In-Mould Labeling Process for Continuous Web Detachment
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Solution Overview
Problem
Conventional in-mould labelling processes face high operating costs and require complex mechanical equipment, making them inefficient and costly, especially when removing labels for recycling purposes.
Innovation Solution
The process involves feeding a labelstock web into a mould, forming an article that adheres to the label, detaching the label from the web during the moulding process, and removing the labelled article, eliminating the need for additional positioning means and equipment for label removal, and allowing for continuous labelling with a labelstock web that has no removable backing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional in-mould labelling processes are used with separate label positioning and removal steps, then labels can be applied to articles, but operating costs increase and equipment complexity increases
Solution Approach 1:
The patent combines the label positioning, article formation, and label removal operations into a single integrated in-mould labelling process. The label is positioned in the mould cavity, the article is formed around it, and the label is automatically removed through the moulding action itself, eliminating the need for separate positioning and removal equipment.
Solution Approach 2:
The moulding process itself performs the label removal function. As the article is formed and removed from the mould, the label is automatically detached and removed without requiring external positioning means or separate removal equipment. The system uses its own operational forces to achieve the labelling function.
2Ease of manufacture
If conventional in-mould labelling processes are used with separate label positioning and removal steps, then labels can be applied to articles, but operating costs increase
Solution Approach 1:
The patent enables continuous in-mould labelling operation where labels are continuously fed into the mould cavity and continuously removed as articles are formed. This eliminates idle time between labelling steps and maintains continuous productive action throughout the moulding cycle.
Solution Approach 2:
By merging the label application and removal operations into the single moulding cycle, the patent eliminates unnecessary intermediate steps and positioning operations, thereby reducing operating costs and improving overall productivity.
3Adaptability or versatility
If labels are removed for recycling purposes using conventional methods, then labels can be separated from articles, but additional equipment and complexity are required
Solution Approach 1:
The moulding process automatically performs the label removal function needed for recycling. As the article is formed and extracted from the mould, the label is automatically detached and removed, providing the separation function required for recycling without requiring external equipment.
Solution Approach 2:
The patent extracts the label from the article during the moulding process itself. The label is positioned in the mould cavity and is automatically removed along with the article formation, separating the label material from the article material for subsequent recycling processing.
4Loss of substance
If a labelstock web with no removable backing is used, then waste is reduced and the process is simplified, but the label must be detached during moulding
Solution Approach 1:
The patent merges the label detachment operation with the article formation operation. As the article is formed around the label in the mould cavity, the label is automatically detached from the labelstock web without requiring separate cutting or removal operations, thereby reducing waste and simplifying the process.
Solution Approach 2:
The continuous labelstock web is fed through the mould cavity and labels are continuously detached during the moulding process without interruption. This continuous operation eliminates the need for separate label removal steps and reduces material waste by minimizing handling and positioning operations.
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 waste, simplifies the labelling process, lowers costs, and enables efficient recycling by integrating the label with the article, enhancing durability and environmental sustainability.
Implementation Method 1
The in-mould labels must, therefore, be able to tolerate the heat applied during the moulding process
Implementation Method 2
a polymeric article is moulded by injecting a mass of polymeric melt or by blowing a polymeric parison against the mould walls
Implementation Method 3
feeding a labelstock web into a mould
Implementation Method 4
detaching the adhered label from the labelstock web
Data Source
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AI summary
There is disclosed an in-mould labelling process for the manufacture of a labelled article comprising the steps of: feeding a labelstock web ( 2) into a mould (41); forming an article in the mould such that the formed article contacts and effectively adheres to a label (3) of the labelstock web (2); detaching the adhered label from the labelstock web; and removing the formed and labelled article from the mould.