Deep-Drawing Packaging Encoding via Mold Inserts
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Solution Overview
Problem
Existing methods for producing packaging containers from rigid plastics materials for the food industry face challenges such as deformation during the deep-drawing process, making it difficult to apply codes like barcodes without damage, and resulting in environmental issues due to lack of recyclability, as well as the risk of barcode alteration or fraud.
Innovation Solution
A method where a film-shaped plastics material undergoes shape-changing treatment during deep-drawing to integrate digital watermarks or codes directly onto the packaging container's surface, using a tool mold with prepared inserts and a laser device to create three-dimensional code patterns that are almost invisible but easily readable, allowing for quick identification and recyclability without additional application aids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If barcodes are applied as stickers after deep drawing, then encoding is achieved, but the encoding can be damaged, torn, or altered during handling and deformation
Solution Approach 1:
The barcode is integrated into the mold insert before the deep drawing process begins. This preliminary action ensures the encoding is created during forming rather than applied afterward, preventing damage from subsequent handling and deformation.
Solution Approach 2:
The encoding process is merged with the deep drawing process by integrating the barcode pattern into the mold insert. This combines two separate operations (forming and encoding) into a single simultaneous process, eliminating the need for separate application steps.
2Loss of information
If barcodes are applied before deep drawing, then encoding is achieved, but the deformation process damages the barcode surface
Solution Approach 1:
The barcode pattern is prepared in advance in the mold insert at the correct position and orientation. This preliminary preparation ensures the encoding survives the deformation process intact because it is formed simultaneously with the container shape rather than being applied to a flat surface before forming.
Solution Approach 2:
The barcode is transferred from a flat 2D plane to a 3D curved surface through the mold insert integration. This dimensional transformation allows the encoding to conform to the deformed container surface while maintaining readability, as the barcode is formed in three dimensions along with the container geometry.
3Adaptability or versatility
If multiple codes are integrated during deep drawing, then recyclability and tracking are improved, but the manufacturing process becomes more complex
Solution Approach 1:
The mold insert is designed to perform multiple functions simultaneously: it forms the container shape, integrates the barcode for identification, and incorporates recycling information for material tracking. This multi-functionality allows a single component to provide diverse capabilities without requiring separate systems.
Solution Approach 2:
Multiple encoding functions (barcode, recycling information, tracking data) are merged into a single integrated mold insert design. This consolidation combines what would otherwise require multiple separate components or process steps into one unified solution during the deep drawing operation.
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
The method ensures that packaging containers can be easily read and recycled, preventing barcode fraud and facilitating efficient sorting and recycling by integrating multiple codes across the container's surface, maintaining the material's integrity and enabling accurate tracking of origin and content information.
Implementation Method 1
a laser device to create three-dimensional code patterns
Implementation Method 2
a film-shaped plastics material undergoes shape-changing treatment during deep-drawing to integrate digital watermarks or codes directly onto the packaging container's surface
Data Source
AI summary
The invention relates to a method for encoding a dimensionally stable packaging container or an associated constituent made of plastics material, wherein the packaging container is suitable for storing consumer goods such as food, detergents, etc., wherein a film-shaped, flat plastics material for forming the three-dimensional packaging container or the associated constituent is deep-drawn using a tool mold while, at a plurality of positions, the outer sides or the inner sides thereof undergo a first shape-changing treatment acting on the first surface thereof for producing a plurality of three-dimensional codes.