Injection Molded Label Fusion via Angled Gate Pinning
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Solution Overview
Problem
Current injection molding processes for signage, tags, and labels face issues with microorganisms being trapped between the ink or film and the sign base, leading to contamination, and small labels are easily dislodged due to insufficient static force, causing improper attachment and biological growth in moist environments, while traditional reinforcement methods are time-consuming.
Innovation Solution
The method involves injecting thermoplastic through a runner system with gate members that angle and taper to pin the indicia carrier in place, ensuring it is fused to the mold cavity during curing, eliminating air bubbles and wrinkles, and applying high pressure and temperature to achieve complete fusion and sterility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If traditional injection molding processes are used with static electric charge to hold labels, then small labels are easily dislodged due to insufficient static force, but using larger labels increases the total static force enough to hold them in position
Solution Approach 1:
The patent changes the fundamental parameter from static electric force to dynamic injection pressure. By injecting molten thermoplastic at high pressure through the runner system, the label is held firmly in position during the molding process, eliminating the insufficiency of static force for small labels.
Solution Approach 2:
The patent replaces the static electric charge mechanism with a mechanical injection system. The molten thermoplastic acts as a mechanical force that pins the label to the mold cavity during injection, providing sufficient holding force regardless of label size.
2Ease of manufacture
If the runner system provides thermoplastic nearly parallel to the label, then the process is simple, but this causes the label to be misplaced, mispositioned or completely dislodged
Solution Approach 1:
The patent introduces asymmetry in the gating technique by directing the molten thermoplastic flow at an angle to the label rather than parallel. This asymmetric flow pattern creates a pinning effect that secures the label in position, resolving the conflict between simple manufacturing and precise positioning.
3Ease of manufacture
If labels are attached in mold cavities using static electric charge, then the process is straightforward, but wrinkles and bubbles form under labels causing improper attachment
Solution Approach 1:
The patent changes the physical state parameter from static electric field to molten thermoplastic flow. The flowing molten material actively pushes out air bubbles and smooths wrinkles as it fills the cavity, ensuring proper label attachment without the defects associated with static charge methods.
4Reliability
If high pressure and temperature are applied to achieve complete fusion, then sterility and sanitation requirements are met, but energy consumption increases
Solution Approach 1:
The patent merges the labeling process with the injection molding process itself. The label is attached and fused during the same high-pressure, high-temperature injection cycle that forms the product, eliminating the need for separate sterilization steps and reducing total energy consumption.
Solution Approach 2:
The injection molding process serves multiple functions simultaneously: it forms the product, attaches the label, fuses the label to the product, and sterilizes the assembly. This multi-functionality achieves sanitation compliance without additional energy-intensive separate processes.
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 process results in a completely fused label that meets sanitation requirements, reduces manual labor, and provides a tamper-proof, safe product that prevents biological growth, while efficiently manufacturing labels with RFID capabilities.
Implementation Method 1
The gate member (20) angles and tapers to provide a flow of material (28) that pins the indicia carrier (30) in place
Implementation Method 2
The indicia carrier (30) is then fused to the thermoplastic during the curing process
Implementation Method 3
applying high pressure and temperature to achieve complete fusion and sterility
Data Source
AI summary
A method of manufacturing an injection molded product. Thermoplastic is injected through a runner system and into a gate member. The gate member is generally V-shaped and thermoplastic is displaced through the gate into a mold cavity at a nearly perpendicular angle to the surface of the indicia carrier to hold the indicia carrier against the mold cavity. This allows the indicia carrier to be fused to the thermoplastic body during the making of a product.