GB2337149A

GB2337149A - Improvements in or relating to carpet sample cards

Info

Publication number: GB2337149A
Application number: GB9809525A
Authority: GB
Inventors: Keith Taylor
Original assignee: TAYLOR MADE SAMPLES Ltd
Current assignee: TAYLOR MADE SAMPLES Ltd
Priority date: 1998-05-06
Filing date: 1998-05-06
Publication date: 1999-11-10
Anticipated expiration: 2018-05-06
Also published as: GB2337149B; GB9809525D0

Abstract

A sample card for displaying samples of carpets or the like comprises a tray having one or more recesses adapted to receive the samples and a backing board. The tray is directly secured to the board by heat sealant. Apparatus for manufacturing the sample card comprises a mould (16) having raised portions (18) to be received in the recesses of the tray with means for applying heat and or pressure between the raised portions of the mould and the backing board so as to secure the tray to the board. Pressure is applied by means of upper and lower plates (10,12, Figure 3), the lower plate 12 having apertures 14 to receive corresponding mould (16, Figure 5).

Description

2337149 - 1 IMPROVMWIENTS IN OR RELATING TO CARPET SAMPLE CARDS The

present invention relates to sample cards for carpets or the like and, in particular, to improved sample cards and method and apparatus for manufacturing sample cards.

Known sample cards for displaying samples of carpets or the like often comprise a vacuum-formed tray having a plurality of recesses for receiving the carpet samples. One or more trays are secured to a backing board to form the sample card display album. Known trays generally comprise either polystyrene or pvc, the latter generally being the preferred material since it is cleaner in so far is as white polystyrene trays get very dirty in use. Polystyrene trays are stuck down onto the backing board using double-sided adhesive tape around the peripheral underside of the tray or using a double-sided adhesive sheet to ensure better securement of the tray to the board. Conventional double-sided adhesive tape used on pvc trays is not very effective since the tray unsticks or starts coming off due to plasticiser migration when plasticisers in the tape react with plasticisers in the tray. For this reason, special plasticiser-free tape is used for sticking pvc trays to backing boards. However, such tape is relatively expensive, costing about 16p per metre and given that about one metre of tape is required to secure the peripheral edge of a tray the consequent cost for a multi-tray sample card display is relatively high.

Furthermore, the step of applying tape to the tray is slow and is a timeconsuming and consequently expensive part of the sample card manufacturing process.

In addition, in order to improve the overall aesthetic appearance of the sample cards, it is generally desirable to eliminate or reduce as much as possible any areas of the tray which would be exposed in use. Thus, referring to Figure 1 which shows a plan view of a typical tray 1, the upraised borders 2 around the recesses 4 which accommodate the carpet samples should be minimised and the peripheral edge 6 should preferably be eliminated. However, current methods of securing trays using double- sided adhesive tape require a reasonable size border area 6 to ensure secure attachment of the tray to the backing board. once the tape is secured to the underside of the tray border 6, the tray border must be mechanically pressed onto the backing board, manual pressure not being is sufficient for long-term adhesion. Although in principle it would be better to stick the underside of the recesses 4 rather than the peripheral edge 6 in order to eliminate the edge area 6, in such cases the trays are not mechanically pressed due to potential damage to carpet samples in the recesses.

Attempts have been made to apply glue through apertures formed in the recesses in order to bond the tray to the board. However, the resultant sample cards are not effectively bonded and again the hot melt adhesive used contains plasticisers which is only effective on polystyrene trays.

other methods involve using a welding tool to weld around the edge of the tray. However, welding methods can only be used on pvc trays, since polystyrene trays cannot be welded. Welding is effective for securing pvc trays to pvc backing boards but again the resultant sample cards have a peripheral welded edge. welding is not generally suitable for securing pvc trays to backing boards of other materials.

The present invention has been made from a consideration of the disadvantages with known sample cards and methods of manufacture thereof and in order to provide an improved sample card and method and apparatus for the manufacture of sample cards which overcomes one or more of the above mentioned disadvantages.

Thus, one preferred object of the invention is to provide a sample card which is easier and more cost effective to produce. Further preferred objects of the invention are to provide a method whereby the exposed tray areas may be reduced or eliminated and to provide a sample card wherein the tray is effectively secured, particularly a pvc tray, to the backing board.

According to a first aspect of the invention there is provided a sample card for displaying samples of carpets or the like comprising a tray having one or more recesses adapted to receive said samples and a backing board wherein said tray is directly secured to said board by heat sealant.

Preferably, a surface of the backing board is coated with the heat sealant. Preferably, the sealant is laminated onto the board. Alternatively or additionally, the under surface of the tray, typically the under surface of the base of one or more of the recesses, is coated with the sealant or the sealant is laminated thereto. Preferably, the sealant is a liquid sealant applied by rollers or otherwise.

- 4 Preferably, the heat sealant comprises a blister pack adhesive. Preferably, the sealant comprises a blister heat sealant of the type conventionally used for coating printed boards, such as those suitable for packaging with pre-formed APET or PVC blisters, in the blister packaging industry. Preferably, the heat sealant comprises NC-2231 Heat Seal provided by Novacote Flexpack Limited.

Preferably, the tray is secured to the board by the application of pressure and heat between said tray and said board. Preferably, the pressure is applied between the bases of one or more recesses of the tray and the underlying regions of the board.

Preferably, the tray comprises an upraised peripheral edge. Preferably, such peripheral edge defines at least one side wall of each recess. The tray may comprise an upraised boarder and a lower peripheral edge. Preferably, the width of the upraised peripheral edge or upraised border and the width of the lower peripheral edge are less than or equal to substantially 1 cm. Preferably, the width of the upraised edge is in the region of 0. 3 to 1.Ocm and the width of the lower peripheral edge is in the region of 0 to 0.5cm.

The recesses may be of different depths to accommodate carpet samples of different thicknesses.

Preferably, the tray comprises plastics material, such as pvc or polystyrene. The backing board may comprise any suitable material. one or more trays may be provided on a single backing board.

According to a second aspect of the invention there is provided a method of manufacturing a sample card for displaying samples of carpets or the like comprising the steps of applying heat sealant to a surface of a backingboard and/or a surface of a tray, the tray having one or more recesses, adapted to receive said samples, and applying pressure between said tray and said board to secure the tray to the board.

Preferably, the method includes the step of coating the board with the sealant or laminating the sealant onto the board. Preferably, the pressure is applied between the bases of one or more recesses of the tray and the underlying regions of the board.

Preferably, a pressure of up to 1000 psi is applied. More preferably a pressure in the range 300-500 psi, typically substantially 400 psi is applied. Preferably, the pressure applied is not sufficient to distort the backing board. Preferably, the minimum pressure required to secure adhesion is applied.

Preferably, the pressure is applied at a temperature in the range 50-150T, more preferably 80-1200C and typically at substantially 1000C. Preferably, the temperature is not sufficient to melt the tray.

Preferably, the pressure is applied by a mould located in the recesses of the tray. Preferably a heated mould is used.

Preferably the method includes temporarily securing the backing board to the underside of the trayand locating the tray on a mould such that upraised portions of the mould locate in the recesses of the tray.

The invention further includes a sample card manufactured according to a method of the invention.

According to a third aspect of the invention there is provided apparatus for manufacturing a sample card for displaying samples of carpets or the like comprising a plate, one or more moulds having up- raised portions adapted to be received in the recesses formed in a tray for receiving said samples and means for applying heat and/or pressure between said up-raised portions of such moulds and said plate.

The invention further includes a sample card and a method of manufacturing a sample card using an apparatus is of the invention.

Preferably, the apparatus includes features as hereinbefore described. Thus preferably the apparatus comprises means for heating said moulds, typically to a temperature of substantially 1000C. Typically the pressure means is adapted to provide substantially 400 psi.

Preferably, the apparatus comprises a lower pressure plate having one or more apertures, each adapted to receive a mould therein. Preferably, such moulds are removably located in such apertures. Preferably, a range of moulds comprising various numbers and heights of upraised portions corresponding to various configuration of trays are provided. Preferably, the moulds comprise one, two, three or four columns of up-raised rectangular portions.

Preferably, the apparatus comprises a removable bar adapted to be removably received in an aperture of the lower pressure plate to partially fill said aperture.

7 - Preferably, the width of the aperture is greater than the width of a mould to be located therein. Preferably, when the bar is located in the aperture the mould is a close fit in the unfilled portion of the aperture. Thus, preferably the relative position of the mould in the aperture may be altered by suitable location of the bar in the aperture. Preferably, the location of the bar in the aperture reduces the effective width of the aperture.

The invention will now be described further by way of example only and with reference to the accompanying drawings in which:

Figure 1 is a plan view of a conventional tray; Figure 2 is a cross-sectional view taken through the line AA of Figure 1; Figure 3 is a schematic front view of one embodiment of an apparatus of the invention; Figure 4 is a plan view of one embodiment of a lower press plate for use with an apparatus of the invention; and Figure 5 is plan view of a mould for use with an apparatus of the invention.

Referring to Figures 1 and 2, a tray 1 comprises a lower peripheral edge 6 surrounding an upraised border 2. The border 2 extends around and defines a plurality of recesses 4. In use, carpet samples are located in the recesses 4. The depth of the recesses may vary, as shown in Figure 2, to accommodate carpet samples of different thickness. In use, the exposed surfaces of the carpet 8 samples should be substantially f lush with the upraised border 2. In general, a tray will have, any number of recesses, typically from one to twenty four, of square or rectangular shape to accommodate a range of carpet samples. The display of the samples is more aesthetically pleasing if the width of the border regions 2 are minimised and particularly if the edge 6 is minimised or eliminated altogether.

The present invention allows the edge 6 to be eliminated and the border 2 to be minimised. In the sample card of the invention, the undersurface of the tray, which may be as shown in Figure 1 or of other configuration, such as without the lower peripheral edge 6, is secured to a backing board by heat sealant, such as blister pack adhesive.

The preferred method involves laminating the sealant onto one or more regions of one side of a backing board and locating the undersurface of the tray or trays to be used onto that side of the backing board. Temporary sticking means, such as a small portion of double-sided adhesive tape, may be used to temporarily hold the tray in position on the board. The board and tray are then taken to a pressing machine 8 as schematically illustrated in Figure 3. The machine 8 has an upper flat pressing plate 10 and a lower pressing plate 12 which in use act as a press. The lower pressure plate 12 may be as shown in Figure 4 and comprises one or more apertures 14 spaced along the length thereof. Typically the apertures 14 are rectangular or square recesses which receive a corresponding mould 16 therein. Figure 5 shows one example of a mould 16. In general, the configuration of mould to be used will correspond to the configuration of the tray such that upraised portions 18 of the mould locate in recesses 4 of the tray. Typically, an upraised portion of the mould will locate in each recess of the tray. The appropriate moulds 16 are located in the apertures 14 such that the base of the mould 20 lies substantially in the plane of the upper surface of the plate 12 and the upraised portions 18 extend above the surface.

The tray and board are located upside down on the mould such that the upraised portions locate in the recesses. The board and tray are then pressed between the pressure plates 10, 12 so that the pressure is applied to the recesses of the tray only to ensure secure attachment to the board. The mould 16 is heated to provide a is suitable temperature. The right combination of temperature and pressure provides secure attachment while avoiding distortion of the board or melting of the tray. Since the bases of the recesses are adhesively secured to the board, the sample card can be manufactured with a tray having a minimal or no peripheral edge. The reduction in border and peripheral edge allows a greater relative portion of the tray to be secured.

Typically, 400 psi at about 1000C is applied for about 15 seconds. Using the method and apparatus of the invention a complete sample card can be manufactured in less than about one minute, typically in about 30 seconds, whereas conventionally about 40 seconds per tray is required. Thus, the invention provides a major improvement over the conventional throughput of about 90 trays per hour, leading to consequent cost and labour reduction. Furthermore, the method of the invention can more readily be automated than previous methods.

NC-2231 blister heat seal supplied by Novacote Flexpack Limited, Loughborough is a suitable sealant. The product is a petroleum mixture with a flash point below 220C. Suitable diluents are blends of ethyl acetate and toluene and the sealant can be applied by roll application techniques. The application rollers are preferably resistant to toluene and ethyl acetate blends. Typically a coating density in the region of 4 to 8g/rrJ is applied. The individual components used in the manufacture of NC 2231 are listed in the Code of Federal Regulations 21, in section 175,300.

A moveable bar 22 may be removably located in one or more of the apertures 14 and in such case when the bar is located in the aperture, the effective aperture 15 accommodates the mould 16. In use, the bar 22 may be located at either side of the aperture 14 to alter the relative location of the effective aperture 15 on the plate 12.

This is useful where a plurality of trays, typically one to four, are to be secured to a board and the board is to be subsequently folded over to form the sample card.

Such folding requires different spacings between the trays along the outstretched board to accommodate the folding action and the thickness of the trays. The correct spacing between the trays can be selected by moving the bar 22 in the aperture 14.

The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

- 11 All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

Each feature disclosed in this specification (including any accompanying claims, abstract and drawings), may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

is The invention is not restricted to the details of the foregoing embodiment (s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

- 12

Claims

3.

A sample card for displaying samples of carpets or the like comprising a tray having one or more recesses adapted to receive said samples and a backing board wherein said tray is directly secured to said board by heat sealant.

A sample card according to Claim 1 wherein a surface of the backing board is coated with the heat sealant.

A sample card according to any preceding claim, wherein the sealant is laminated onto the board.

is 4. A sample card according to any preceding claim, wherein the under surface of the base of one or more of the recesses, is coated with the sealant or the sealant is laminated thereto.

5. A sample card according to any preceding claim, wherein the sealant is a liquid sealant.

6. A sample card according to any preceding claim, wherein the heat sealant comprises a blister pack adhesive.

7.

8.

A sample card according to any preceding claim, wherein the tray is secured to the board by the application of pressure and heat between said tray and said board.

A sample card according to Claim 7, wherein the pressure is applied between the bases of one or more recesses of the tray and the underlying regions of the board.

- 13 9. A sample card according to any preceding claim, wherein the tray comprises an upraised peripheral edge.

10. A sample card according to any preceding claim, wherein the tray comprises an upraised border and a lower peripheral edge.

A sample card according to Claim 9 or Claim 10, wherein the width of the upraised peripheral edge or upraised border and the width of the lower peripheral edge are less than or equal to substantially 1 cm.

12. A sample card according to Claim 11, wherein the width of the upraised edge is in the region of 0. 3 to 1.Ocm and the width of the lower peripheral edge is in the region of 0 to 0.5cm.

13. A sample card according to any preceding claim, wherein the tray comprises plastics material.

A sample card according to any preceding claim, wherein one or more trays are provided on a single backing board.

A method of manufacturing a sample card for displaying samples of carpets or the like comprising the steps of applying heat sealant to a surface of a backing board and/or a surface of a tray, the tray having one or more recesses, adapted to receive said samples, and applying pressure between said tray and said board to secure the tray to the board.

16. A method of manufacturing a sample card according to Claim 15, wherein the method includes the step of 14 coating the board with the sealant or laminating the sealant onto the board.

17. A method of manufacturing a sample card according to any preceding claim, wherein the pressure is applied between the bases of one or more recesses of the tray and the underlying regions of the board.

18. A method of manufacturing a sample card according to any preceding claim, wherein a pressure of up to 1000 psi is applied.

is 19. A method of manufacturing a sample card according to any preceding claim, wherein a pressure in the range 300-500 psi is applied.

20. A method of manufacturing a sample card according to any preceding claim, wherein the pressure is applied at a temperature in the range 501500C.

21. A method of manufacturing a sample card according to any preceding claim, wherein the pressure is applied by a mould located in the recesses of the tray.

22. A method of manufacturing a sample card according to Claim 21, wherein a heated mould is used.

23. A method of manufacturing a sample card according to any preceding claim, wherein the method includes temporarily securing the backing board to the underside of the tray and locating the tray on a mould such that upraised portions of the mould locate in the recesses of the tray.

- is - 24. A sample card manufactured according to a method as claimed in any preceding claim.

25. Apparatus for manufacturing a sample card for displaying samples of carpets or the like comprising a plate, one or more moulds having upraised portions adapted to be received in the recesses formed in a tray for receiving said samples and means for applying heat and/or pressure between said up-raised portions of such moulds and said plate.

A method of manufacturing a sample card using an apparatus according to Claim 25.

1 1 is 27. Apparatus according to Claim 25 comprising means for heating said moulds.

28. Apparatus according to Claim 25 or Claim 27, wherein the pressure means is adapted to provide substantially 400 psi.

Apparatus according to any preceding claim wherein the apparatus comprises a lower pressure plate having one or more apertures, each adapted to receive a mould therein.

30. Apparatus according to Claim 29, wherein such moulds are removably located in such apertures.

31. Apparatus according to any preceding claim, wherein a range of moulds comprising various numbers and heights of up-raised portions corresponding to various configuration of trays are provided.

- 16 32. Apparatus according to any preceding claim, wherein the moulds comprise one, two, three or four columns of up-raised rectangular portions.

33. Apparatus according to Claim 29 or Claim 30, wherein the apparatus comprises a removable bar adapted to be removably received in an aperture of the lower pressure plate to partially fill said aperture.

34. Apparatus according to Claim 33 wherein the width of the aperture is greater than the width of a mould to be located therein.

is 35. Apparatus according to Claim 34 wherein when the bar is located in the aperture the mould is a close fit in the unfilled portion of the aperture.

36. Apparatus according to Claim 33 or any succeeding claim, wherein the relative position of the mould in 20 the aperture may be altered by suitable location of the bar in the aperture.

Apparatus according to Claim 33 or any succeeding claim, wherein the location of the bar in the aperture reduces the effective width of the aperture.

38. A sample card substantially as described.

hereinbefore 39. A method of manufacturing a sample card substantially as hereinbefore described.

40. Apparatus for manufacturing a sample card substantially as hereinbefore described.

Amendments to the claims have been filed as follows 2.

is A sample card for displaying samples of carpets or the like comprising a tray having one or more recesses adapted to receive said samples and a backing board wherein said tray is directly secured to said board by heat sealant applied as a coating to a surface of said tray and/or said board.

A sample card according to Claim 1 wherein a surface of the backing board is coated with the heat sealant.

3. A sample card according to any preceding claim, wherein the sealant is laminated onto the board.

4.

A sample card according to any preceding claim, wherein the under surface of the base of one or more of the recesses, is coated with the sealant or the sealant is laminated thereto.

5. A sample card according to any preceding claim, wherein the sealant is a liquid sealant.

6. A sample card according to any preceding claim, wherein the heat sealant comprises a blister pack adhesive.

A sample card according to any preceding claim, wherein the tray is secured to the board by the application of pressure and heat between said tray and said board.

8. A sample card according to Claim 7, wherein the pressure is applied between the bases of one or more (g recesses of the tray and the underlying regions of the board.

9. A sample card according to any preceding claim, wherein the tray comprises an upraised peripheral edge.

10. A sample card according to any preceding claim, wherein the tray comprises an upraised border and a lower peripheral edge.

A sample card according to Claim 9 or Claim 10, wherein the width of the upraised peripheral edge or upraised border and the width of the lower peripheral edge are less than or equal to substantially 1 cm.

12. A sample card according to Claim 11, wherein the width of the upraised edge is in the region of 0.3 to 1.Ocm and the width of the lower peripheral edge is in the region of 0 to 0.5cm.

13. A sample card according to any preceding claim, wherein the tray comprises plastics material.

14. A sample card according to any preceding claim, wherein one or more trays are provided on a single backing board.

1 15. A method of manufacturing a sample card for displaying samples of carpets or the like comprising the steps of applying heat sealant as a coating to a surf ace of a backing board and/or a surf ace of a tray, the tray having one or more recesses, adapted to receive said samples, and applying pressure - M - 1 between said tray and said board to secure the tray to the board.

16. A method of manufacturing a sample card according to 5 Claim 15, wherein the method includes the step of coating the board with the sealant or laminating the sealant onto the board.

17. A method of manufacturing a sample card according to any preceding claim, wherein the pressure is applied between the bases of one or more recesses of the tray and the underlying regions of the board.

18. A method of manufacturing a sample card according to is any preceding claim, wherein a pressure of up to 1000 psi is applied.

19. A method of manufacturing a sample card according to any preceding claim, wherein a pressure in the range 300-500 psi is applied.

20. A method of manufacturing a sample card according to any preceding claim, wherein the pressure is applied at a temperature in the range 501500C.

A method of manufacturing a sample card according to any preceding claim, wherein the pressure is applied by a mould located in the recesses of the tray.

22. A method of manufacturing a sample card according to Claim 21, wherein a heated mould is used.

23. A method of manufacturing a sample card according to any preceding claim, wherein the method includes 35 temporarily securing the backing board to the underside of the tray and locating the tray on a mould such that upraised portions of the mould locate in the recesses of the tray.

24. A sample card manufactured according to a method as claimed in any preceding claim.

25. Apparatus for manufacturing a sample card for displaying samples of carpets or the like comprising a plate, one or more moulds having upraised portions adapted to be received in the recesses formed in a tray for receiving said samples and means for applying heat and/or pressure between said up-raised portions of such moulds and said plate.

26. A method of manufacturing a sample card using an apparatus according to Claim 25.

27. Apparatus according to Claim 25 comprising means for heating said moulds.

28. Apparatus according to Claim 25 or Claim 27, wherein the pressure means is adapted to provide substantially 400 psi.

29. Apparatus according to any preceding claim wherein the apparatus comprises a lower pressure plate having one or more apertures, each adapted to receive a mould therein.

30. Apparatus according to Claim 29, wherein such moulds are removably located in such apertures.

31. Apparatus according to any preceding claim, wherein a range of moulds comprising various numbers and -l - heights of up-raised portions corresponding to various configuration of trays are provided.

32. Apparatus according to any preceding claim, wherein the moulds comprise one, two, three or four columns of up-raised rectangular portions.

33. Apparatus according to Claim 29 or Claim 30, wherein the apparatus comprises a removable bar adapted to be removably received in an aperture of the lower pressure plate to partially fill said aperture.

34. Apparatus according to Claim 33 wherein the width of the aperture is greater than the width of a mould to be located therein.

35. Apparatus according to Claim 34 wherein when the bar is located in the aperture the mould is a close fit in the unfilled portion of the aperture.

36. Apparatus according to Claim 33 or any succeeding claim, wherein the relative position of the mould in the aperture may be altered by suitable location of the bar in the aperture.

37. Apparatus according to Claim 33 or any succeeding claim, wherein the location of the bar in the aperture reduces the effective width of the aperture.

38. A sample card substantially as hereinbefore described.

39. A method of manufacturing a sample card substantially as hereinbefore described.

40. Apparatus for manufacturing a sample card substantially as hereinbefore described.