Injection Molded Nameplate with Resilient Yokes
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Solution Overview
Problem
The existing methods for producing name badges, such as those disclosed in DE 89 01 912 U and DE 199 12 788 C2, require lengthy heating and cooling processes, making them costly and inefficient, especially when trying to incorporate a cardboard insert and ensure a secure fit.
Innovation Solution
The name tag is designed as an injection molded part with specific features like an injection point between the front and back parts, a yield point on the back part, and strategically placed grooves and recesses to facilitate injection molding, allowing for the use of multiple molds and leveraging the shrinkage behavior of plastic to create a spring effect for secure fitting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional heating and bending processes are used to form yokes, then the name tag can be produced with the required shape, but the production time and cost increase significantly
Solution Approach 1:
The patent changes the fundamental manufacturing parameter from thermal processing (heating and bending) to injection molding. This allows the yokes to be formed directly during the injection molding process, eliminating the need for separate heating and bending operations. The injection molding process forms the yokes by injecting molten plastic into a mold cavity that defines the final shape, including the resilient connection between front and back parts.
Solution Approach 2:
The patent replaces the mechanical thermal processing system (heating equipment, bending tools) with an injection molding system. The injection molding machine directly forms the complete name tag structure including yokes in a single operation, substituting multiple sequential mechanical processes with a single integrated injection molding process.
2Manufacturing precision
If traditional multi-step forming processes are used, then the name tag structure can be achieved, but the manufacturing cost increases
Solution Approach 1:
The patent merges multiple separate forming operations (front part formation, back part formation, yoke formation, and embossing) into a single injection molding process. The mold cavity is designed to form all these features simultaneously in one operation, eliminating the need for separate stamping, heating, bending, and embossing processes that would otherwise be required.
Solution Approach 2:
The injection molding process serves multiple functions simultaneously: it forms the front and back parts, creates the resilient yokes for attachment, produces the cardboard insert retention feature, and embosses the manufacturer's note. This multi-functionality in a single process step dramatically reduces manufacturing complexity and cost compared to traditional sequential operations.
3Reliability
If the name tag is designed with a holding web for cardboard insert, then the insert can be securely retained, but the shape becomes complex and difficult to mold
Solution Approach 1:
The patent incorporates the holding web feature directly into the injection molding process. The mold cavity is designed with the holding web geometry pre-defined, so the feature is formed during the initial injection molding operation rather than requiring subsequent assembly or attachment steps. This preliminary formation ensures the holding web is integrated into the name tag structure from the beginning.
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 significantly reduces production costs by replacing traditional forming processes with injection molding, enabling secure fits for both the label and the cardboard insert while maintaining a clean appearance and functionality.
Implementation Method 1
skillfully utilizing the shrinkage behavior of the injected plastic part, which enables the realization of a spring effect emanating from the yokes both between the front and the back part
Implementation Method 2
with a cooling line in the lower part for influencing the shrinkage process around two molds for each runs a clip
Data Source
Figure 1~4
Figure 5~7
Figure 8~9
AI summary
A nameplate, made from transparent plastic and having a front part (1) and a rear part (2) which is connected resiliently to the former via a first yoke (3) and having at least one holding web (5) for a paperboard insert, which holding web (5) protrudes into the intermediate space between the front part (1) and the rear part (2), does not comprise a formed blank but rather an injection moulded part, in a deviation from previous practice.