weights. Higher
energy deposition and film thicknesses of microns would be required
to match resistance levels attained with sprayed and UV-cured organic
coatings
3 Multi-chamber sputtering, Spray and metallisation processes are automatically linked. The metallising
linear machines (from 1970s – equipment consists of load-locks and multiple chambers linked with gate
CHEVROLET) valves. High equipment costs. Line capacities are usually several times
faster than the injection moulding operation, making for an off-line process
4 Ceramic deposition (from 1990s) Large chamber and reactive sputtering or arc deposition are used to
hardcoat plastics with 1-3 μm coloured film. ZrN and TiN and similar
products are gold coloured. Used to provide lower-cost gold colours onto
electroplated plastic substrates (no topcoat required). Slow deposition rate
5 Cromatipic® process Recently developed by SIDASA ENGINEERING, this process avoids solvents
by using a water-based basecoat and employs vacuum deposition of
chromium over a basecoat. Chromium thickness is 100-300 nm
6 Small-volume rotary table multi- Shorter cycle times which today have attained <10 seconds, and even as
chamber rapid-cycle sputtering low as 5 seconds with several substrates at a time. Process output rate
(from 1990s) is reduced to approximate moulding speed, thereby facilitating link-up, or
at least running in tandem with moulding. Improved substrate control by
running in-line creates the possibility of reducing or removing basecoat
and avoiding solvents. Slower output rate allows indexed spraying, thereby
saving wastage between parts
Common IPC codes are any of B05D (Processes for Applying Liquids or Other Fluent Materials to Surfaces,
in General), B32B (Layered Products, i.e., Products Built-Up of Strata of Flat or Non-Flat, e.g., Cellular or
Honeycomb, Form) and C23C (Coating Metallic Material; Coating Material with Metallic Material; Surface
Treatment of Metallic Material by Diffusion into the Surface, by Chemical Conversion or Substitution;
Coating by Vacuum Evaporation, by Sputtering, by Ion Implantation or by Chemical Vapour Deposition,
in General). Recent process innovation has included processes for depositing both organic and metallic
materials in the same process [2, 3]; methods to improve internal barrier coating of PET bottles (KHS,
KIRIN BEER, KRONE, MITSUBISHI SHOJI PLASTICS, TOYO SEIKAN and others); organic deposition;
improvements to deposition devices, targets, pumps and process control. A technique for controlling
metal film thickness on a product [4]. Among prominent recent innovators in the equipment field have
been CREAVAC, HAUZER, LEYBOLD OPTICS, MUSTANG, OERLIKON, ULVAC, VAPOR TECHNOLOGIES
and VTD. OERLIKON has been particularly active in applying for patents.
29.2 Recent Commercial Developments in Decorative Deposition
Rapid-cycle PVD machines for metallising 3D objects with dimensions of less than 100 mm, in under
10 seconds have recently appeared from MARCA COATING TECHNOLOGIES [5] and TAPEMATIC [6,
200
7]. Whereas equipment costs are currently much higher in relation to throughput, overall net savings
are realised from a combination of automation and automatic inspection, together with spray coating
consumption reduction because of indexing and other advances allowed by the process.
Recently publicised innovations in vacuum deposition equipment have included the Meta Table C short-
cycle metalliser from VTD [8]; the Press-Side 4000SL from VERGASON [9]; an in-line rotary table sputtering
device from WATANBE [10]; and the in-line Metalliner® from HAUZER for the Cromatipic Process (surface
preparation, organic basecoat and chrome) [11]. The first TAPEMATIC PST, 2400 parts/h in-line spray
coating and metallising line with automatic inspection and quality control has been delivered [12], see also
Figure 29.1. VTD has announced a new in-line machine for metallising 600 mm rods in 12 seconds [13].
Figure 29.1
TAPEMATIC PST Line fully automated in-line 3D sputtering coating system.
Reproduced with permission from TAPEMATIC SPA, Ornago, Italy. ©2014, TAPEMATIC SPA
Other innovations have included a low-fogging PBT resin for direct metallising from BASF called Ultradur®
High Gloss B4570 [14]; a true black PVD coating from VAPOR TECH [15].
29.3 Patent Trends
Table 29.4
3D, tactile and depth effects Relief substrate surface • Slip effects
Colour effects Black physical vapour deposition (PVD) finish • Colour from plasmon
resonance in clear PVD applied topcoat with metallic particles • Final colour
obtained from coloured metallising undercoat • Luminescent effects •
Separating colour and wear resistant functions in reactive coating in order to
improve colour control • Thermochromic topcoat
Gloss and matte effects Ion implantation of substrate • Matte topcoats
Interference effects Improved control of interference film on 3D surfaces
Metallic or reflective effects Additional PVD layer before basecoat for electrostatic assist • Al-Si
translucent white coating • Ceramic deposition • Decorating before applying
topcoat • Electromagnetic interference (EMI)/radiofrequency (RF) shields •
In-chamber topcoating • Mirrors and reflectors • Stacked layers of Cr/CrN •
Stainless steel deposition for cutlery • Titania protective topcoat
Selective coating deposition Laser etching • Masking followed by chemical etching • Oil masking agent
applied prior to metallising • Physical masking
Surface quality improvement Compliant basecoat to prevent cracking • Dry ice cleaning of substrate •
Hardcoat basecoat to prevent cracking • Ion implantation of substrate to
improve gloss
201
Table 29.4 shows the themes presented by patents mentioned in this chapter. Vacuum deposition has the
inconvenience of high capital costs, and therefore it is expected that future exploitation in the decoration
to be focused on areas where uniqueness or significant economic or environmental benefits are most
evident. Possible avenues are:
• New rapid-cycle metallising devices and in-line processing, exploiting accompanying advantages
such as reduced consumption of organic coating materials, automatic inspection, and lower footprint.
• Development of methods for avoiding the need for spray coated basecoats: e.g., improved in-chamber
organic and organic/metal deposition methods, or zero basecoat alternatives provided by moulding.
• Development of methods for avoiding spray coating of topcoats (silica or ceramic deposition).
Table 29.5
Specific novel patent subject trends
1 Reactive deposition of ceramics 7 17
2 Ion implantation to improve substrate gloss 3 7
3 Selective laser removal 3 7
4 Direct metallising without basecoat 2 5
Table 29.1 shows that the most common category in recent innovation relates to metallic effects, and
Table 29.5 that reactive cathodic arc deposition of ceramic materials onto polymers appears to be coming
to the fore. As already mentioned, such a process negates the need for a sprayed topcoat. Of particular
note, ES2365995T8 [16] and CN102328477A [17] disclose application of a ceramic finish over an organic
basecoat. CN101700703B [18] discusses the deposition of chromium over an organic basecoat using
cathodic arc deposition, followed by a protective translucent TiO2 coating. US20130064536A1 [19], talks
of a stacked Cr/CrN deposition using cathodic arc deposition.
Basecoats can be avoided by improving substrate surface quality. US20110070411A1 [20] talks of the
use of ion implantation to improve or modify the gloss and surface hardness of a substrate polymer.
WO2012038369A1 VALEO VISION [21], also talks of the use of ion implantation.
In US20110008602, [22], an alternative PVD method is proposed for creating colour in clear coatings,
using aluminium oxide, silica and so on, deposited over reflective layers, is to co-deposit small metallic
particles (chromium copper, gold, platinum, silver, titanium, and so on) to exploit the phenomenon of
surface plasmon resonance. Colours are created by interaction of light with oscillating electrons at the
nanoparticle surface, a phenomenon that has been used in the past for stained glass windows. Film
thickness is controlled so as to avoid degrading colours produced through interference effects.
Table 29.6
1 XIAMEN RUNNER INDUSTRIAL CORPORATION 3 7
The most frequent innovating companies are listed in Table 29.6.
202
Black from chromium and amorphous carbon deposition; gloss control using ion implantation; PVD-applied
colour applied to transparent coatings using plasmon resonance; selective deposition using masking oil;
separation of colour and wear-resistance functions in reactive deposition.
Reactive deposition of ceramic materials.
29.4 Listed Patent Literature 2011-2103 (for 29.4.2 Colour Effects

Coating which gives an article a coloured
appearance.
US20110008602 Jan 13th 2011.
Depth Effects
HAUZER
Surface plasmon resonance, a phenomenon caused
Injection-molded product having multi-layer by the interaction of light with oscillating electrons
pattern and method of fabricating the same. on the surface of metallic nanoparticles dispersed in
US20110020613A1 Jan 27th 2011. a transparent medium, is used to provide colour to a
SAMSUNG physical vapour deposition-applied coating.
3D visual effect for a compact or mobile telephone case
from a combination of injection moulding and physical Colored plating structure and method thereof.
vapour deposition. US20110039116A1 Feb 17th 2011.
An organic topcoat protected metallisation by
Method for depositing fluorocarbon films on sputtering whereby the colour is imparted by an
polymer surfaces. undercoat.
US7879418B1 Feb 1st 2011.
UNIV CALIFORNIA Making metallized container for perfume
A fluorocarbon coating is applied to a polymer surface or cosmetics, comprises disposing hollow
using inductively coupled plasma in order to improve body with metallization coating layer and
properties such as slip. thermochromic coating layer, disposing laser
on selected zones, and controlling thickness
Decorative member and injection molding of coating layer.
method. FR2958661A1 Oct 14th 2011.
US2011262713A1 Oct 27th 2011. LOTOISE D EVAPORATION SOLEV SOC
PANASONIC CORP A method for controlling metallisation film thickness
A method for producing a pronounced 3D visual effect using a laser to isolate an area to be tested electrically.
by the injection moulding of a translucent material and The metallisation includes a thermochromic coating
metallising or painting or laminating the back surface layer above the metallisation.
with a reflective material.
Metalized plastic molded article.
Decorative member. JP2011235644A Nov 24th 2011.
US20110281075A1 Nov 17th 2011. BAYER MATERIALSCIENCE AG
PANASONIC CORPORATION A 3D metallised plastic moulded article showing a
An improved 3D depth look is achieved by varying luminescent surface using an electroluminescent
substrate thickness in a convex manner as opposed layer.
to a conventional stepped manner and backing with a
coloured reflective layer. Decorative part for motor vehicles.
WO2013034259A1 Mar 14th 2013.
OERLIKON TRADING AG TRUEBBACH
203
The colour and wear-resistant functions of a physical CHITWING MOULD INDUSTRY DONGGUAN CO LTD
vapour deposition layer applied over electroplating are A single film of TiO2 is deposited over a film of SiO2 in
separated in order to give more flexibility in controlling order to obtain an optical effect without resorting to
colour. multiple layers.
Method for coating cellular phone case with

color black.
WO2013137520A1 Sep 19th 2013.
Chromium and amorphous carbon are co-deposited Decoration effect treatment method of plastic
under vacuum in order to produce a black finish. outer shell.
CN102101404A Jun 22nd 2011.
Coated article with black color. SUZHOU MITAC PREC TECHNOLOGY CO LTD
EP2186927B1 Dec 18th 2013. Applying an ultraviolet-cured basecoat, metallising and

MASCO CORPORATION then decorating a plastic substrate before applying a
A black multi-layer coating applied by reactive physical ultraviolet-cured topcoat.
vapour deposition.
Method for preparing composite interlayer
coating film on surface of engineering plastics.
29.4.3 Gloss and Matte Effects CN102152541A Aug 17th 2011.
XIAMEN RUNNER IND CORP
Plastic with improved gloss properties and In order to avoid the use of CrVI in electroplating,
surface treatment method. a substrate in an engineering plastic is cleaned,
US20110070411A1 Mar 24th 2011. metallised by physical vapour deposition, spray coated
HYUNDAI MOTOR COMPANY with a ultraviolet-curable organic coating, and then
An argon ion beam is used to improve or alter gloss metallised using reactive sputtering or reactive arc in
and scratch resistance of plastic substrates, thereby order to produce a ceramic layer.
avoiding the need for a protective coating.
Coated article with polymeric basecoat having
Decorative member. the appearance of stainless steel.
US20120015180A1 Jan 19th 2012. ES2365995T8 Nov 11th 2011.
FUJIKURA LTD
VAPOR TECHNOLOGIES INC
A luminous matte effect obtained by avoiding a matte A plastic or metal article is coated with an organic
basecoat (which is difficult to ultraviolet-cure) and
basecoat and then subjected to reactive physical vapour
instead applying a topcoat with 2 types of matting
deposition such as cathodic arc or sputtering. The
pigment incorporated.
advantage of reactive deposition is that an organic topcoat
is no longer needed, thereby simplifying the process
29.4.4 Interference Effects steps, and providing a limited range of gold colours.
Method for forming a decorative coating, a Method for compounding double-layer plating
decorative coating, and uses of the same. films on plastic surface by fully dry method.
WO2011055012A1 May 12th 2011. CN102328477A Jan 25th 2012.
BENEQ OY RUNNER XIAMEN IND CORP
The deposition of an inorganic interference layer, A metallised finish consists of a basecoat followed by
e.g., chromium oxide, for aesthetic purposes requires ceramic deposition.
precise film thickness control, which is a particular
challenge on a 3D surface. The method proposed Unit for the treatment of an object, in
consists of deposing an intermediate material and particular the surface of a polymer object.
controlling film thickness of the functional derivative by WO2012038369A1 Mar 29th 2012.
surface treating the deposited film to a controlled depth. VALEO VISION
(1) ion bombardment followed by (2) metallisation by
Mobile phone and manufacturing method for thermal evaporation or sputtering; and (3) plasma
vacuum coating. enhanced chemical vapour deposition coating of the
CN102816993B Nov 27th 2013. substrates.
204
Metallized cutlery and tableware and method layers onto a polymer substrate in order to achieve
therefor. improved electromagnetic shielding.
US8176641 May 15th 2012.
WADDINGTON NORTH AMERICA INC Metallized multilayer structure made of
Direct-metallised plastics cutlery using sputtered specific polycarbonates with low coefficient of
stainless steel. thermal expansion.
WO2013079398A1 Jun 6th 2013.
Method of preparing sandwich composite BAYER INTELLECTUAL PROPERTY GMBH
coating on engineering plastic surface. A material and process for moulding a polycarbonate
EP2463031A1 Jun 13th 2012. material, direct metallising, followed by in-chamber
XIAMEN RUNNER INDUSTRIAL CORPORATION topcoating using plasma enhanced chemical vapour
Deposition of (1) physical vapour deposition applied deposition.
metal; (2) sprayed organic basecoat; and (3) physical
vapour deposition applied chromium, imitation nickel, Plastic article and method for manufacturing
stainless steel, zirconium/copper. the same.
US20130157046A1 Jun 20th 2013.
Chromium-plated plastic product. FIH (HONG KONG) LIMITED
CN101700703B Oct 24th 2012. Cost of indium and oxygen sensitivity issues during
GUANGZHOU JINTAI SCIENCE AND T processing of indium and tin are avoided for the
Organic basecoat, cathodic arc deposited Cr, followed deposition of translucent white coatings by sputtering
by a physical vapour deposition deposited TiO2. an Al-Si layer protected by sprayed ultraviolet basecoat
and topcoat.
Imitation plating processing method for
surface of automobile exterior decoration. Method for preparing reflector.
CN102086511B Jan 9th 2013. WO2013157700A1 Oct 24th 2013.
JIAXING MINHUI AUTOMOTIVE PARTS CO LTD ALTO CO LTD
Dry ice cleaning and sputtering are used to replace Moulding, degreasing and vacuum deposition to
electroplating. produce a polymer reflector.
Composite plastic member and method for

producing the same. 29.4.6 Selective Coating Deposition
US20130064536A1 Mar 14th 2013.
NIKON CORPORATION Article-surface decorative structure and
Applying a highly wear-resistant ceramic to a method of processing for the same.
temperature-sensitive plastic (acrylonitrile-butadiene- EP2281696A1 Feb 9th 2011.
styrene, polypropylene and so on) involves using a HAMANO PLATING CO LTD
filtered cathodic arc method and stacked layers, in this Use of a laser to selectively remove physical deposited
case of Cr/CrN. metal prior to topcoating.
Electromagnetic shielding article and method Method of fabricating injection-molded

for manufacturing same. product.
US8436258 May 7th 2013. US20110250400A1 Oct 13th 2011.
HONG FU JIN PRECISION INDUSTRY (SHENZHEN) CO SAMSUNG ELECTRONICS CO LTD
LTD The internal or external surface of a translucent
An electromagnetic/radio-frequency interference shield injection moulded substrate is metallised by deposition
of copper, silver, or stainless steel over radio-frequency or painting and areas removed by laser to form a
plasma deposited nickel vanadium. decorative pattern prior to protective coating. An
opaque coloured paint is used to enhance the engraved
Method for electromagnetic shielding and areas.
product made by same.
US20130143065A1 Jun 6th 2013. Vacuum metallization device with means to
FIH (HONG KONG) LIMITED create metal-free areas.
Physical vapour deposition is used to apply multiple US20110297087A1 Dec 8th 2011.
205
GALILEO VACUUM SYSTEMS SPA Plastic automotive mirrors.

A high definition selective vacuum metallisation process WO2011075796A1, Jun 30th 2011.
designed to apply via a flexographic process a thin film CO-OPERATIVE RESEARCH CENTRE FOR ADVANCED
of oil as a masking agent. AUTOMOTIVE TECHNOLOGY LTD
A first-surface plastic mirror is proposed that does not
Method of producing an article having have the inherent previous disadvantages of crazing
patterned decorative coating. and interference fringes, and which resists salt spray
US8123967 Feb 28th 2012. testing and other weathering tests. A hardcoat is
VAPOR TECHNOLOGIES INC applied between the polycarbonate substrate and
A physical vapour deposition applied decorative multi- physical vapour deposition-deposited metal.
colour patterned coating using masking and chemical
etching. Surface-treated material based on polymers.
US20130224480A1 Aug 29th 2013.
Mobile telephone, antenna whose surface VALEO VISION
is processed by vacuum coating and Moulded polymer substrates are surface hardened
manufacturing method thereof. and re n d e re d g l o s s i e r a n d c o l o u r a d j u s t e d
WO2012139280A1 Oct 18th 2012. by ion implantation (bombardment). (See also
SHENZHEN HOUZE VACUUM TECHNOLOGY CO LTD US20130223086A1 and US20130224400A1)
An integrated antenna is manufactured by vacuum
metallising through a mask, applying a decorative PVD coatings embedded in coats of paint.
coating, laser engraving the metal deposition and then WO2013178363A2 Dec 5th 2013.
topcoating. OERLIKON TRADING AG TRUEBBACH
In order to provide a low-stress physical vapour
Device and method for coating a substrate. deposition layer solution for a flexible plastic substrate,
WO2012175651A1 Dec 27th 2012. a metallised polymer substrate has an organic
FICKER, FRANK basecoat, the metallic layer is, for example, aluminium
A masking device for sputtering patterns onto a applied over titanium. The aluminium layer is anodised
substrate. prior to topcoating.
Method for metallizing polymer layer systems, Plastic part having a layered, decorative,
and polymer layer systems. colored-metal finish.
WO2013023812A1 Feb 21st 2013. US20130337276A1 Dec 19th 2013.
ROBERT BOSCH GMBH GLOBAL IP HOLDINGS LLC
A laser is used to selectively remove metal. A metallised component with superior weather
resistance consists of an ultraviolet-cured basecoat,
or optionally applied by physical vapour deposition, a
vacuum metallised layer, a heat-cured coloured layer
with ultraviolet light stabilisers, and then an ultraviolet-
Techniques for marking a substrate using a cured clear topcoat.
physical vapor deposition material.
US20110051337A1 Mar 3rd 2011.
In a physical vapour deposition marking process, a
compliant intermediate layer is used between a physical
vapour deposition layer and the substrate in order to
avoid substrate cracking.
References
1. C.P.G. Schrauwen, A.J.W. Schuurmans and G.C.H. Schuurmans, inventors; Vacumetal BV,
assignee; EP1129232B1, 2003.
2. M. Vergöhl and T. Neubert, inventors; Fraunhofer-Gesellschaft zur Forderung der Angewandten

Forschung eV, assignee; US20110111131A1, 2011.
206
3. H. Irikura, D. Omori, K. Motegi, K. Momono and Y. Hashimoto, inventor; Ulvac, Inc., assignee;
EP2202059A4, 2012.
4. M. Pivaudran and B. Allegret, inventors; Societe Lotoise D’Evaporation (SOLEV), assignee

FR2958661A1, 2011.
5. J.W. Gresik, J.J. Black, S. Brooks, J. Shaw and L. Zuckerman, inventors; Marca Machinery, LLC,
assignee; US20130037407A1, 2013.
6. L. Perego, inventor; Tapematic SpA, assignee; US20120234670A1, 2012.
7. L. Perego, inventor; Tapematic SpA, assignee; EP2500448A1, 2012.
8. First VTD ‘Meta Table C’ Handed over, VTD.

http://www.vtd.de {Accessed June 2014}
9. Improved Rapid Cycle Metallizer, Vergason Technology Inc.

http://www.vergason.com {Accessed June 2014}
10. S. Moore, IPF show: In-line Sputtering Process Boosts Plating Efficiency, Plastics Today.
11. Launch Metalliner, Hauzer Techno Coating.

http://www.hauzertechnocoating.com {Accessed May 2014}
12. First Tapematic PST Line Installed, Tapematic.

http://www.tapematic.it {Accessed June 2014}
13. Meta Inline. VTD.

http://www.k-online.de {Accessed June 2014}
14. New Low-Fogging, High-Gloss PBT for Headlight Bezels, BASF.

http://www.basf.com {Accessed June 2014}
15. Vapor Tech Introduce First True Black PVD Coating, Business Wire.
http://www.businesswire.com/news/home/20111206005027/en/Vapor-Tech-Introduces-True-
Black-PVD-Coating#.U6bB0ctOWc0 {Accessed June 2014}
16. C. Guocun, inventor; Vapor Technologies Inc, assignee; ES2365995T8, 2011.
17. Z. Wu and M. Li, inventors; Runner Xiamen Industrial Corporation, assignee; CN102328477A,
2012.
18. L. Feng, J. Pan and M. Qian, inventors; Huzhou Jintai Science and Technology, assignee;
CN101700703B, 2012.
19. Y. Taki, Y. Takahashi and Y. Urakawa, inventors; Nikon Corporation, assignee; US20130064536A1,
2013.
20. Y.J. Jang, K.C. Lee, S.S. Park, K.R. Lee, M.W. Moon and F.A. Sk, inventors; Hyundai Motor
Company, Kia Motors Corporation and Korea Institute of Science and Technology, assignees;
US20110070411A1, 2011.
21. F. Moret, M. Brassier and A. Chenet, inventors; Valeo Vision, assignee; WO2012038369A1, 2012.
22. P. Peeters, inventor; Hauzer Techno Coating BV, assignee; US20110008602A1, 2011.
207
30 Water Transfer Printing

Table 30.1
30.1 Background
Water transfer printing (sometimes referred to as hydraulic transfer printing, or by brand names such as
Aquagraphix, Cubic, or Hydrographic printing) consists of pre-printing a transfer sheet with a dissolvable
release layer and then posing the sheet on a water surface in order to transfer the thin ink layer to the water
(activation). In an automatic process, suitably racked pretreated and primer coated (as required) 3D substrates
are slowly dipped into the water bath so that they become enshrouded by the flexible ink film. The parts are
then washed to remove any residual traces of the film material and then dried. Decorated substrates are often
subsequently spray coated with a UV curable coating in order to protect the image and provide a uniform finish.
Recently TAICA developed their E-Cubic® process, which provides 3D tactile finishes without the need
for a separately applied topcoat [1], and the principles are mentioned in patent applications appearing
in Part D, Section 30.4.
By virtue of its low speed and complexity, this is a relatively expensive process when compared to many
other decoration technologies, and accurate image positioning is not possible. However, the decorative
result has remarkable potential and quality: a) because of its capability to fully enshroud the tops and sides
of 3D objects, and b) because sheet or web multi-colour printing processes such as digital, flexographic,
gravure, or screen or printing can be used to print the transfer image. Since placement accuracy is limited,
the process is mostly used to print random designs and effects, including halftone. Where a simpler shape
allows, water transfer finds itself under increasing competition from in-mould film processes.
Recent publicised innovation has included an installation provided by HYDRO GRAPHICS for motorcycle
helmets [2]; the DecoraToy process developed for toys by the AIJU - THE TOY RESEARCH INSTITUTE [3].
30.3 Patent Trends
Table 30.2
3D, tactile and depth effects Imitation wood pattern • Laser etching • Relief pattern transfer • Swelling inks
Gloss and matte effects Gloss level manipulation • Matte effects • Surface wrinkling
Metallic or reflective effects Decorating a metallised substrate • Reflective beads
Surface quality improvement Rough edge suppression
208
Water transfer remains a unique and versatile decorative process for moulded substrates, with more shape
versatility than in-mould film techniques. Table 30.1 shows that new developments in water transfer that
allow tactile effects lead innovation in this area. The concept of an integrated protective coating serves
to expand the potential and affordability of this process.
TAICA is the most frequently innovating company, as shown in Table 30.3.
Table 30.3
1 TAICA CORPORATION 4 36
Methods for tactile effects.
3D, Tactile and Depth Effects.
30.4 Listed Patent Literature 2011-2103 (for Method for decorating objects.
search phrases see Part A, Section 2) EP1526001B1 Dec 21st 2011.
V.I.V. INTERNATIONAL SPA
Method for decorating imitation wood or marble or
30.4.1 Three-dimensional, Tactile and other patterns through a water transfer process and
Depth Effects then sublimating the dyes in the coating in an oven.
Manufacturing method of decorative Water pressure transfer method, a water

component, decoration method of pressure transfer article and a coating agent
component. for water pressure transfer film.
JP2011126179A Jun 30th 2011. US20120048136A1 Mar 1st 2012.
TRINITY IND CO LTD TAICA CORPORATION
A hydraulic transfer image is provided with a 3D tactile A method for obtaining a 3D tactile surface using water
effect by coating and then laser etching the coating. transfer printing.
Decorative molded article and method for

producing the same.
US20110189445A1 Aug 4th 2011.
DIC CORPORATION Method and product of hydraulic transfer.
A swelling ink is used in conjunction with water transfer US20120111951A1 May 10th 2012.
printing in order to give a 3D tactile effect. TAICA CORPORATION
A water-transfer image consisting of ultraviolet-curable
ink merged with a ultraviolet-curable coating is first
Method of forming three-dimensional patterns
exposed to slight ultraviolet radiation in order to cause
on article surface.
the ink to wrinkle prior to full exposure.
US20110209640A1 Sep 1st 2011.
A method is proposed for water transfer printing 3D
relief patterns onto surfaces.
209
Matting activator for hydraulic transfer film, carrier. The protective ‘cover’ layer is then removed to
hydraulic transfer method, and hydraulic expose the beads and ink.
transfer product.
US20120321862A1 Dec 20th 2012. Surface decorative article, and method of
TAICA CORPORATION decorating surface.
A method for producing a matte effect with a water- JP2011230404A Nov 17th 2011.
transfer film. SEVEN CORP KK
A metallised substrate is decorated with a 3D water
Water transfer printing method, transfer film transfer image and then topcoated.
for water transfer printing, ink for transfer film,
and water transfer printed product.
US20130291746A1 Nov 7th 2013.
TAICA CORPORATION
A method for adjusting the gloss level of a hydraulically Case printing.
transferred image and also have selectively adjacent US20110236577A1 Sep 29th 2011
gloss and matte areas for both dark and light colours. Rough edges associated with water transfer printing
are avoided by carrying out the decoration step prior to
over-moulding a rubber interior to protect the electronic
30.4.3 Metallic or Reflective Effects device being contained by the case.
Reflective structure.
US20110141563A1 Jun 16th 2011.
CHEN SHIH YU
A water decal process is used in order to transfer
reflective beads embedded in an ink layer onto a
surface, separating them from a dissolvable layer and
References
1. Cubic Printing®, E-Cubic®, TAICA.

http://www.taica-na.com/cubic-printing-e-cubic/ {Accessed June 2014}
2. Powder Coater Turns to Flashy Football Helmets, PF Products Finishing.

3. Toy Research Institute Explores Water Printing Method to Decorate Toys, AZoM.
210
Abbreviations
Abbreviations
3D Three-dimensional
ABS Acrylonitrile-butadiene-styrene
BOPP Biaxially oriented polypropylene
CD-ROM Compact Disk Read-Only Memory
CIE International Commission on Illumination (French Commission: Internationale de
l’Eclairage
CMYK Cyan, magenta, yellow and key
CNC Computer numerical control
DC Direct current
DOD Drop-on-demand
DOI Distinctness of an image
dpi Dots per inch
DTEX Decitex (g/10 km)
DVD Digital Versatile Disk
EB Electron-beam
EMI Electromagnetic interference
EPO European Patent Office
EVA Ethylene vinyl acetate
FIM Film insert moulding
HRC Rockwell hardness C
HVLP High-volume-low-pressure
IM Insert moulding
IMD In-mould decoration
IMF In-mould forming
IML In-mould labelling
IMR In-mould roller
IPC International Patent Classification
IR Infrared
ISO International Organization for Standardization
LAB L*, a*, b* values
LDS Laser direct structuring
LED Light-emitting diode
LLPE Low linear polyethylene
MFP Mean-free-path
MW Molecular weight
Nd:YAG Neodymium doped yttrium aluminium garnet
PBT Polybutylene terephthalate
PC Polycarbonate
PCT Patent Cooperation Treaty(s)
PE Polyethylene
PECVD Plasma enhanced chemical vapour deposition
211
Abbreviations
PET Polyethylene terephthalate

pl Picolitres
PMMA Polymethyl methacrylate
PP Polypropylene
PU Polyurethane
PVD Physical vapour deposition
Ra Roughness average
RF Radio frequency
RHCM Rapid heat cycle moulding
RI Refractive index
Rmax Maximum roughness depth
rpm Revolutions per minute
Rz Mean roughness depth
SIPO Chinese Patent Office
SPI The Society of the Plastics Industry
TPE Thermoplastic elastomer(s)
UPVC Unplasticised PVC
USPTO US Patent and Trademark Office
UV Ultraviolet
WIPO The World Intellectual Property Organization
212
Index
Index
3D (see also Crackle, compositions 71 treatment processes 56

Embossed, Relief, Tactile decorated sheet 51 Atmospheric pre-treatment
and so on) materials 68 processes 57
depth look 92-93, 195-196, resin 71 Audible effects 13
203 substrates 83, 104
effect 10, 13, 47-49, 57, 92, Acrylonitrile-butadiene-
95, 137, 163-164, 174- styrene/polycarbonate 182
176, 192 Acrylonitrile-butadiene- B
decorative surface 92 styrene/styrene-acrylonitrile
polymer 70 Back moulding/back molding
printing method 192
Active packaging 45 88, 90, 93-94, 96, 98
sheet 48
wrinkle-free 98
electroluminescent surfaces Additive dispersion 75
Backing roller 127, 130-131
25 Adhesion 6, 23, 44, 46, 51, 53,
finely textured decorative film 56-57, 61-62, 68, 71, 76, Balling 124-125, 141
47 87, 89, 96, 98, 113-115, Basecoat 18-19, 21, 35, 38,
finish 139 151, 168, 182, 184, 198, 40, 46, 84, 86, 119, 129-
metallised plastic moulded improvement 56 131, 135, 137-138, 141-
article 203 Adhesives 6, 124, 127 142, 152-153, 162-167,
moulding 148 178, 198-202, 204-206
Aerosol jet printing 133
objects 57, 116, 129, 133, Basecoat/clearcoat coating
Al-Si layer 205
136, 152, 158, 188, 195, 165
Anti-counterfeit
197, 199-200, 208 Bi-injection moulding 76, 108
effect pigment 35
print film structure 91 identification 23
Blenders 75
printed images 175 markers 114 Blending plastics with wood
printing techniques 1 measures 17 particles 79
relief effects 11, 89-90, 135 pigment 39 Blow moulded/blow molded
relief film 91 solution 175 52, 78, 79, 93, 101, 109
relief pattern 102, 209 Anti-fingerprint 23, 38, 46, 52, Blow moulding/blow molding
shapes 195 56, 59, 63, 113, 145, 197 21-22, 88, 105-106, 109
substrate 15, 17, 129, 135- Anti-fingerprinting 145 Blowing
137, 157, 160, 167, 177, Antiglare cycle 21
208 coating film 62 stage 109
tactile effect 49, 139, 147, 209 hardened film 50 Boron nitride filler 67, 71
tactile films 46 Anti-reflection coating 62, 198 Bottles with gradation patterns
tactile relief 49 Anti-reflection/anti-fog 79
visual depth effects 90 coatings 61 Braille-printed matter 139
water transfer image 210 Anti-reflective coating 50, 62,
157
Anti-slip skin 46, 48
Antistatic/conductive
C
A
properties 63 Cathodic arc (see also
Abrasion 23, 30, 43-45, 50, 54, Antistatic label 52 Vacuum)
56, 58, 61-62, 70, 85-86, Antistatic grades 161 deposition 202
96, 143, 157, 197 Aqueous laser-sensitive evaporation 198
resistant plastic 86 composition 31 processes 198
resistant coats 23 Archaizing surfaces 164 Cavity
Acoustic effects 8-9, 13, 56, Argon ion beam 204 heating 16, 21, 106-107
58, 61, 66-67, 70, Atmospheric and low-pressure polishing level 104
Acrylate(s) 45, 47, 53, 58, 65, (vacuum) plasma treatment Cellulose acetate butyrate-
115 methods 56 containing film 196
Acrylic/polyvinyl chloride 31 Atmospheric plasma Ceramic
Acrylonitrile-butadiene-styrene coating apparatus 114 coatings 198
(ABS) 20, 31, 161, 177, 182, deposition 23, 113 deposition 23, 197-199, 204
184 Atmospheric pressure surface materials 14
213
Index
wear-resistant 205 low-friction smooth anti- plastics decoration 12

Chain-on-edge conveyor reflective 61 Colloidal
machines 124 low-temperature 185 palladium 177
Chemical method 142, 187 silver 35
attack 177 molded articles 167 Colour/color
coating composition 31 multi-colour 38 change 14
etching 128 non-pigmented 161 change inks and pigments 25
grafting 41 non-stick 171 change laminate 32
resistance 23, 37-41, 44, 49- operations 157 change (chromogenic)
50, 53, 56, 58, 60, 62-63, plastic surfaces 64 materials 25
65-72, 85, 93, 104-106, polyurethane soft-touch 60 density 14
109, 113, 124, 127, 145, reduced defects 167 effects 13, 14
150, 160, 168, 170, 194- reflective 166 gradient coatings 164
195, 198, 200, 203-204, retro-reflective 186 gradient effect 165
206 scratch-and abrasion- gradients 14-15, 75, 163
weathering resistance 23 resistant 61 impregnation 196
Chromium scratch-resistant anti- matching 13
and amorphous carbon 204 reflective 50 measurement 13
deposition 199 semi-translucent coloured polymeric moulded bodies 80
plated plastic product 205 layer 60 process printing 36
plating 184 slip 58 resin composition 38
Class A Surface 97, 104, 109 soft touch 11, 60 saturation 13
Clean room 21 solventborne clearcoat 64 shift effects 50
CMYK process colour printing thermally-cured sprayed swirls in plastic containers 80
38, 135, 137 multi-layer 168 variation control process 79
CO2 76, 105, 149-150 translucent water-based 60 Colorant 154
Coated moulding 85 transparent textured 61 Coloring
Coating(s) ultraviolet 123
direct colouring screw 76
anti-reflection 62, 198 ultraviolet curable 63
Cooling 20, 57, 76, 105, 106-
anti-reflection/anti-fog 61 ultraviolet cured organic 44
108, 110
anti-reflective 50, 62, 157 ultraviolet-curable 122, 164
Compounding
aqueous 39, 41, 61, 119, ultraviolet-curable anti-
just-in-time 80
162, 165 reflective 62
Compressed air cleaning and
black multi-layer coating 204 ultraviolet-curable organic
204
heating systems 161, 186
black PVD coating 201, 207 Computer numerical control
cured 127 ultraviolet-curable
superhydrophobic and (CNC) movements 133,
durable aqueous 61 135, 137, 188, 190-191
elastomeric surface coatings self-cleaning 63
water-based heat-curable 39 Computer-aided colorimetry 13
60 Condensed thermal technique
film formation process 165 water-based soft-touch 61
zero-solvent or high solids 133
fluorocarbon 203
UV cured 199 Conformal cooling tool 108
gloss 122
Co-extrusion 14, 44, 76, 79 Copolyester (non-plateable)
gradient color 165
Co-injected patterning 78 178
hand-feeling 60
hydration controlled variable Co-injecting plateable and Corona and plasma treatment
reflectivity 32 non-plateable resins 20 56
liquid 157-169 Co-injection 76 Cotton straw enhanced plastic
liquid coating processes 158 hot runner injection molding wood product 69
liquid coating techniques 9, system 78 Cr/CrN 201-202, 205
19, 22, 157 Cold foil Cracking 96-97, 201
liquid-crystalline 176 decoration 126, 131 ultraviolet coating 61
low friction waterborne 61 stamping 145 Crackle (see also 3D,
low gloss heat-cured 61 transfer technique 127, 131 Embossed, Relief, Tactile
low gloss metallic color 165 Cold foiling 127, 129-130, 210 and so on)
low gloss radiation-curable Cold plasma spraying device heat-curing acrylic lacquer 60
compositions 61 114 Curing
low refractive index Cold touch 12, 68 final 45
ultraviolet-cured 50 electroplating of plastics 12 Curtain coating 158, 167
214
Index
Cushioning effect 128 206 infusion 195

Cyanide 178 Demetallisation 126 leuco 25, 29, 30
Cycle time 20, 67, 71, 87, 89, De-moulding 100 Dye-receptive coating 194
105-106, 108, 110-111, Deposition processes 11
158, 195, 197, 199-200 Depth effects 9, 10, 12, 24,
Cyclo-olefin-copolymer 184 33, 34, 36, 43, 46-47, 56,
58-60, 66-68, 75-78, 83-85,
E
87, 89-90, 100-101, 113- Easy-cleaning film 86
114, 121-122, 126, 130- Easy-to-clean (see also
D 131, 133, 138-139, 145- Superhydrophobic)
147, 149, 152-153, 157, effect 152, 157
Decal
162, 164, 174-175, 177, properties 63
printing 126
180-181, 185-186, 188, Edge build-up 185
solutions 127
191-192, 194-197, 201, Electroless
Decorated
203, 208-209
image 15 copper deposition 184
Detection system [bottle seam] method 165
molded article 93
148 plating 178
Decoratingdevice 22
Die face temperature 129 Electrolytic deposition 177
Decoration
Die locking injection molding Electromagnetic
device 51
method 94 interference (EMI) 95, 113,
film 50-51
Dies 199, 201
high speed 127
processes 21-23 dual durometer 128 shielding 205
hard metallic 129 Electronic solutions 15
special effect 114
stereoscopic 122
Die-slide technology 18, 83 Electroplating 20, 177-184
tri-dimensional 48 Digital chrome 181
Decorative additive manufacturing 139 chromium metal 182
capability chart 9 controls 2, 16 cold touch 12
casing 50 mold texturizing 102 darker electroplated coatings
coating 28, 204 print gloss 141 181-182
coating film 92 printer printing 92 hexavalent chromium (CrVI)
dynamic effects 2 printing 126, 145 177, 182, 204
effects 2, 4, 6, 8, 10-11, 17, thermal transfer marking 129 levelling copper layer 19
22, 25, 44, 76, 90, 130, Dipcoating 21, 158, 165-167 matt copper deposits 181
138, 145, 149, 170, 186 apparatus 167 palladium 184
effects, multiple 2 Direct metal laser sintering 105 plastics 12
electroplating 177 Direct-current (DC) 115, 124, rectifier 177
in-mould film 95 177, 198 sulfochromic chemistry 178
intent 75 pulsed arc processing thick electrodeposited brass
lamination structure 48 system 115 coating 181
membrane 50 Doming 158 Electro-slag-remelting or
paint 28 Doped oxide powders 31 vacuum-arc-remelting 104
resin molded article 47 Dot gain reduction 118 Electrostatic (see also Spray)
sheet 29, 47-48, 52-53 dpi 134, 137-138 bells 160
surface finish 181 Drum coating 18, 158-159 bell spray atomizer 162, 166
vacuum metallising Dry blending powders 36 bell spraying system 167
processes 200 Dry offset 15-16, 22, 116-117 devices 164
Deep drawing blanket cylinder 116 fluidised powder bed coating
applications 53 blankets 117 187
methods 53 gear backlash reduction spraying 160-161, 164
mould film 97 system 119 Embossable sheet 48
processes 52 ghosting effects 119 Embossed (see also 3D,
Definition 1, 4, 8-9, 15, 25-26, ink temperature control 119 Crackle, Relief, Tactile and
30, 43, 46, 49, 56, 58, 61, large single form roller 119 so on)
87, 89, 95, 108, 116-118, roller assembly 119 decorative injection-molded
126, 131, 133-134, 138, wet-on-wet trapping 117 92-93
140, 149-150, 152, 154, Dye in-mould films 12
170, 172, 188-192, 195, chemistry 194 look 139
215
Index
metallic flakes 39 metallized 51 Flock 124

thermoplastic label 49 multi-layer coating film 168 attraction 124
Embossing 121, 145, 174 multi-layer decorative 52 deposition process 124
ultraviolet cured lacquer films multi-layer 51, 94 ground effect 125
121 nanometre scale transparent inner flock coating 125
wet coatings 175 inorganic 14 Flocking 11, 124, 185
Encapsulated non-metallic in-mould 52 machine 124
dye 30 polarising 50 partial 125
thermochromic pigment 29 release layer 96 Flood coating 167
Energy sources 160 roll-fed decorative 95 Flow coating 21, 56, 58, 158-
ambient air 160, 170 roll-fed film 146 159
electron-beam (EB) curing shallow fringe transparent Fluorescent additives 14, 110
57, 124, 160 hard coating 50 Foaming
hot air 160 soft feel decorated 48 agent 147
long, medium, or short wave soft touch in-mould 49 microcellular 58
IR 160 switchable reflectivity 32 Focal distance 150-151
UV 160 tailor-made production 44 Foil(s)
European Coatings Show 34 tamper-proof marker 114
decoration 126
Excimer 16, 17, 62, 149, 152, temporary mating cover layer
flat hit application systems
155, 163 89
127
Excimer UV curing 16, 17 temporary protective sheet
guiding device 131
96
Extruded striped plastic heat transfer pre-printed 15
thick translucent10
products 80 IMD 47
thin structure 94
Extruders non-metallic in-mould
transfer 43, 49-50
multiple screw 75 transfer 52
ultraviolet cured lacquer 121
Extrusion-blow 2 paper-backed heat transfer
waterproof self-luminescent
127
spray-painted 29
process(es) 126, 130
Film defects 21, 185
register methods 129
F cissing 21
used foil backing 88
cratering 21-22
Food decomposition 29
Faraday and edge effects 124 edge effects 21
Form over part technology 88,
Film(s) fisheyes 21
145
antiglare coating film 62 orange peel 21-22, 160, 185,
Functional surfaces 152
antiglare hardened film 50 187, 190
clamping system 98 pinholing 21
decorating techniques 100 reticulation 21
electroplateable 183 sagging 160 G
embossed in-mould films 12 Film insert
gas barrier, shrink 53 molded product 93 Glass 2, 11, 33-42, 59, 61, 63-
hard-coated PET 45 moulding (FIM) 49-50, 88, 64, 86, 131, 143-144, 167,
hard coating forming 97 91, 93, 96 197, 202
heat transfer 49 Film transfer method 94 crushed 35, 40
hot stamping 50 Fingerprint resistant matte film Glitter image 186
IMD 45 50 Gloss
in-mould 2, 19, 43, 45, 47- Flame treatment 57, 113 increasing 16
48, 50, 97 Flexographic 145 level adjustment 102
in-mould decorating 51 adjusting pressure system liquid coatings 60
in-mould decoration 49, 52 118 matteness manipulation 16
decoration transfer 48 anilox roll 119 multi-layer plastic container
integral 43 pad 15 80
mating pattern 89 indirect 118 polycarbonate 71
metallic effect in-mould 47 pressure settings 116 thermoformed article 71
metallic in-mould radio-wave printing 116-118, 134 ultraviolet-curable coating 140
transmitting 51 printing plate 119, 133 variation issues 142
metallic label 51 printing processes 170 Glossy translucent polymer 18
metallic tone decorative film Flexography 22, 126 Gold
95 Flip-flop 35, 37-39 colour 182, 204
216
Index
colour electroplated In mold lamination 91 large format 22

products 179 Infrared absorption 48 machines 137
real gold 177, 179, 182 Injection molding 33, 83, 88 nozzle clogging issues 135
stamping 131 apparatus 92, 96 print heads 133, 135
Goniometer 16 compounder 80 printhead nozzle 140
Grained cycle time 105 printing 11, 133, 135, 139-
mould surface 102 fluid injection moulding 141, 195
plastic moldings 101 process 108 printing machines 134
Graphite nanoplatelets 30 hold pressure step 109 slight off-contact 133
Gravimetric feeder machine 108 spray coating techniques 13
performance 76 microcellular 108 stacked printing 139
Gravure printing 126, 145 opaque coloured layer 75 swaths 134
Grooves two-stage 184 technology 20, 138
fine 122 Ink(s) tyre tracking 142
activated carbon 62 ultraviolet curing 139
electrically conductive 13 versions of printer 135
infrared absorbing inks 47 Inkjetting 19
H inkjet 40, 61 metallic nanoparticles 138
IR absorbing ink 9 Inkless
Halftone
marking 29 multi-colour printing 15, 170,
blending 22
metallic inkjet 41, 135, 137 188, 208
printing 17
non-reversible writing 29 printing 27-28
processing 117
non-tacking tactile 60 printing apparatus 153
screening 119
reflection inks 48 printing method 154
solution 119
scented thermochromic ink printing techniques 153
Heat absorbing additives 31
62 In-line
Heat cycle moulding
silver based 40 cold foiling 129
techniques 199
solvent-based 135 decorating 91
Heat transfer
solvent-borne metallic 141 decorating IMF 90
decoration 129
swelling 209 decoration 2
film 49
thermochromatic 28 integrated raised printing 139
pre-printed foils 15
thermochromic 28 metallising 2
printing 127-128
thermosensitive decolorable processing 202
High DOI 18
composition 29 spray coating 161
High powered light 149 tunable fluorescent UV sputtering system 199
High refractive index curable gel 30 In-mold/in-mould
translucent alternatives 33 two-stage thermochromic 25 application 49
bismuth oxychloride 33 ultraviolet-curable snowflake back-filling 91
lead carbonate 33 effect 38 base coating 84
High-shear mixers 75 ultraviolet curing inks 116 coating 13, 22, 85
Holographic metallic flakes 39 water-based inks 140 coating solution 85
Hot filling 52 Ink film 14, 22, 98, 170, 175, coating technology 84
Hot foil stamping 18, 22, 46, 208 decorated article 98
51-52, 127-128, 145, 194 thickness 14 decorating 126
Hydraulic transfer (see also Inkjet decorating a complex shape
Water transfer) bottle printing machine 133 98
image 209 Braille 139 decorating film 51
printing 208 coating device 142 decorating printing film
decoration 40 forming 97
devices 2, 15 decoration (IMD) 44, 46, 87,
direct 139 89
I drop-on-demand (DOD) decoration (IMD) mold 96
Image manipulation 16, 138 technologies 133 decoration 96
Imitation flatbed machines 137 decoration film 49, 52
metal 40 flatbed printers 135 decoration technique 91
plating 205 indirect 135, 140 decoration transfer film 48
stone thermoplastic material ink-bleed problems 140 decorative appliqué 96
70 inks 40, 61 decorative method 96
217
Index
decorative operations 2 145, 161, 171, 179, 190, 200 PP flexible self-adhesive 49
decorative processes 2 B05B 6, 161 printing 118
double-side decorating mold B05D 6, 136, 161, 179, 190, scented 51
96 200 self-adhesive label 51
film application 23 B08B 6 time-temperature dependant
film decoration process 96 B23K 6 colour-change 30
film processes 88, 94 B29 6 Labeling device 48
film techniques 9, 12, 87, 209 B29C 44, 76, 83, 105, 129, Lacquer (see also Coating,
films 2, 19, 43, 45, 47-48, 145, 171 varnish) 1, 12, 18, 45, 54,
50, 97 B32B 6, 44, 76, 145, 200 60, 83, 121-122, 140, 152,
flexible tubes 88 B41 6 155, 164, 166, 167, 174
flocking 90, 94 B41F 117, 129, 171, 190 coatings 167
forming (IMF) 88, 92 B41J 129, 136 film product 166
forming method 52 B41K 171 pattern production method
hold pressure 105 B41M 44, 117 164
IMD/IMR transfer pattern B41N 117, 190 Laminated acrylonitrile-
method 96 B44C 6, 44, 145 butadiene-styrene
label 51 B65C 6, 145 decorative sheet 50
labelling (IML) 1, 22, 52, 87, B65D 6 Laser(s)
89-91, 95 C09D 6 absorbing compounds 31
laminating 88, 95 C23 6 active coatings 153
lamination 92 C23C 179, 200 additives 26, 30
metallising 18 C25D 6, 179 beam 150, 196
metallized polymer H05K 190 beam steering 150
components 80 International Patent colour transfer process 151,
method 47, 95 Classification search codes 178-179
micro engraved decoration 44 decorating plastics 154
foil 43 International Standards direct structuring (LDS) 151,
moulding 95 Organisation (ISO) scale 178-179, 184
operation 8 104 direct writing 151
patterning 102 Ion implantation 16, 22, 202- engrave pattern 97
roller (IMR) 87-88 203 engraving 154
roller applications 47 Iridescent printed engraving and in-mold 97
roller process 91, 96 polychromatic transparent etching 11, 31, 131, 201
roller technique 94, 96 image 38 fibre 150-151
rolling technique 92 fusible coating compositions
skinning 102 28
solutions 1, 121 induced deposition 151
techniques 1 K induced plastic foaming 153
transfer film 51 induced transfer process 127
transfer printing 98
K 2013 67, 76, 81, 99, 129,
137, 161 key parameters 151
transfer process 194 mark auxiliary agent 31
Innovation tracking 1 markable coating 31
Insert moulding (IM) 76 markable inks 29
Interference L markable polymers 31
effects 17 marked laminate 154
two-dimensional 17 L*, a*, b* (LAB) colour space marking 15, 27, 29, 31, 118,
Infrared (IR) 89, 105 13 155-155
Interference pigments (see LAB colour gamut 13 marking additive(s) 25, 28, 30
also Pigments) 33, 36 Label(s) marking techniques 25
gonioapparent 33 antistatic 52 Nd:YAG 30, 149-150
goniochromatic 33 bubble-free applying 148 neodymium vanadate 150
Interferential effects 17 butt-join 87 on-the-fly marking system
International Commission on embossed thermoplastic 151
Illumination (CIE) 13 label 49 pretreatment 183
International Patent film 51-53, 146 repetition rate 155
Classification (IPC) Codes 6, in-mould label 51 staggered laser-etch line
76, 83, 105, 117, 129, 136, intelligent 45 graphic system 155
218
Index
system 171 oil 203 Metallisation 16, 18, 20, 44,

transfer film 151 physical 201 51, 77, 87, 95, 126-127,
treatment 150-151, 180, 184 process 155 138, 145, 150, 163, 178,
use of 20 Masterbatch tablets 34 181-184, 199-200, 203-
weldable polymers 31 Matte 8-10, 16-18, 43, 46, 204, 206
welding 146 50, 56, 58, 60-62, 66-67, Metallised
ytterbium fibre 150 70, 75, 85, 87, 89, 95, 100, direct 205
Leachable materials 56 101-102, 121-122, 133, glass bubbles 41
Leather 11, 46-47, 67-69, 87, 137-141, 149, 152, 155, Metallising 2, 6, 18, 19, 39, 71,
89, 92, 94, 122, 147 157-158, 162-163, 165, 83, 139, 152-153, 163, 179,
and wood effects 47 177-178, 180-181, 197, 182-184, 197-206
pellets 69 201, 204, 208-210 traditional decorative 197
thermoplastic polyurethane manipulation 163 Metallization 145, 165, 183-
film 47 polymethyl methacrylate 184, 203, 205
Lenticular polymer mixture 70 Metallized
3D images 93 surfaces 10 films 51
decorated film 93 Matting partially metalized plastic 71
holographic effects 10 activator 210 Metallocene polypropylene
Moiré method 48 novel agent 62 oxide/polyphenylene oxide
molding 122 Mean-free-path (MFP) 198 161
sheet 48-49 Memorized set-up parameters Metallocene-produced
stereoscopic image 94 2 polyethylene 70
Lotus effect 121 Metal Metamerism 13
Low toxicity 23 free laser marking additive 26 Micro pattern replication 122
Low-emission burn-off oven marking 40 Microencapsulation 19
161 plating polyacetal Microwrinkling 16
Lower molecular weight 20 compositions 71
Milling techniques 33
Lubrication 23 soap-free lubricant 71
Mold
Luminous Metallic
delay 108
matte effect 204 bright 18
tool surface 110
printing 28, 60 decorative sheet 95
Molded
effect in-mould films 47
skin 86
effect pigments 33
effect(s) 13, 17-20, 28, 33, two-color article 80
M 35, 39, 77, 89, 113, 118, Molding
126, 131, 147, 158, 163, core-back 76
Machine engineering concept 171, 180, 197, 199, 202 two-color die
15 finish 18, 20, 35, 39, 41, 46, two-color equipment 93
Magnetic 98, 114, 146, 171, 178, Molecular weight (MW) 20, 23
and embossing techniques 181, 190 Mould
13 flake pigments 18, 33, 39, cavity polishing 21
external component 175 163 concept 107
gradated orientation 10 high chroma sprayed paint Moulded
orientation techniques 175 165 plastic skins 86
pigment orientation 175 inkjet printing ink 41, 135, multi-component plastic
rubber sheet 174 137 parts 85
solutions 174 in-mould polymer substrates 206
Mandrel(s) films – radio wave polypropylene component
centring device 118 transmitting 51 69
floating system 118 label film 51 relief article 101
horizontal machine concept paint effect 40 skin 47
118 pearlescent polyester 39 thermoplastic polymers 7
multi-mandrel concept 131 pigment(s) 9-15, 17-18, 23, Moulding/Molding
Mapping innovation 1 25, 27-28, 31, 33-36, 38- and in-mould 11
Marbleised look 75 42, 75, 85, 117, 150, 153, die 79
Marbleizing 76 159, 171, 174-176, 179, material 69
Masking 163, 201 190, 200 multi-material 76
device 206 tone decorative film 95 operation 2
219
Index
single multi-barrel machine Optical reflection 80 titles 4, 7

76 Organic USA (USPTO) 5
substrates 174 silicone particles 68 World Intellectual Property
two-shot 178 topcoat protected Organization (WIPO) 1,
Multi-colour/Multi-color 13-15, metallization 203 5-6
35, 37-38, 77, 79-80, 86, Overflow passages 110 Patenting process 5
93, 127, 135, 137, 152-154, Overlap blending using Patterned
166, 170-172, 188, 208 halftone 118 decorative coating 206
coatings 38 Overlapping method 155 roller 123
effects 13 Over-moulding 11, 76, 86, 89, sheet 141
halftone printing 171 91, 93, 210 Patterning robot 140
moulding 75-82 cosmetic 81 Pearlescent 36, 39
printing processes 208 Phase-separation 76
Multi-layer Phosphor nanoparticle 30
blow-molded hollow articles Phosphorescent additives 14
79 P Photochromic 185
coated pigment flakes 17 curable composition 30
coating film 168 Pad printing 170-171
digital transfer techniques
container 78 automatic cleaning step 171 188
decorative film 52 machine 172 effects 14
film 51, 94 pads 172 fast-response photochromic
molding 79 reciprocating process 170 film 25
moulding 106 two-axis servo-driven printer injection moulding additive
patterned multi-layered 171 29
patterned 164 two component (2K) systems molding compositions 28
Multi-shot 170 pigments or dyes 14
injection molding 183 U type motion 170 resin mixtures 28
moulding 13, 76-77 Paint(s) Photoluminescence 37, 39
MUNSELL colour gamut 13 chrome effect 35 Photoluminescent
diffusively light reflective effect 29
61-62 powder coatings 185
light-reflecting 41 resin mixtures 28
N mask material blend 166 Physical deposition processes
masking 166 197
Natural coated 94
metallic high chroma 165 Physical vapour/vapor
Non-laser irradiative
pearl gloss 38 deposition (PVD) 6, 18, 33,
applications 152
polyurethane special-effect 40, 44, 41, 95, 104, 171,
Non-Newtonian 189
38 190, 200, 201-207
Non-relief tactile effects 11 resistant metallic 40
Nylon 124 Picolitres (pl) 134
scented 62 Picosecond lasers 152
silver colour paint with high Piezoelectric principle 133
flop index 41 Pigment(s) 31, 33, 35-36, 38-
O Paint booth system 162 40
Painting plastic substrates 86 aluminium 35
Odor reduction 155 Paintjet process 142 aluminum powder 34, 80
Odour-sensitive materials 29 Paper anti-counterfeit effect
Off-line finely pleated 94 pigment 35
hot foil stamping 87 Patent(s)1-4, 19 anti-counterfeit pigment 39
operations 2 China (SIPO) 5 black effect pigment 36
Offset 126 coding 6 bright flaky black 36
flexography 116 Cooperation Treaty (PCT) 5 concealment 39
printing 119 count ranking 9 cornflake 33
Olefin-based elastomer 68 documentation 14 covering power 13
Olfactory 8-9, 19, 43, 46, 51, documents 1, 3-6, 17, 44, development 7
56, 58, 62, 66-67, 70, 70, 136, 171 embossed metallic flakes 39
149, 152, 155, 188, 191- Europe (EPO patent) 5 exhibiting colour interference
192 information 1 effects 34, 36
On-mould painting 84, 100 searches 6 Fabry-Pérot structures 33
220
Index
flake 10, 13, 18, 80, 163, 181 low-haze random copolymer
174-175 platinum-rhodium layers 181 69
flat 18, 163 selective 182, 184 modified 69
for laser marking 31 Polishing machine, portable Polyurethane (PU) 30, 38, 47,
hot melt coating 129 108 60, 83, 97, 124
loose 102 Poly(cyclohexylenedimethylene soft-touch coating 60
magnetically sensitive 175 terephthalate) acid 20 special-effect paint 38
metallic effect 33 Poly(p-phenylenesulfide) 161 Porcelain plastic 36
metallic flake 18, 33, 39, 163 Polyacetylenic indicators 29 Powder
mica flakes 33-34 Polyamide 12, 20, 184, 194 coating 22, 36, 40, 58, 63,
micronised aluminium moulding compositions 69 113, 124, 185-187
powder 40 substrates 184 coating method 187
micronised flakes 20 Polybutylene 194 overspray 185
micronized aluminium 35 Polybutylene terephthalate Pre-compounding 75
multi-layer coated pigment (PBT) 20, 40, 44, 71, 194, Pre-cure 141
flakes 17 199, 201, 207 Pre-forming technique 92
nanoparticulate organic 36 Polycarbonate (PC) 18, 20, 29 Pre-printed
non-flake 80 44, 54, 70-71, 81, 97-99, films 15
orientation 175, 187 161, 171, 182-184, 190, ink 184
orientation techniques 33, 194, 199, 205-206 protective film 96
121 Polycarbonate blend articles sheet 91
preparations 41 70 sheet stability 195
special effect 17 PC/ABS 161 Printing
sub-micron sized particles 14 Polycarbonate or polymethyl finer detail 192
thermochromatic 30 methacrylate (PMMA) 18, flat 145
whitest effect pigments 34 20-21, 44, 52, 61, 69-70, heads 135
Pigmented solutions 18 85, 171, 190, 199 non-planar shapes 135
Pinning 21-22, 134, 138-141, material 69 Product filling 21
158-160, 162-164, 167 Polyester
energy 141 elastomer 71
techniques 164 film backing 127
Plasma 6, 9-10, 17, 19, 21, 23, metallic pearlescent 39 Q
56-57, 86, 134, 198, 203- molding compound 40
205 Quick colour change 76
Polyethylene (PE) 57, 60, 70, 76
deposition 19 Quick-change guns 162
Polyethylene furanoate 71
deposition process variants Polyethylene terephthalate
113 (PET) 44, 45, 52, 108, 137,
enhanced chemical vapour 194, 198, 200 R
deposition (PECVD) 23, Polymer
86, 198-199, 204-205 blends 66 Radiation hardening 165
Plasmon resonance 203 compositions 70 Radiation-curable lacquer
Plastic laser marking 154 surface 122
decoration 8, 10, 12, 15, 174 resin 7 Radio frequency (RF) shields
electroplating 183 substrates 17 198, 201
molded skins 85 Polyolefin Rainbow effect 39
moulding machine 85 based composite resin Raised area on a plastic
resin 183 spherical particles 62 container 90
surface processing 181 composition 69, 72 Rapid heat cycle moulding
Plastic wood-imitation material painted articles 69 (RHCM) techniques 20,
69 spherical particles 60 22,105, 106
Plate costs 97, 126, 129 Polyoxymethylene 194 gas-assisted surface heating
Plateless paintable 71 system 107
transfer printing film 131 Polypropylene (PP) 10, 20, 49, heat/cool 105
substrates 33 54, 57, 68-70, 72, 76, 87, heated injection molding
Platemaking 117, 119 161, 168, 205 system 108
Plating (see also high-gloss multi-layer rapid thermal response 105
Electroplating) 18, 177-184 container 70 solution 107
blackening treatment solution impact copolymers 69 techniques 107
221
Index
Rapid-cycle Roto-moulding material blend matting 3, 17, 61-62, 68,

metallising devices 202 81 138, 142, 152, 155, 159,
PVD machines 200 Roughness 163, 204, 210
Reaction over-moulding 86 average (Ra) 104 metallising process 182
Reactive maximum roughness depth plating 184
deposition 203 (Rmax) 104 plating method 182
mesogenic compounds 38 mean roughness depth (Rz) Self-cleaning 23, 56, 157, 185,
sputtering 23, 197-206 104 198,
Refracted light 80 rpm 158, 160 Self-healing 23, 56, 58-59, 63,
Refractive index (RI) 17, 33, Rubber 67, 69, 71, 92-93, 116, 73, 157
50, 198 153, 158, 170, 174, 188- Self-stratification 19
Register 15, 126-127, 129, 189, 210 moulding 76
135-136, 172, 174, 188 Rubber-modified acrylic resin Self-stratifying coatings 60
Registration between colours 71 Self-structuring surfaces 60
188 Sensual effect 43
Relief (see also 3D, Crackle, Servo controlled printing
Embossed, Tactile and so on) heads 2
and tactile effects 11 S Servo-controlled substrate 188
decorations 102 Shaping
Sandblasting 16
die 127 localized 102, 122
operation 92 Silica containing additives 70
effects 13, 90, 121
hot stamping 47 Scented Silica or ceramic deposition
image 119, 122 label 51 202
in-mould film 49 paint 62 Silicone
pattern 89, 93, 153, 164, 174 preparation 62
dies 128
printing 116 stuffed toy 70 membrane vacuum 194
printing plate 119, 128 thermochromic ink 62 pad 170
silicone die 128 Scratch and Sniff printing 19 roller 129
surfaces 94-95 Screen(s) 126 Silver
Residue cleaning feature 108 automatic screen cleaning based inks 40
Resin 190 colour paint with high flop
blend 72 continuous motion printer index 41
coated material 60 190 dollar 33
injection molding method curved squeegee 192 reduction 19, 163
108 flat screen printing 135 reduction process 18, 19
mouldable 184 flat 188 Skin-integrated foam article 93
molded article 92 positioning 188 Skinning 84
molding with skin 94 print reflection transfer 192 Skin(s)
substrate 64 printing 11, 15-16, 22, 57, anti-slip 46, 48
transfer moulding 102 117, 134, 145, 175, 189, differently coloured moulded
Robot arm 87 191-192 84
Robotic inkjet printing 137 printing doctor blade 192 molded 86
Roller coating 61, 116, 158 making process 188 moulded 47
Rotary decorating processes softer squeegees 189 plastisol moulded 86
135 split 189 Sleeving 145
Rotary squeegee positioning control Society of the Plastics Industry
device 199 188 (SPI) scale 104
machines 128 squeegee re-sharpening 189 Soft
pad printing 170 squeegee vibration 192 component with decorative
spray device 166 stainless steel meshes 191 surface finish 85
Rotating steel meshes 190 feel decorated film 48
carousel 119 technical printing 192 haptic materials 11
curved die 131 Scuffing 16 silicone pad 132
mould 91 Search phrases 1 touch coating 11, 60
Rotationally moulding two Selective touch effect 69
differently coloured bright metallization 20 touch in-mould film 49
materials 79 Coating deposition 20 Spherical metal particles 31
Roto-moulded articles 81 infusion dying process 196 Spin coating 158, 166-167
222
Index
layer thicknesses 167 control 15 152-153, 157-159, 162-

Spray (see also Electrostatic) heating 113 164, 174-175, 177, 180-
application process 166, 185 holding devices 2 181, 185-186, 188, 191-
atomisation 159-160 marking 149 192, 194-197, 201, 203,
coating 11, 13, 14, 16-17, materials 7 208-209
22-23, 57, 59, 65, 92, polymer gloss 16 effects 1, 11, 13, 209
104, 135, 140, 158-165, precise 188 perception 11
178, 189, 199, 201-202 surface quality 8-9, 16, 20- relief effects 11
conventional spray coating 22, 33, 35, 40-41, 43, surface(s) 47-48, 55, 77-79,
135 45-46, 52, 56, 58, 62, 66- 124, 132, 139, 52, 209
devices 22, 162 68, 70-71, 75, 77, 80-81, Tailor-made holding devices 15
high-volume-low-pressure 83-84, 86-87, 89-90, 96, Talking packaging 45
(HVLP) 160 104-109, 116-117, 119, Temperature
low-investment process 163 126, 130, 131, 133, 138, controlled variable reflectivity
medium pressure guns 162 141, 145, 146, 148-149, coatings 32
multi-jet nozzle system 168 152, 155, 157, 161-163, cycling injection moulding 105
overspray 64, 135, 160-161, 166, 172, 181, 185-187, dependent reflectivity 28
185, 199-200 197, 201-202, 206, 208, Tetrafluoroethylene and alkyl
painting 184 210 methacrylate additive 70
pattern sensor mat 161 wetting 58, 157, 161 Thermal
pneumatic electrostatic gun Superhydrophobic (see also evaporation 126, 198
166 Easy-to-clean) print head technology 190
powder 64 microstructure a coated spray 113, 114
recycling systems 159 surface 152 transfer film 95
regular 162 Super-soft thermoplastic transfer printing 129
wet-on-wet 165 elastomers 69 transfer sheet 49
Sprayed basecoat-topcoat Surface cure epoxy 124
aqueous system 166 change techniques 2 Thermochromatic
Spraying (see also decoration method 140 ink 28
Electrostatic) 199 defects 178 materials 25, 28
airless 159-160 energy 23, 56, 113, 121, 134 microencapsulated dye
method 168 grained mould 101 systems 30
ultrasonic 160 metalizing method 182 pigment 29-30
Sputtering (see also Vacuum) micro-folding 152 Thermochromic
198-199, 206 non-glossy surface 16 ink 28
DC magnetron 198 plasmon resonance 14, 202- materials 25
Static electricity190 203 leuco dyes 25, 29-30
Stone-based composite quality improvement 20, 43, microencapsulated liquid
material 36 68, 90, 141 crystals 25
Straw-containing polymer 69 tension effects 163 pigments or dyes 14
Stress crack performance 109 tension phenomenon 21 Thermoformable 3D retro-
Structural color 176 treatment 1,8, 10 reflective article 51
Styrene-acrylonitrile 20 wrinkling 152, 162-163, 165, Thermoforming 2, 44, 48, 88,
208 91, 194
Subject classification codes 1
Swirls or marble appearance high-pressure 88
Sublimation
79 Thermoplastic elastomer (TPE)
dry processes 194
non-contact 196 11, 12, 67, 72
printing 1-2, 6, 9-22, 27, 28- Thermoplastic resin
composition 70-71
29, 35-36, 38-41, 44-46, T Thixotropy 189-190
49-54, 57, 60-62, 71, 88-
94, 96-98, 100-102, 116- Tactile (see also 3D, Crackle, Time-temperature
119, 124, 126-129, 131, Embossed, Relief and so dependant colour-change
133-145, 151-153, 157- on) 1-2, 8-12, 35-36, 38, label 30
158, 170-175, 182-184, 43, 45-49, 55-56, 58-61, indicator 30, 45
186, 188-196, 208-210 66-68, 75-79, 83-85, 87-91, TiO2 pigment 41
process 195 100-101, 113-114, 121- TiO2/SiO2 deposition 102
transfer process 195 122, 124, 126, 129-133, Tonal range increase 118
Substrate 138-139, 145-147, 149, Tool steel 104
223
Index
Topcoat 6, 17, 19, 35, 40, 44, cured digital printing 137 W
60-61, 71, 85, 95-96, 116, cured lacquer films 121
122, 135, 138-139, 141- cured organic coating 44 Wash-out effects 75
142, 150, 153-154, 163, curing 135, 29, 56, 190 Water
165-166, 180, 186, 195, curing inks 116 decal process 210
198-208, 210 curing liquid resins 83 detecting label 29
Transfer light-emitting diode (LED) pressure transfer method
decorative sheet 97 curing 57, 116 209
film 43, 46, 48-51, 91, 95-96, light-emitting diode (LED) slide decals 129
131, 151, 209-210 curing devices 133 transfer printing 13, 15, 208-
foil 2, 20, 22, 46, 52, 88, 127, light-emitting diode system 209
151 141-142 transfer printing method 210
foils and labels 2 pinning 139 Water-based
reel-fed transfer foil 88 resistant topcoat 195 heat-curable coating 39
mold body 95 staggered curing systems inks 140
printing process 91 140 soft-touch coating 61
printing substrate 50 xenon or krypton flash lamp Waterborne
sheet 48-49, 97, 186-187, 142 effect base coats 38
194, 208 Ultraviolet-curable tactile coating 60
Transferred decorative layer anti-reflective coating 62 Waterless lithography 116
126 coating 122, 164 Water-transfer
Transition lenses 14 inkjet decoration 142 image 209
Transitions 25 metallic ink 40 reflective structure 210
Translucent organic coating 204 Web coating device 168
injection moulded 164 replication layers 47 Web printing processes 2
layer 75 snowflake effect ink 38 Weld-line elimination 108
silica topcoats 199 superhydrophobic and self- Wet friction material 78
TiO2 coating 202 cleaning coating 63 Wet process 194
water-based coating 60 Urea resin 31 Wetting 23, 58, 65, 67, 157,
Transparency 10 161, 168, 77,
haze 10, 39, 67-69 Wetting additive 58
distinctness of an image V Witness marks 178
(DOI) 10, 18 Wood 11, 15, 46-49, 67, 69,
water-whiteness 10 Vacuum (see also Cathodic 71-72, 77-79, 85, 89, 91,
Transparent arc, Sputtering) 101, 153, 208-209
laser-inscribable coating 204 Wood film 91
polyurethane 30 contact bonding 147 Wood-like
molding composition 68 deposition 2, 17, 19, 197, appearance 49
textured coating 61 202, 205 decorative sheet 48
Twin-screw extrusion 66 deposition methods 179 resin molding 48
deposition patent 14 Wood-plastic composites 71
Two-tone coated substrates
forming 147, 195 ageing-resistant 67, 69, 71
164
metallisation 16, 20, 138, Wrinkle-free finish 44
Types of sensory effect 8
163, 178, 199, 206 Wrinkling 11-12, 87, 89, 96-97
metallised (PVD) 33
metallising 18-19, 39
U metallising process 18
metallization 16, 20, 138, Y
Ultrasonic 142 178, 199, 206
assisted molding 110 metallization device 205 Year-to-year analyses 3
spraying 160 thermoforming 52
treatment 182 Variegated effects 84
Ultrasound monitoring system Varnish (see also Coating,
108 lacquer)
Ultraviolet (UV) 45, 160 embossing techniques 118
CNC printer 137 low-viscosity 64
coating 123 Varnishing 117, 145
curable coating 63 Voxels (3D pixels) 139
224
Innovation Trends in Plastics Decoration and Surface Treatment

The plastics industry is a major player for consumer items, notably for the automotive,
consumer electronics and packaging industries, and is necessarily very active in
innovation. As a result, moulded thermoplastics are achieving new heights in decorative
Treatment
appearance and quality. Many striking aesthetic effects are possible by employing
new polymer blends coupled with a diverse range of decoration and surface treatment
technologies. These can produce three-dimensional and tactile finishes, high definition
images, flawless high gloss and metallic surfaces, as well as effects ranging from
imitation materials, interferential colours, colour gradients, colour change and travel,
gloss and matte combinations, and even acoustic or olfactory effects. Manufacturing
processes to achieve these include several types of in-mould film, coating or decorating
technique, relatively recent technologies to improve surface quality, as well as traditional
separate decorating or coating processes such as dry offset; flexographic; inkjet; pad
and screen printing; foil transfer; labelling; laser marking; plating; spray coating; and
vacuum deposition.
This unique book analyses and compares recent trends in each of over 20 types of
mainstream manufacturing process and 10 classes of sensory effect they can produce.
Supported by over 100 tables, a three-year sampling of over 1,000 mentioned patent
documents and hundreds of commercial developments helps to identify the main trends
and their innovators, key innovative clusters and the most sought-after effects, as well
• 3-year review
as provide indications for the future.
• Process-by-process perspective
Ed Crutchley is a consultant in plastics decoration and surface treatment. After studying • Analysis of over 1,000 patents
printing technology at the London College of Printing he has worked in the rigid plastics
packaging industry in the UK, France and the USA in the fields of manufacturing plant
• Commercial developments
management, running technical and quality departments, and R&D and innovation. He • Innovating companies
has contributed to several patents.
Ed Crutchley
Ed Crutchley
ISBN: 978-1-909030-84-8
Smithers Information
Telephone: +44 (0)1939 250383 Fax: +44 (0)1939 251118
http://www.smithers.com

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Innovation Trends in Plastics

Innovation Trends in Plastics Decoration and Surface Treatment

Innovation Trends in Plastics

A Smithers Group Company

Shawbury, Shrewsbury, Shropshire, SY4 4NR, United Kingdom

First Published in 2014 by

Smithers Rapra Technology Ltd

©Smithers Information Ltd., 2014

All rights reserved. Except as permitted under current legislation no part

ISBN: 978-1-909030-84-8 (softback)

Typeset by SA Hall Typesetting, Brixham

4.2.2 General Subjects......................................................................................................................25

5 Materials for Effects and Other Special Colours ............................................................... 33

6 Films, Foils and Labels.......................................................................................................... 43

7 Inks, Paints, Coatings (Excluding Colour Change or Effect Materials)............................ 56

7.2 Recent Commercial Developments .................................................................................................58

8 Substrate Polymer Resins, Blends and Additives.............................................................. 66

PART C: IN-MOULD PROCESSES

9.4.1 Three-dimensional, Tactile and Depth Effects............................................................................78

10 In-mould Coating and On-mould Painting.......................................................................... 83

11 In-mould Film Techniques.................................................................................................... 87

12 In-mould Printing, Marking, or Use of Engraved Cavities .............................................. 100

13 In-mould Surface Improvement......................................................................................... 104

Part D: Stand-alone or In-line Processes

15 Dry Offset and Flexographic Printing................................................................................ 116

16.4.1 Three-dimensional, Tactile and Depth Effects..........................................................................122

18 Foil Transfer Processes...................................................................................................... 126

19 Inkjet and Droplet Printing.................................................................................................. 133

20 Labelling, Sleeving and Form Over Part............................................................................ 145

20.3 Patent Trends................................................................................................................................146

21 Laser and Irradiative Marking, Engraving or Transfer..................................................... 149

22 Liquid Coating Techniques ................................................................................................ 157

23 Pad Printing.......................................................................................................................... 170

24 Pigment Orientation Techniques........................................................................................ 174

25 Plating, Electroplating and Chemical Deposition............................................................. 177

26 Powder or Particulate Coating........................................................................................... 185

27 Screen Printing.................................................................................................................... 188

28 Sublimation Printing, and Dye Infusion............................................................................. 194

29 Vacuum Deposition............................................................................................................. 197

30 Water Transfer Printing....................................................................................................... 208

30.3.1 Subjects, Ranking and Innovators...........................................................................................208

But what of decorative effects themselves?

1.2 Innovation and Patents

1.3 Prediction of Trends

1.5 Comments on Presentation

1.5.1 Subject Classification

1.5.2 Year-to-year Analyses

1.5.3 Text Formatting

3. Patent titles are in bold italics.

Original spelling has been preserved.

1.5.4 Definition of ‘Patents’

2.1 Commercial Developments

2.2 Patenting Authorities and Obtaining Copies of Patents

2.3 Approaches to Patents

2.4 Patent Coding

2.5 How Patent Searches Were Carried Out

2.5.3 Search Results

2. Patents where the description or innovative step is not clear.

3. Patents where there is no clear indication of applicability to polymer substrates.

3 Decorative Effects on Plastics

Table 3.4 Cont'd...

3.1 Introduction to Decorative Effects

3.1.1 Three-dimensional, Tactile and Depth Effects