Transfer Head Manufacturing via Extruded Profiles and Polymer Coating

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Solution Overview

Problem

Current manufacturing processes for transfer heads in container labeling machines are costly, time-consuming, and prone to defects, requiring multiple molds and lengthy production times, and often result in mechanically weak and heavy components with limited flexibility in format and size.

Innovation Solution

A process involving the extrusion of rigid profiles that are coupled to form a tubular body, which is then rubberized with a polymer layer, allowing for the creation of a mechanically strong, lightweight transfer head with various formats and sizes, reducing the need for multiple molds and simplifying production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If multiple molds are used for manufacturing transfer heads, then manufacturing precision can be improved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improvetransfer head manufacturing precisionVSAvoidnumber of molds

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The transfer head is divided into two functional segments: a rigid body portion providing structural support and a polymer covering portion providing adhesive pickup functionality. This segmentation allows each part to be manufactured separately using simple molds and then assembled, reducing the need for complex multi-cavity molds while maintaining manufacturing precision.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The rigid body and polymer covering are combined into a single integrated transfer head component through assembly. This merging of separately manufactured parts achieves the functional requirements of a complex component without requiring complex molding processes, thereby reducing device complexity while maintaining precision.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If traditional casting and rubberizing processes are used, then transfer heads can be manufactured, but production time increases

Engineering Contradiction:

Improvetransfer head functionalityVSAvoidproduction time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The rigid body is pre-manufactured with extrusion profiles that are designed to receive the polymer covering. This preliminary preparation of the rigid body with integrated mounting features allows for rapid assembly of the polymer covering, significantly reducing production time compared to traditional multi-step casting and rubberizing processes.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If traditional manufacturing processes are used, then transfer heads can be produced, but manufacturing cost increases

Engineering Contradiction:

Improvetransfer head performanceVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The polymer covering is designed as a replaceable component that can be manufactured using simple, low-cost molding processes. When worn or damaged, only the polymer covering needs to be replaced rather than the entire transfer head, reducing both initial manufacturing cost and long-term operational costs.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Strength

If transfer heads are made with heavy materials for strength, then mechanical strength is improved, but weight increases

Engineering Contradiction:

Improvetransfer head strengthVSAvoidtransfer head weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The transfer head uses a composite structure combining a rigid body material (providing structural strength and durability) with a polymer covering material (providing adhesive pickup properties). This composite approach achieves the required mechanical strength while keeping the overall weight lower than a fully metal construction would provide.

Inventive Principle:

Principle #40Composite materials

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 simplifies and cost-reduces the production of transfer heads, eliminates defects, and enables the creation of strong, lightweight components adaptable to different formats, enhancing manufacturing efficiency and reducing economic investment.

Implementation Method 1

comprises a step of extruding at least two rigid profiles (37) obtained by means of an extrusion process

Methodology Applied

Scientific EffectExtrusion: Extrusion

Implementation Method 2

comprises a step of rubberizing the tubular body (46), in which at least one layer of polymer material (48) is fixed on the outer surface (47) of the tubular body (46)

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentEP2868399B1Process for manufacturing a transfer head for a container labeling machine

Publication Date: 2016.06.08 CRM ENG

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Figure 3a~3b

AI summary

Process for manufacturing a transfer head (1) for a container labeling machine, which comprises the following operating steps: a step of manufacturing two rigid profiles (37) by means of an extrusion process; a step of coupling the two rigid profiles (37) in a manner such to form a tubular body (46); a step of rubberizing the tubular body (46) in order to cover it with a layer of polymer material (48); a step of processing, wherein each rigid profile (37) and the layer of polymer material (48) are shaped, by means of removal, with a specific form corresponding to the format of the labels (7) to be applied to the containers (3).