DECAL APPLICATION APPARATUS

Abstract: Decal application apparatus comprising means for locating a heat release decal on an article (12) such that a part of the decal extends beyond an edge of the article (12). The apparatus also comprises a turntable (14) upon which the article (12) is locatable and an adjustable blade (16) locatable against an article (12) on the turntable (14) so as to cut the excess decal therefrom when the turntable (14) is rotated.

Description: DECAL APPLICATION APPARATUS This invention relates to decal application apparatus; and particularly but not exclusively apparatus for applying heat release decals onto an article to be decorated, where the decoration is required to extend to an outer edge of the article. This invention also relates to a method of decoration, and particularly but not exclusively a method of decorating an area on an article and particularly a ceramic article; and also a decal usable in such a method. By virtue of their nature, the size of ceramic articles cannot usually be wholly accurately reproduced. Differences in size can occur during firing and/or as a result of wear to a mould or other conditions such as variations in the clay used. Furthermore, ceramic articles do not usually conform to exact shapes. For example, whilst the outline of a plate may appear circular, usually the plate is not wholly circular. Accordingly, difficulties are often encountered when applying an "edge to edge" decoration to a ceramic article which covers the whole of an area on the article between opposite edges. In view of the differences in size and shape which are likely to be encountered in different articles, conventionally water slide transfers are used which are slightly undersized. These transfers can then be stretched to fully cover the area to be decorated. The application of such transfers is a difficult task and therefore a skilled lithographer is required. Applying such a transfer is relatively time consuming as for example all air must be removed from between the transfer and the article being decorated. Fairly high levels of wastage generally occur in such a process . Items which require edge to edge decoration traditionally include wall plaques. Furthermore, such decoration may be required on other items of flatware such as plates and may also be desirable on items of holloware such as mugs. Edge to edge decoration is often required on articles with a decorated edge, such as a gold or silver band applied around the rim of a plate. If water slide decals are not to be used, decals such as those of the heat release type are required to be initially applied and fired onto the article prior to application of the banding and hence further firing. It would be advantageous if a decal could be applied other than by hand onto an already banded article, such that only one firing would generally be required. According to the present invention there is provided decal application apparatus, the apparatus comprising means for removing from an article which has had a decal applied to it which extends beyond the edge of the article, said part of the decal which extends therebeyond . The apparatus preferably includes a blade for removing said part of the decal. Means are preferably provided to permit relative rotation between the blade and the article. A rotatable mounting is preferably provided upon which the article is located. The blade is preferably provided on a sprung mounting to permit removal of said part of the decal from a non-circular article. The inclination of the blade relative to the mounting is preferably variable, and may be varied during cutting of said part. The apparatus may be arranged such that the inclination of the blade moves between two predetermined orientations during use of the apparatus. Said predetermined orientations are preferably adjustable. The apparatus preferably comprises means for urging said part of the decal to a generally horizontal alignment to ease cutting thereof. The urging means may comprise a brush engageable with said part of the decal. Means are preferably provided for receiving said part of the decal following removal from the article, and the receiving means may comprise a suction removal arrangement . The apparatus is preferably automatically operable to receive a decorated article, remove said part of the decal, and subsequently pass said article on to permit another article to be received. The apparatus is preferably locatable downstream of a heat release decal application machine so as to receive decorated articles from said machine. The invention provides decal application apparatus comprising means for locating a decal on an article such that a part of the decal extends beyond an edge of the articte, and means according to any of the preceding eight paragraphs for removing from the article said part of the decal which extends therebeyond. According to a further aspect of the present invention there is provided a method of decorating an area on an article, the method comprising applying on to the article a decal of a greater size than the area, and removing the part of the decal which does not cover the area . The area preferably extends from one edge of the article to another edge. The decal preferably comprises a heat release decal which is applied from a release member of a decal applying apparatus. Only the part of the decal which covers said area is preferably applied from the release member to the article, with the remainder of the decal remaining on the release member. Said remainder of the decal is preferably subsequently removed from the release member, desirably by application on to a waste receiving member which could comprise a sheet of paper. Alternatively, the whole of the decal can be applied from the release member such that the decal extends beyond the area. An excess receiving member may be provided around the area to receive the excess decal. The excess receiving member may comprise for example paper and a former may be provided to support the excess receiving member. As an alternative, the excess decal may be permitted to extend into space beyond the area, and the excess decal can be subsequently cut away around the area . The excess decal may be cut away by a spinning blade . The invention further provides a method of decorating an area on a ceramic article, the method comprising applying a decal to the article by a method according to any of the preceding seven paragraphs, and subsequently firing the article. The invention also provides a decal usable in a method according to any of the preceding eight paragraphs . Preferably no cover coat is provided on the decal. ■ " Alternatively, a relatively thin cover coat may be provided on the decal, the cover coat preferably having relatively low tear resistance. As a further alternative, a cover coat may be provided which is friable. Any cover coat provided is preferably relatively inelastic. Embodiments of the present invention will now be described by way of example only, with reference to the accompanying drawings, in which:- Fig. 1 is a diagrammatic side view of apparatus according to the present invention; and Fig. 2 is a plan view of the apparatus of Fig. 1. Conventionally, heat release decals are held prior to application on a heated plate by vacuum, with the heated plate melting the heat sensitive adhesive. The decals are picked up from the plate by a tacky flexible silicone pad. The decals are subsequently applied to articles to be decorated. The decals are applied from the centre of the pad outwards thereby preventing any air from being trapped between the decal and the articϊe. Upon contact with the cold articles the heat sensitive adhesive solidifies bonding the decal thereto. The decals are subsequently fired on to the articles. In a first embodiment of said further aspect of the invention, a wall plaque is provided with edge to edge decoration by a heat release decal. The decal is made so as to be larger than the face of the plaque so that it can overlap therearound. No cover coat is provided on the decal. The decal is applied to the face of the plaque from a flexible pad in the usual manner. Only the part of the decal which contacts the plaque is taken up thereby from the pad. The edge of the decal which does not contact the plaque remains on the pad. The part of the decal remaining on the pad is removed by pressing the pad on to an excess receiving member such as a sheet of paper. As the heat release decal does not require to be slid on to the article unlike water slide decals, a cover coat in this instance is not necessary to protect the colours in the decal. In a second embodiment of said further aspect, a similar method is used but in this instance a relatively thin essentially inelastic cover coat is provided on the decal. A ring of paper is provided immediately around the edge of the face of the plaque. A former is provided beneath the paper to provide support therefor. When the decal is applied by the pad on to the plaque the excess part of the decal which extends beyond the plaque is taken up by the paper. In a third embodiment of said aspect of the invention, again a similar method is used. In this instance however a relatively thick friable inelastic cover coat is provided on the decal. When the decal is applied on to the ware the whole of the decal will be taken from the pad such that the decal will extend beyond the edge of the plaque. The excess decal can be cut from around the edge of the plaque using a spinning knife or other suitable arrangement. There is thus described a method which permits edge to edge decoration to be applied using heat release decals. These decals can readily be applied automatically thereby removing the requirement for skilled lithographers. Furthermore, the amount of wastage will be reduced when using such decals. The drawings show apparatus 10 for trimming excess decal which extends beyond the edge of an item of flatware such as a plate 12. The apparatus 10 comprises a rotatable turntable 14 upon which the plate 12 is mountable. Suction means (not shown) are provided for holding the plate 12 on the turntable 14. A blade 16 is mounted on the end of an arm 18 so as to generally contact the edge of the plate 12. The blade 16 is provided on a sprung mounting 20 on the end of the arm 18 so as to be urged against the side of the plate 12 but to be movable outwardly against the force of the mounting as shown in the direction of the arrow 22. The blade 16 is mounted on the arm 18 such that it can be periodically slid up or down to provide wear across different parts of the blade 16. The arm 18 can be rotated about a substantially horizontal axis as shown by the arrow 24 for a purpose hereinafter to be described. Adjustable stops (not shown) may be provided to limit the rotation in the direction about the arrow 24. The arm 18 is rotatably mounted about a vertically upstanding bar 26 so as to be pivotal towards or away from the plate 12 in the direction as shown by the arrow 28. A brush 30 is provided adjacent the point of contact between the blade 16 and plate 12. Means are provided for selectively moving the brush 30 to be engageable with the upper edge of the plate 12 in the direction shown by the arrow 32. Located to extend beneath the brush 30 and blade 16 is a waste receiving receptacle 34 connected to a suction supply (not shown). In use, when the plate 12 is to be decorated, an oversized heat release decal is applied onto the plate 12 to extend beyond the edge thereof around the plate 12. The edge of the decal extending beyond the plate 12 will generally adopt a generally upstanding orientation. The plate 12 is transferred onto the turntable 14 and held thereon. The turntable 14 is rotated in the direction of the arrow 36 as shown in Fig. 2. The brush 30 is brought into contact with the upper surface of the edge of the plate 12 to urge the excess decal into a generally horizontal alignment so as to be cut from around the edge of the plate by the blade 16. Once the plate 12 has completed a full revolution the decal will extend across the whole upper surface thereof and end precisely at the edge thereof. The decals usable with such apparatus would generally be of the third embodiment as described above. To adjust the precise point to which the edge of the decal will extend the position of the blade 16 can be adjusted by rotating the arm 18 in the direction of the arrow 24. If it is required to provide an upper edge of the plate clear of decal, to for example show a band of plate not bearing the decal around the portion bearing the decal, this can be achieved by rotating the plate 12 through a number of revolutions whilst simultaneously rotating the arm 18 between predetermined positions in a direction as per the arrow 24 at a different speed. For instance the blade 16 may be moved between an orientation as shown in Fig. 1 and an orientation extending substantially horizontal above the plate 12. This feature is particularly useful if for example the plate 12 is predecorated with an edge band of for example gold or silver or any other colour which may be required. In such an instance a plate with a prefired band could have a decal applied, followed by a single further firing. The apparatus 10 will generally be located downstream of an automatic decal applying machine, and usually arranged such that plates bearing decals are automatically supplied to the apparatus 10. There is thus described apparatus which enables a precise edge to edge decal finish to be applied mechanically to an item of flatware. The apparatus is ideally suited to leaving a band around the decal to show a coloured band or the like. The apparatus is of relatively simple construction and can thus be robustly and inexpensively manufactured to provide essentially maintenance free operation. The sprung mounting 20 of the biade 16 enables a decal to be trimmed from a non-circular plate, such as one provided with a scalloped edge . Various modifications may be made to the apparatus without departing from the scope of the invention. For example the blade can be mounted differently and different mounting means can be provided for the plate. The brush may be arranged differently and a different item could be provided to urge the excess decal into an orientation to enable cutting thereof. Whilst endeavouring in the foregoing specification to draw attention to those features of the invention believed to be of particular importance it should be understood that the Applicant claims protection in respect of any patentable feature or combination of features hereinbefore referred to and/or shown in the drawings whether or not particular emphasis has been placed thereon.

Claims: CLA I MS : - 1. Decal application apparatus, characterised in that the apparatus comprises means (16) for removing from an article (12) which has had a decal applied to it which extends beyond the edge of the article (12), said part of the decal which extends therebeyoπd. 2. Apparatus according to claim 1, characterised in that the apparatus includes a blade (16) for removing said part of the decal. 3. Apparatus according to claim 2, characterised in that means (14) are provided to permit relative rotation between the blade (16) and the article (12). 4. Apparatus according to claim 3, characterised in that a rotatable mounting (14) is provided upon which the article (12) is locatable. 5. 'Apparatus according to any of claims 2 to 4, characterised in that the blade (16) is provided on a sprung mounting (20) to permit removal of said part of the decal from any non-circular article. 6. Apparatus according to any of claims 2 to 5, characterised in that the inclination of the blade (16) relative to the mounting (14) is variable. 7. Apparatus according to claim 6, characterised in that the inclination of the blade (16) relative to the mounting (14) may be varied during cutting of said part of the decal . 8. Apparatus according to claim 7, characterised in that the apparatus (10) is arranged such that the inclination of the blade (16) repeatedly moves between two predetermined orientations during use. 9. Apparatus according to claim 8, characterised in that said predetermined orientations are adjustable. 10. Apparatus according to any of the preceding claims, characterised in that the apparatus (10) comprises means (30) for urging said part of the decal to a generally horizontal alignment to ease cutting thereof. 11. Apparatus according to claim 10, characterised in that the urging means comprises a brush (30) engageable with said part of the decal. 12. Apparatus according to any of the preceding claims, characterised in that means (34) are provided for receiving said part of the decal following removal from the article (12). 13. Apparatus according to claim 12, characterised in that the receiving means comprises a suction removal arrangement ( 34) . 14. Apparatus according to any of the preceding claims, characterised in that the apparatus (10) is automatically operable to receive a decorated article (12), remove said part of the decal from the article (12), and subsequently release said article (12) to permit another article to be received. 15. Apparatus according to any of the preceding claims, characterised in that the apparatus (10) is loctable downstream of a heat release decal application machine so as to receive decorated articles (12) from said machine . 16. 'Decal application apparatus, characterised in that the apparatus comprises means for locating a decal on an article such that a part of the decal extends beyond an edge of the article, and means (10) according to any of claims 1 to 15 for removing from the article (12) said part of the decal which extends therebeyond. 17. A method of decorating an area on an article, the method comprising applying on to the article a decal of a greater size than the area, and removing the part of the decal which does not cover the area. 18. A method according to claim 17, in which the area extends from one edge of the article to another edge. 19. A method according to claims 17 or 18, in which the decal comprises a heat release decal which is applied from a release member of a decal applying apparatus . 20. A method according to claim 19, in which only the part of the decal which covers said area is applied from the release member to the article, with the remainder of the decal remaining on the release member. 21. A method according to claim 5, in which said remainder of the decal is subsequently removed from the release member. 22. A method according to claim 21 , in which said remainder of the decal is subsequently removed from the release member by application on to a waste receiving member . 23. A method according to claim 22, in which the waste receiving member comprises a sheet of paper. 24. A method according to claim 19, in which the whole of the decal is applied from the release member such that the decal extends beyond the area. 25. A method according to claim 24, in which an excess receiving member is provided around the area to receive the excess decal. 26. A method according to claim 25, in which the excess receiving member comprises paper. 27. A metho ' d according to claims 25 or 26, in which a former is provided to support the excess receiving member . 28. A method according to claim 24, in which the excess decal which extends into space beyond the area is subsequently cut away around the area. 29. A method according to claim 28, in which the excess decal is cut away by a spinning blade. 30. A method of decorating an area on a ceramic article, the method comprising applying a decal to the article by a method according to any of claims 17 to 29 and subsequently firing the article. 31. A decal usable in a method according to any of claims 17 to 30. 32. A decal according to claim 31 , in which no cover coat is provided on the decal. 33. A decal according to claim 31 , in which a relatively thin cover coat is provided on the decal. 34. A decal according to claim 33, in which the cover coat has relatively low tear resistance. 35. A decal according to claim 31, in which a cover coat is provided which is friable. 36. A decal according to any of claims 33 to 35, in which the cover coat provided is relatively inelastic.

Inventors: PASS PETER ALLAN, RATHBONE CHRISTOPHER CHARLES, PASS, PETER, ALLAN, RATHBONE, CHRISTOPHER, CHARLES
Applicants: PASS PETER ALLAN, RATHBONE CHRISTOPHER CHARLES, SERVICE ENGINEERS PLC, PASS, PETER, ALLAN, RATHBONE, CHRISTOPHER, CHARLES, SERVICE (ENGINEERS) PLC
Application year: 1995
Main classification: B44C1
IPC codes: B44C1, C04B41