Thermoform Labeling via Softening Point Matching
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Solution Overview
Problem
Conventional thermoforming processes require separate labeling operations, increasing production costs and complexity, and existing in-mold labeling techniques need special equipment and controls, while pre-lamination methods do not fully address these issues.
Innovation Solution
A method involving a thermoforming apparatus and a label with a softening point close to the sheet material, allowing immediate thermoforming to integrate labeling directly into the process without pre-lamination, using a label with an adhesive underside and compatible materials to ensure the label stretches with the sheet without tearing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate labeling operations are used after thermoforming, then labeling can be performed, but production costs and process complexity increase
Solution Approach 1:
The patent combines the labeling operation with the thermoforming process by placing labels on the sheet before thermoforming. The labels are positioned on the sheet, and the entire assembly (sheet with labels) is then thermoformed in a single continuous operation, merging two previously separate processes into one integrated process that reduces complexity and cost.
2Productivity
If in-mold labeling techniques are used, then labels are incorporated during thermoforming, but special molding equipment and controls are required
Solution Approach 1:
The patent applies preliminary action by positioning the labels on the sheet before the thermoforming process begins. The labels are placed on the sheet in advance, and then the entire assembly is thermoformed without requiring special in-mold labeling equipment. This preliminary positioning allows standard thermoforming equipment to be used while still achieving integrated labeling.
3Ease of manufacture
If pre-lamination operations are used to create formable webs, then labeling is incorporated, but additional processing steps and inventory requirements increase
Solution Approach 1:
The patent extracts the labeling step from the pre-lamination process. Instead of requiring pre-lamination of labels to create formable webs, the method places labels on the sheet immediately before thermoforming and removes the need for separate pre-lamination operations. This extraction eliminates unnecessary intermediate steps and reduces inventory requirements while maintaining label incorporation capability.
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 eliminates the need for additional labeling steps, reduces production costs, and allows for labeling of complex shapes, enhancing flexibility and inventory management.
Implementation Method 1
The various materials are selected such that the material of the polymeric film has a softening point, the material of the sheet has a softening point, and the difference between the softening point of the material of the polymeric film and the softening point of the sheet is less than 10° C.
Implementation Method 2
the label stretches with the sheet without tearing
Implementation Method 3
the sheet is positioned into a mold cavity by application of vacuum to a side of the sheet
Implementation Method 4
a polymeric sheet or film is first heated to its softening point. Once the sheet or film becomes pliable
Data Source
AI summary
Processes for forming a thermoformed labeled article are described. Labels are attached to a sheet to be thermoformed or to a section thereof. Label attachment can optionally use an adhesive. If the label material is completely or partially compatible with the sheet then the use of adhesive may not be necessary. The labels may also receive various graphics or other designs, such as by printing. After appropriate placement of the label relative to the sheet, the assembly of both sheet and label is thermoformed. After thermoforming, a finished and labeled article is produced. Also described are various labels and label assemblies which are uniquely suited for use in the processes described herein.