GB2089284A - A method of manufacturing a plurality of letter or number tiles - Google Patents

Abstract

A method of manufacturing a plurality of letter or number tiles is described, the method including a first step of moulding, in an injection moulding machine, a mould block 1 which has a plurality of tiles 5, each tile 5 of the block is joined by a secondary runner 3 and an interconnecting gate 4 to a main runner 2, adjacent tiles 5 are connected together at a point spaced from the main runner 2 by a second interconnecting gate 9, the tiles each having one surface which is generally in the same plane as that of the other tiles and on which a raised letter or numeral is moulded; and a second step in which the mould block is fed through a printing machine (not shown). The printing machine can be an offset printing press or a hot stamping gold blocking press, both of which are adapted to imprint or fix on the raised region representing the shape of the number or letter on each tile a distinctive coloured surface. <IMAGE>

Description

SPECIFICATION A method of manufacturing a plurality of letter or number tiles The invention relates to letter or number tiles and more particularly relates to a method of manufacturing letter or number tiles of the type used mainly by children for educational or play purposes.

An object of the present invention is to provide a method of manufacturing number of letter tiles which results in considerable handling and cost savings and which produces in one operation a plurality of generally similar constructions of number or letter tiles.

A further object of the present invention is to provide an alternative method of manufacturing letter or number tiles which offers to the public a useful alternative choice.

Further objects and advantages of the present invention will become apparent from the following description both as regards the important teaching of fundamental spelling and reading and to provide the basic concepts of number work in schools or in the home.

According to the present invention there is provided a method of manufacturing a plurality of letter or number tiles, the method including a first step of moulding, in an injection moulding machine, a mould block which has a plurality of tiles, each tile of the block is joined by a secondary runner and an interconnecting gate to a main runner, adjacenttiles are connected together at a point spaced from the main runner by a second interconnecting gate, tiles of the block have one surface which is generally in the same plane; and a second step in which the mould block is fed through a printing machine in which metal foil or printed numerals or letters are fixed in one operation to said one surface of the tiles.

The dimensions of the block and therefore the number of tiles joined thereto is governed by either the size of the injection moulding machine or the printing machine to which the moulded block is moved.

The mould block can have on either side of the main runner a series of tiles each of which is joined to an interconnecting gate which is joined to the main runner by a secondary runner formed integrally therewith.

The printing machine can be an offset printing press or a hot stamping gold blocking press both of which are adapted to imprint or fix on a raised region representing the shape of the number or letter on each tile a distinctive coloured surface.

Further aspects of the present invention which should be considered in all its novel aspects will become apparent from the following description which is given by way of example only.

An example of the present invention will be described herein with reference to the accompany.

ing drawings in which: Figure 7: shows a plan view of part of a moulded block formed in accordance with the method accord- ing to the present invention; Figure 2: shows a perspective view from above of an example of a letter tile formed in accordance with the method according to the present invention; Figure 3: shows a plan view of a mould block according to the present invention; and Figure 4: shows a side view of the mould block shown in Figure 3.

The method according to the present invention requires a mould block which has a plurality of number or letter tiles attached thereto to be formed in an injection moulding machine. The moulded block of tiles is formed in a single operation and the number of tiles moulded in each operation is dependent upon the dimensions of the injection moulding machine.

An example of moulded block 1 is shown in the drawings and the mould block 1 is shown in more detail in Figures 3 and 4 than the part block 1 shown in Figure 1. The mould block 1 is formed with a main runner 2. The main runner 2 has extending therefrom generally at right angles thereto a series of secondary runners 3 in which are formed integrally therewith. Each secondary runner 3 has a gate 4 joined thereto which interconnecting gates 4 join each individual letter or numeral tile 5 to the main runner 2.

An example tile 5 is shown in more detail in Figure 2 accompanying the provision specification and has on the upper surface 6 thereof a raised portion 7 formed in the shape of a letter. The example shown in Figures 3 and 4 shows numerals thereon. It is envisaged that the top cavity of a mould in the injection moulding machine can have a series of interchangeable plates on which a series of different letters and/or numeral recesses are incorporated. It is envisaged that the interchangeable insert plates which are placed on a sprue side of the mould are engraved or spark eroded in reverse with either capital letters, lower case lettering, numerals or symbols. The numerals and/or letters etc. are of an approved type style so that a required range of tiles is produced. This enables in moulding operation an appropriate numer of letters, symbols and numeral tiles to be formed.

It is to be appreciated that each of a series of plates can be used to produce a preselected number of vowels and consonants. The number of each letter, numeral or symbol on each mould block is decided from past experience.

Each tile 5, 5', 5"... has the side edges 8 thereof joined together by second interconnecting gates 9 between which a dimple is positioned. This ensures that the mould block 1 is maintained together as an integral unit after the moulding operation. The surface 6 of the mould block 1 is generally held together in one plane.

The surface of the raised planar portions 7 of each tile 5, 5', ....... is thus formed and held substantially in a single plane by the joins between the main runner, interconnecting gates and secondary runners.

It is envisaged that in practice a bank of ten tiles are moulded on each side of the main runner 2. In each moulding operation twenty tiles are therefore produced.

The overall number of tiles moulded in this operation is governed by the size of the injection moulding machine or alternatively a printing means used to print the tile with the numeral or letter.

The second step in the operation of forming the tiles requires the moulded block to be bed to the printing means. The printing means can be off-set printing machine or a hot stamping gold blocking machine. This operation requires the whole block of tiles held together by the runners and gates (20 tiles) to be printed at one time in a single operation. This operation requires the mould block 5 after it has cooled to be moved automatically or manually to the printing means which prints or blocks on the raised portion 7 of each tile 5 added emphasis to the letter or numeral thereon. For example if the mouded block 1 is moulded from a light colour plastics material a dark numeral is printed or blocked on the raised surface 7. The raised surface 7 can be printed or blocked with a light colour if the mould block 1 is moulded from a dark coloured plastics material.

The plastics material from which the moulded blocks are formed can be any injectable plastics material and the formed article after it has been moulded and printed or blocked is packaged and sold with the moulded block 1 still maintained as a unit. Each tile 5 can be simply separated from the secondary and main runners by breaking the small interconnecting gates or dimples therebetween.

Thus by this invention there is provided a method of manufacturing a plurality of number or letter tiles which results in substantial savings in handling costs.

A particular example of the present invention has been described herein by way of example and it is envisaged that improvements and modifications thereto can take place without departing from the scope of the appended claims.

Claims (4)

1. A method of manufacturing a plurality of letter or number tiles, the method including a first step of moulding, in an injection moulding machine, a mould block which has a plurality of tiles, each tile of the block is joined by a secondary runner and an interconnecting gate to a main runner, adjacent tiles are connected together at a point spaced from the main runner by a second interconnecting gate, the tiles of the block have one surface which is generally in the same plane; and a second step in which the formed and complete block is fed through a printing machine in which metal foil or printed numerals or letters are fixed in one operation to said one surface of the tiles.

2. A method as claimed in claim 1 wherein the dimensions of the block is governed by either the size of the injection moulding machine or the size of the printing machine to which the moulded block is moved.

3. A method as claimed in claim 1 or claim 2 wherein the printing machine is an offset printing press or a hot stamping gold blocking press which are adapted to imprint or fix on a raised region of each tile a distinctive coloured surface representing the shape of the number or letter.

4. A method of manufacturing a plurality of letter or number tiles substantially as hereinbefore described with reference to the accompanying drawing.