Conductive Roller Unwinder for Semi-Punched IML Obates
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Solution Overview
Problem
Current methods for handling pre-printed polymer oblates (IML) in injection molding are inefficient due to static electricity issues, high labor and resource requirements, significant waste generation, and costly equipment investments, making it difficult to stack and integrate IMLs into injection press tools effectively.
Innovation Solution
A method and apparatus that allow direct conveyance of semi-punched, pre-printed polymer oblates from a roller to an injection press, eliminating the need for prior cutting and stacking, utilizing a tool with shaped holes and a robot for vacuum suction to transfer oblates directly to the molding tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pre-printed polymer oblates are punched out and stacked using conventional methods, then individual products can be supplied to the injection press, but static electricity accumulates making it impossible to assemble products in an acceptable stack
Solution Approach 1:
A conductive roller is introduced as an intermediary element between the punched IML products and the stacking surface. The roller conducts away static electricity charges from the products, preventing accumulation and enabling proper stacking. This mediator resolves the contradiction by providing a path for charge dissipation without affecting the punching or stacking processes themselves.
Solution Approach 2:
The invention replaces mechanical stacking methods with a system that uses electrical conductivity to manage static charges. Instead of relying purely on mechanical handling and stacking, the system incorporates electrical field management through the conductive roller, substituting electrical principles for mechanical solutions to the static electricity problem.
2Productivity
If IML are cut free and stacked using conventional equipment, then stacks can be produced for injection casting, but a lot of labour and resources are required
Solution Approach 1:
The invention extracts and eliminates the unnecessary cutting and stacking steps from the conventional process. By allowing IML to remain on the roller and conveying them directly to the injection press, the system removes the complex equipment and labor associated with cutting free and stacking individual pieces, while still achieving the required production output.
Solution Approach 2:
The system maintains continuous conveyance of IML from the roller directly to the injection press without interruption for cutting or stacking. This continuous action eliminates the discontinuous steps of conventional methods, reducing equipment complexity and labor requirements while maintaining productivity.
3Productivity
If IML are cut into sheets and stacked using guillotine and sausage roller, then stacks can be created for injection press, but products tend to coalesce along the edge and waste material is generated
Solution Approach 1:
The invention extracts and eliminates the cutting operations (guillotine cutting and sausage roller processing) from the stack creation process. By conveying IML directly from the roller to the injection press without cutting, the system removes the source of waste material generation and edge coalescence problems, achieving stack creation without substance loss.
4Productivity
If conventional equipment for IML production is used, then IML can be processed and stacked, but the initial investment is relatively large constituting up to one million Euros
Solution Approach 1:
The invention extracts and eliminates the need for expensive conventional equipment (cutting machines, stacking devices, pressing equipment) by using a simple conductive roller and direct conveyance system. This drastic simplification reduces the initial investment from up to one million Euros to a fraction of that cost, while maintaining the ability to process and supply IML to the injection press.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces production costs and equipment investments by up to 90% by enabling efficient, labor-saving integration of IMLs into injection press tools without generating excess waste, addressing static electricity challenges and streamlining the process.
Implementation Method 1
A handling robot collects an IML by means of vacuum and places it in the injection moulding tool
Data Source
Figure 1~2
AI summary
The invention includes a method for conveying pre-printed polymer oblates (IML), which are for example manufactured in a flexo printing machine, and supplied in a roller, to a casting machine such as an injection press that moulds items such as cups or lids, where the oblates must be integrated in items by the oblates being partially punched such that they remain fixed to the roller in points or bridges, after which the roller with the semi-punched oblates is placed on a device (1) from which the roller with oblates is rolled out in stages, such that the oblates pass through a tool (5) with holes (9) which are shaped to fit the circumference of the oblates, after which the oblates are removed with a device such as a robot with vacuum suction that tears over the river bridges that fix the oblate to the roller and transfers the oblates to the injection casting tool. The invention also includes a device (1) that is suitable for conveying rolled-up, pre-printed polymer oblates, which are partially punched as specified by the claim as the device (1) comprises an unwinder (10) for attaching a roller of oblates from which the rolled-up oblates are fed through a tool (5) that contains holes (9) which are shaped to fit the circumference of the oblates. With this invention, the initial investment for the production of injection-moulded articles with integrated IML oblates is reduced by 90% compared to current technologies and methods.