IML Label Handling Transfer Device with Micro-Perforated Web
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The handling of IML labels in injection moulding processes is hindered by static electricity issues, curved labels, and the need for high-stability, high-force stamping machines, which limits the use of certain materials and requires manual handling and reduced production speeds.
Innovation Solution
A transfer device with an unrolling mechanism that uses micro connections to maintain labels on a web, allowing for adjustable spacing and orientation, enabling efficient retrieval and delivery of labels to the label handling system, reducing static issues and accommodating complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If anti-static agents are used to handle stamped labels, then static electricity is eliminated, but printing machines have to run at reduced speed and labels may lose adhesion capability
Solution Approach 1:
The invention extracts the problematic stamped labels from the continuous web and replaces them with labels that have micro-perforations allowing controlled separation. The labels remain connected to the web through these micro-connections during printing, eliminating static electricity issues while maintaining high printing speeds, then separate cleanly during application.
Solution Approach 2:
The invention changes the physical structure of the label-web connection by introducing micro-perforations with specific dimensions and patterns. This parameter change allows the labels to remain attached during high-speed printing without static electricity problems, yet separate easily during label application.
2Ease of operation
If a complete stamping machine is used to stamp out labels, then labels can be separated from the web, but the machine requires high stability, heavy dimensioning, and intermittent operation which conflicts with production speed
Solution Approach 1:
The invention extracts the stamping function entirely and replaces it with a continuous web feeding system with micro-perforated labels. The labels are separated from the web through controlled tearing at the micro-connection points during label application, eliminating the need for heavy intermittent stamping machinery.
Solution Approach 2:
The invention replaces the mechanical stamping system with a continuous web feeding system using micro-perforated labels. The separation mechanism changes from forceful intermittent stamping to controlled mechanical tearing at pre-defined weak points during normal label application operations.
3Strength
If laminated label material is used, then label durability is improved, but static electricity accumulates and labels curve making automated handling difficult
Solution Approach 1:
The invention segments the label structure by introducing micro-perforations that create controlled separation zones. This segmentation allows the laminated label material to maintain its durability while enabling easy separation from the web and reducing curvature issues through the distributed micro-connection points.
4Ease of operation
If labels are stamped out individually, then they can be handled separately, but static electricity makes them difficult to handle and requires manual intervention
Solution Approach 1:
The invention extracts the static electricity problem by changing how labels are connected to the web. Instead of complete separation causing static buildup, micro-perforations maintain controlled connections that prevent static accumulation while allowing automated handling and separation.
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 solution allows for higher printing and stamping speeds, reduces the need for anti-static agents, minimizes manual handling, and enables the use of previously unsuitable label materials, improving the handling of curved and complex label geometries.
Implementation Method 1
The idea behind this technology is to place a label inside the cavity, in which the package is moulded, before the cavity is closed and the plastic is injected. The most common method is to charge the label with static electricity in order to make it adhere to the surface of the tool.
Data Source
AI summary
A transfer device with unrolling device, intended for providing a label handling system in an IML machine (In Mould Labelling) with IML labels. The transfer device comprises at least four holders, which are movable between a first and a second position, wherein the first position has a first predetermined relationship between the four or several holders regarding the distance in the X-direction. The holders are intended for retrieval of IML labels from the unrolling device, which comprises a label web, the length of which extends in the Y-direction, with partially stamped out labels, connected to the web with micro connections. The second position has a second predetermined relationship between the four or several holders regarding distance in the X-direction. The holders are intended to deliver the IML labels to the label handling system. The unrolling device comprises adjustment means to make possible the retrieval of labels in the Y-direction, so that the distance in the Y-direction between delivered labels has a different distance in the Y-direction than between two adjacent labels in the web. Further, a method of providing an IML machine with IML labels.