Integrated Tagging Foil Moulding for Balanced RFID Cable Holders
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing manufacturing processes for devices with integrated wireless tags, such as RFID or optical foils, are complex and time-consuming, involving multiple steps and potential damage to the tagging foil during moulding.
Innovation Solution
A method for injection moulding a device with an integrated wireless tag using a thin tagging foil with a sandwich structure, where the foil is held in place by a supporting device and injected with thermoplastic material symmetrically through a single entrance, balancing forces and minimizing deformation, allowing for a single-shot production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple injection steps are used to mould a glass transponder into a flat device, then the manufacturing precision and reliability of the wireless tag are improved, but the manufacturing time and process complexity increase significantly
Solution Approach 1:
The mould cavity is divided into multiple cavity parts (first, second, third, fourth cavity parts) that adjoin the two main surfaces of the tagging foil. Injection material is injected simultaneously into these segmented cavity parts through a single entrance, achieving precise positioning and protection of the foil while reducing total injection time compared to sequential multi-step processes.
Solution Approach 2:
Multiple injection operations that would traditionally be performed in separate steps are merged into a single injection step. The injection material flows simultaneously into multiple cavity parts from one entrance, combining what would have been multiple injection cycles into one continuous operation, thereby reducing manufacturing time while maintaining precision.
2Device complexity
If a thin tagging foil is used to reduce device size and complexity, then the device becomes more compact and cost-effective, but the foil becomes more susceptible to damage during the moulding process
Solution Approach 1:
The tagging foil has a sandwich structure with different regions serving different functions: a tagging-relevant layer (chip and antenna) in the center and protective outer layers forming a border region around it. The injection material flows alongside the two main surfaces of the foil, providing localized protection and support to the thin foil structure during moulding, preventing damage while maintaining the thin profile.
Solution Approach 2:
The sandwich structure of the foil with protective outer layers provides beforehand cushioning for the sensitive tagging-relevant layer. The injection material flowing alongside the surfaces provides additional cushioning support during the moulding process, protecting the thin foil from damage before the device is completed.
3Speed
If asymmetric injection is used to fill the mould cavity, then the injection speed may be increased, but the tagging foil experiences unbalanced forces causing deformation and damage
Solution Approach 1:
While the overall injection process is symmetric, the entrance is positioned asymmetrically relative to the foil. The injection material flows from this single entrance alongside the two main surfaces of the foil in a controlled manner, achieving both high injection speed and balanced force distribution through the specific flow path design.
Solution Approach 2:
The injection material flowing alongside the two main surfaces of the foil creates counterbalancing forces. As the material fills the first and second cavity parts adjoined to one surface and the third and fourth cavity parts adjoined to the opposite surface, the forces exerted on the foil from both sides are balanced, preventing deformation while maintaining injection speed.
4Device complexity
If a single entrance is used for injection, then the process complexity is reduced and manufacturing is simplified, but controlling symmetric force distribution on the foil becomes more difficult
Solution Approach 1:
The injection material flows in a three-dimensional path alongside the two main surfaces of the foil, utilizing the vertical dimension between the surfaces. This allows the single entrance to deliver material to multiple cavity parts in a controlled sequence, achieving symmetric force distribution through spatial management rather than requiring multiple symmetric entrances.
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 method simplifies and speeds up the manufacturing process, reducing the risk of foil damage and enabling the production of thin, robust devices with integrated wireless tags in a single injection step, enhancing process control and efficiency.
Implementation Method 1
injecting an injection material, preferably a thermoplast, into the mould cavity parts adjoining the two main surfaces of the tagging foil
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The disclosure relates to a method for injection-moulding a device (1), in particular a cable tie, with an integrated wireless tag (2), comprising the method steps of a) Putting a tagging foil (5) with two main surfaces (9a, 9b) which are separated by an edge (10), into a mould cavity (12) of an open mould (11), where the tagging foil (5) is held in place by a supporting device (13); b) Closing the mould (11); c) Injecting an injection material (21) into the mould cavity parts (14a, 14b) adjoining the two main surfaces (9a, 9b) of the tagging foil (5) simultaneously and symmetrically with respect to a main extension plane of the tagging foil (5) which is parallel to the two main surfaces (9a, 9b) of the tagging foil (5) so as to simplify and speed up the manufacturing process of a device (1) with an integrated wireless tag or label (2). The disclosure furthermore relates to a corresponding moulding device as well as a corresponding device (1) with an integrated wireless tag (2).