Universal In-Mold Labeling Turntable for Rotary Blow Molding

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Solution Overview

Problem

Conventional rotary blow-molding machines face limitations in production rate due to reciprocating mold concepts, and in-mold labeling systems experience issues with label placement accuracy, efficiency, and reliability, leading to increased scrap and downtime.

Innovation Solution

A universal in-mold labeling (UIML) system that integrates a rotary blow-molding machine with a UIML apparatus featuring a turntable, air rotary unions, suction cups, a Z-axis vertical slide, and a control system for precise label placement and improved operational efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If reciprocating mold concept is used in rotary blow-molding machines, then production rate is limited, but machine complexity is reduced

Engineering Contradiction:

Improveproduction rateVSAvoidmold positioning mechanism complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent replaces the traditional mechanical reciprocating mold positioning system with a rotary indexing mechanism that uses a rotating carousel to position molds at different stations. This substitution enables continuous operation and higher production rates while simplifying the control system through automated indexing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The rotary blow-molding machine implements continuous production by maintaining molds in constant rotation through multiple stations (extrusion, labeling, blowing, ejection). This eliminates the idle time associated with reciprocating systems and ensures that useful action continues without interruption across all mold stations simultaneously.

Inventive Principle:

Principle #20Continuity of useful action

2Manufacturing precision

If conventional in-mold labeling systems are used, then label placement accuracy is insufficient, but system complexity is reduced

Engineering Contradiction:

Improvelabel placement accuracyVSAvoidlabeling system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces conventional mechanical label application mechanisms with a vacuum-based labeling system. Suction cups create vacuum zones that precisely hold labels in position during the blowing process, achieving high placement accuracy without complex mechanical positioning mechanisms.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a vacuum field as an intermediary between the labeling system and the mold cavity. The vacuum field acts as a mediator to precisely position and hold labels against the parison surface, enabling accurate label placement while simplifying the overall system architecture.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If conventional labeling systems are used, then efficiency and reliability are reduced leading to increased scrap, but maintenance time is decreased

Engineering Contradiction:

Improvelabeling efficiencyVSAvoidmaintenance time

Core Design Contradiction:

ProductivityVSEase of repair

Solution Approach 1:

The patent replaces mechanical label transfer and positioning mechanisms with a vacuum-based system that uses suction cups and vacuum zones. This substitution eliminates complex mechanical linkages, reducing maintenance requirements while improving labeling efficiency and reliability through more consistent label placement.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The vacuum labeling system automatically positions and secures labels during the continuous rotary process without requiring manual intervention or complex mechanical adjustments. The system self-regulates through vacuum pressure control, improving efficiency while reducing maintenance needs compared to mechanical systems requiring periodic adjustment and repair.

Inventive Principle:

Principle #25Self-service

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

The UIML system enhances label placement accuracy, reduces scrap, and decreases setup and maintenance time, enabling higher production rates and improved control over the labeling process.

Implementation Method 1

Each turntable has an air rotary union, facilitating rotation of the respective turntable

Methodology Applied

Scientific EffectRotary union:

Implementation Method 2

a plurality of suction cups adapted to pick, hold, and release labels

Methodology Applied

Scientific EffectVacuum: Vacuum

Data Source

PatentUS10350813B2Universal in-mold labeling apparatus and system incorporating the apparatus

Publication Date: 2019.07.16 GRAHAM PACKAGING CO LP

AI summary

A system combining a machine for blow-molding articles with a universal in-mold labeling apparatus. The apparatus has a frame on which turntables are mounted. Each turntable has an air rotary union, facilitating rotation of the respective turntable, and suction cups adapted to pick, hold, and release labels. The turntables deliver labels to the open molds of the machine. The apparatus also has a vertical slide positioned between the turntables. A placement head engages the turntables and moves up the vertical slide to a position in the open molds. At least one label magazine is affixed to the frame and retains the labels. Strategically placed air valves provide air and vacuum to pick, hold, and release labels. A human machine interface facilitates communication between an operator of the system and the system. Finally, a control system is provided to allow the operator to program and control both the machine and apparatus.