Flexible Labels on Armored Electrical Cable
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Solution Overview
Problem
The irregular exterior surface of armored electrical cables makes it difficult to apply and maintain readable information, such as wire size and voltage ratings, during continuous manufacturing processes, as traditional printing methods are ineffective and labels tend to be easily removed or destroyed.
Innovation Solution
A method involving flexible, heat-shrinkable polymer labels with adhesive surfaces are applied to the cable's metal sheath at predetermined intervals, secured by wrapping and heat shrinking, ensuring the labels conform to the cable's peaks and valleys, and are applied during a continuous manufacturing process using a label applicator system that includes vacuum ports, actuators, and a heat tunnel for adherence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If printed information is applied directly to the armor sheath surface, then the information can be permanently attached, but the irregular exterior surface prevents proper application and readability
Solution Approach 1:
A flexible label acts as an intermediary carrier between the information and the irregular armor sheath surface. The label provides a flat, printable surface that can be wrapped around and adhered to the contours of the armor, solving both the readability problem and the application difficulty while maintaining permanent attachment through adhesive and heat shrinkage.
Solution Approach 2:
The label is constructed as a flexible thin film that can conform to the irregular exterior surface of the armor sheath. This flexibility allows the label to wrap around peaks and valleys while maintaining information readability, and the thin film structure enables proper adhesive contact with the surface.
2Ease of manufacture
If traditional printing methods are used on the cable surface, then information can be applied, but the irregular surface causes poor adhesion and readability
Solution Approach 1:
The label serves as an intermediary that provides a suitable surface for traditional printing methods. By transferring the printing process from the irregular cable surface to a flat label surface, both ease of manufacture (printing) and reliability (readability) are achieved.
Solution Approach 2:
The solution moves the information display from two dimensions (printing directly on the curved/irregular surface) to a different approach where a flat two-dimensional label is wrapped around the three-dimensional irregular surface, creating a new dimensional relationship that solves the adhesion and readability problems.
3Productivity
If labels are applied during continuous manufacturing, then production efficiency is maintained, but the labels must be quickly applied and secured
Solution Approach 1:
Labels are pre-prepared with adhesive surfaces and indicia before the continuous manufacturing process. This preliminary preparation allows for rapid application during manufacturing without requiring complex on-the-spot label creation or processing, maintaining productivity while managing system complexity.
Solution Approach 2:
The patent replaces complex mechanical label attachment systems with a combination of adhesive chemistry and thermal energy (heat shrinkage). This substitution simplifies the label application mechanism while enabling continuous manufacturing, as the adhesive and heat shrink processes can occur rapidly without complex mechanical manipulation.
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 durable and readable labeling system that securely attaches alphanumeric information to the cable, ensuring it remains visible and intact throughout the manufacturing and usage phases, addressing the challenges of label application and durability on armored electrical cables.
Implementation Method 1
An adhesive layer is disposed on the adhesive surface
Implementation Method 2
is further secured by heat shrinking the label (i.e. the label substrate) to the surface
Data Source
AI summary
Flexible indicia bearing labels are placed on armored electrical cable at spaced apart intervals while the cable is being moving continuously from an armoring station to a takeup reel or accumulator. A label dispenser places labels in a U shaped recess of a body which is moveable toward engagement with the cable. Opposed rollers fold one edge of the label over into engagement with the surface of the cable and the other edge of the label over onto itself in overlapping relationship. The cable is passed through a heat tunnel to shrink the labels into tight engagement with the cable. A controller monitors movement of the cable and controls actuators for applying and folding labels onto the cable at spaced apart intervals.