FOIL APPLICATOR

Abstract: An applicator (21) for attaching a foil to a screen mesh for use in assembly line screen printing of compact discs provides a vehicle in which foil tape is positioned precisely in the center of a screen frame (24) with repeatability. The applicator has a lid (23) that has vacuum porting for the foil and a precision alignment hole (31) for the centering disc. The applicator hinges (33) to the base that provides a positive screen frame location. The foil is aligned on the applicator by using the centering disc then lowered onto the base. The center points of the applicator and the base meet with an accuracy of 0.002".

Description: OTT, Apoτ.τraτnp Vi »\ti Of T P Tmr n rH pn This invention relates to processes for the mass production of data recording compact discs. More particularly it relates to screen printing on a surface of such discs. Baclcrrounri Of ThP Tnvpnfinn Compact discs are record carriers for digital or analog information, for example audio and/or video information, which have the form of a fiat disc-shaped plastic surface on which a data modulated optical structure is provided in accordance with the information. The data is formed as pits of varying length present in the surface and arranged in a spiral path. The pits have nanometer dimensions and are formed by injection molding against a mold having corresponding raised regions. The data is read through one side of the discwhich is transparent to laser light. The other side of the disc is coated with a screen printed label identifying the disc and containing design and logo information. These screen printed labels may be quite elaborate and employ several different colors formed by several printing stages . The process of screen printing employs a mesh which is pressed against the surface of the disc. ink is applied to the surface of the disc through the mesh by a squeegee. The mesh used for screen printing compact discs is subjected to extreme wear along the perimeter of the disc. The wear is a result of the squeegee climbing from the disc holding fixture onto the printable surface. To lengthen the life cycle of the mesh, an aluminum foil tape is applied along ' the perimeter of the disc. The foil tape is manufactured in ten inch squares with a center hole cut out. The center hole diameter equals one hundred and eighteen millimeters for some and one hundred and twelve millimeters for others depending upon graphics . The foil is manually applied to the screen frame by positioning the "foil hole" around the image area. Just as with any process involving manual application, the foil location can never be consistent. More specifically, if the foil is off center in any direction, to any degree, the result will be premature screen wear caused by the edge of the disc. Brief DesrrioMon Of The invention The foil applicator of the present invention is a device for centering the foil in the screen frame. This device and its method of use ensures that the foil will be located precisely in the center of the screen frame each time. This prolongs screen life and establishes a quality checkpoint for image location. Previous to the foil applicator, all foil was applied manually. The advantages of locating the foil in the exact position with each application are the elimination of variation, having a quality check point of image location, fewer instances of the compact disc being pulled from its holding fixture by a folded foil edge, extended screen life, the elimination of foil wrinkles that can cause smears, fewer instances of edge leak and faster printer setup time. In a mass production system for the manufacture of compact discs these advantages are significant in the reduction of the cost of the disc. In general, the productivity of compact disc printing becomes more efficient and cost effective. Brief Description Of The Drawings Figure 1 is a schematic representation of a carousel for screen printing of compact discs. Figure 2 is a top view of a printing station for screen printing of compact discs. Figure 3 is a top view of the printable surface of a compact disc. Figure 4 is a perspective drawing of a foil applicator. Figure 5 is an exploded drawing of the components of a foil applicator. Detailed Description Of A Preferred Embodiment Figure 1 is a schematic diagram of a carousel 1 onto which compact discs 2. are placed by a robot arm '(not shown) . The discs are held in place by a holding fixture 1, which may be a chuck of some type, and carried by the rotation of the carousel to a printing station 5_. The carousel pauses for a time long enough to complete a screen printing of the disc. The carousel then continues to rotate bringing another disc to the printing station 5_, and rotating the disc just printed to another printing station where a second printing, typically of another color in a multicolor printing process may occur. The movement of the discs is controlled so that sufficient time is allowed for drying between printing stages, which may entail a disc being carried by the carousel for more than a complete rotation before being removed by a robotic arm. As shown in Fig. 2, at the printing station the disc is overlayed by a screen frame 9_ that supports the mesh or screen JJ. that rests on the printable surface of the disc. The mesh is supported by a foil tape 11 that has a circular opening lϋ which has a smaller radius than that of the edge JJ. of the disc. T^e edge of the disc is labeled more clearly in «Fig. 3. The ink is then applied by the ink applicator means 1 , which may be a squeegee and is depicted a roller in the schematic representation. The applicator means is passed radially with respect to the carousel and rises from the level.of the holding fixture to that of the printable surface, passing over an edge of the disc when doing so and subjecting the foil surface to wear. An aspect of the present invention is the application of the foil tape J2 to the screen by means of an applicator 21- Preparing the foil covered screen is begun by raising the applicator lid 22. to its upright position and installing the screen frame. The screen frame sets on the alignment pins 23. of the base 24 With the emulsion side up. The lid, as shown in Fig. 5 has perforations that provide opening to a vacuum distribution plate 22. which allows, planar surfaces to be temporarily held to the lid. The applicator vacuum is then switched on via a foot switch. The proper hole diameter of the foil is chosen, typically one hundred and eighteen millimeters or one hundred and twelve millimeters. A centering disc 23 . s placed in position on a center disc alignment pin 3J and the foil with the adhesive side facing out is rotated until it is squared up along the applicators edge. At this point, the applicator vacuum holds the foil in position. Once the vacuum has been established, it is possible to remove the centering disc .without concern of foil movement. The applicator lid is then lowered onto the screen. This will exert an equal amount of pressure across the surface area of the mesh to adhieve foil to mesh adhesion. Next, the vacuum is shut off by releasing the foot switch.. The applicator lid can now be raised back to its upright position. Lastly, the foil should be rolled, i.e. compressed by passing a roller over it, to insure a permanent bond. The foil applicator provides a vehicle in which foil tape is positioned precisely in the center of a screen frame with repeatability. Such a task is achieved with an applicator lid that has vacuum porting for the foil and a precision alignment hole for the centering disc. The applicator hinges 3_3 connect the lid 22 to the base 2A and provide a positive screen frame location. The foil is aligned on the applicator by using the centering disc then lowered onto the base. The center points of the applicator and the base meet with an accuracy of plus or minus two thousandths of an inch. While there have been shown and described and pointed out the fundamental novel features of the invention as applied to preferred embodiments thereof, it will be under- stood that various omissions and substitutions and changes in the form and details of the device illustrated and in its operation may be made by those skilled in the art without departing from the spirit of the invention, which is specified in the following claims:

Claims: What is claimed is: 1. A method for attaching an adhesive sided foil having a circular opening therein to a screen in an alignment applicator having a base hinged to a vacuum ported lid for use in assembly line screen printing of compact discs comprising placing a centering disc in position on an center disc alignment means attached to said lid, placing the foil with the adhesive side facing out over said centering disc and rotating said foil until it is squared up along an edge of said lid, engaging a vacuum means to provide vacuum to said vacuum ported lid to hold the foil against said lid, removing the centering disc and lowering applicator lid onto the screen, wherein a uniform pressure is exerted across the surface area of the mesh to achieve foil to mesh adhesion, releasing the vacuum and raising the applicator lid. 2. The method for attaching an adhesive sided foil of claim 1 followed by the additional step of rolling the foil to insure a permanent bond. 3. A method for producing compact discs printed on one surface comprising placing said discs on a carousel and advancing by rotation of said carousel the disc to a screen printing station having a foil adhered screen prepared by the method of claim 1. 4. An alignment applicator for adhering a foil tape having a center opening to a screen for screen printing of compact discs comprising a centering disc, an applicator lid attached by a hinge to a base, said base having alignment pins thereon for engaging corresponding holes in a screen frame, said lid having perforations that provide opening to a vacuum distribution plate, and a center disc alignment means for engaging corresponding engaging means in a center disc .

Inventors: PAVLOVIC RICHARD, ZAYKOSKI RONALD, PAVLOVIC, RICHARD, ZAYKOSKI, RONALD
Applicants: WEA MFG INC, WEA MANUFACTURING, INC.
Application year: 1997
Main classification: B32B31
IPC codes: B41F15, G11B7