Embedded Label Fastener Assembly with Electrostatic Laminate
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Solution Overview
Problem
Existing methods for branding plastic fasteners with identifying information, such as paper-based labels, face issues with adhesive security, integration into continuous molding processes, and limited customization capabilities, leading to tampering risks and increased production costs.
Innovation Solution
A system involving a rotatable mold wheel with embedded labels and an electrostatically charged laminate, allowing for secure and customizable embedding of identifying information directly into the fastener paddles during the molding process, enabling efficient and cost-effective production of continuously connected fastener stock.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If paper-based labels with adhesive are used to brand fasteners, then identifying information can be applied to fasteners, but the labels are susceptible to tampering and adhesive security issues
Solution Approach 1:
The patent merges the labeling process with the fastener molding process by integrating label application into the injection molding cycle. Labels are applied to the paddle surface before molten plastic is injected, embedding the labels securely within the fastener structure during a single manufacturing operation, thereby eliminating adhesive security issues.
Solution Approach 2:
The patent applies labels to the fastener paddle in advance, before the molding process completes. By positioning labels on the paddle surface prior to plastic injection and allowing them to be embedded during the molding cycle, the branding is secured beforehand rather than requiring post-manufacturing adhesive application.
2Loss of information
If traditional labeling methods are used, then branding can be applied, but integration into continuous molding processes is difficult and production costs increase
Solution Approach 1:
The patent combines three separate operations—label application, fastener molding, and cooling—into a single integrated continuous molding process. The label applicator feeds labels onto moving fasteners during the molding cycle, and the injection molding machine simultaneously applies molten plastic that embeds the labels, eliminating the need for separate labeling and molding steps.
Solution Approach 2:
The patent enables continuous production by maintaining uninterrupted motion of the fastener feed and label applicator throughout the molding process. Fasteners move continuously through the molding station while labels are applied and embedded in real-time, allowing the process to operate without stopping for labeling operations.
3Loss of information
If conventional branding methods are used, then identifying information can be marked, but customization capabilities are limited
Solution Approach 1:
The patent employs a dynamic label application system where the label applicator can be reconfigured to apply different labels to fasteners based on product requirements. The system allows for variable data printing and label selection during production, enabling flexible customization of branding information without requiring fixed mold cavities for each product variant.
Solution Approach 2:
The patent creates a universal branding system that can accommodate multiple product types and identifying information requirements through a single integrated molding process. The label applicator and injection molding system work together to apply different labels and branding elements to various fastener types, making the system adaptable to diverse customization needs.
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 solution provides a secure, tamper-resistant, and customizable branding method for plastic fasteners, enhancing brand recognition and marketability while reducing production complexities and costs.
Implementation Method 1
an electrically chargeable, stiffness enhancing laminate applied to the top surface of the semi-rigid substrate
Data Source
AI summary
A fastener assembly includes a molded plastic fastener shaped to define a filament, a paddle at one end of the filament, and a cross-bar at the other end of the filament. The fastener assembly additionally includes a printed label embedded in the paddle, the printed label including an electrically chargeable, stiffness enhancing laminate that is applied to a print receptive polymer substrate. An in-line system for manufacturing a continuously connected supply of the fastener assemblies includes a rotatable mold wheel, a feed mechanism for advancing a continuous, ionized, printed polymer web in a near tangential relationship relative to the mold wheel periphery, a cutting mechanism for transversely cutting through the web to form a plurality of rectangular printed labels that are magnetically drawn into corresponding cavities in the mold wheel, an extruder for applying molten plastic into the cavities and a knife for skiving excess hardened plastic from the mold wheel periphery.