IML Process: Electrostatic Adsorption Method
With the improvement of automation in injection molding equipment, in-mold labeling (IML) technology is becoming popular both domestically and internationally. IML products are widely favored by the industry for their advantages such as high clarity, good three-dimensional effect, scratch-resistant surface, enhanced packaging container aesthetics, improved economic benefits, environmental friendliness, and enhanced anti-counterfeiting. The following mainly introduces the key points of electrostatic adsorption in injection molding IML.
For injection molding in-mold labeling, an automated robotic arm attaches the label to the inner wall of the mold. After mold closing and injection filling, the high temperature of the resin melts the hot-melt adhesive resin on the back of the in-mold label, thereby fusing the label and container into one body.
If the synthetic label carries static electricity, it can be adsorbed on the inside of the mold, thereby combining the label and the molded part together. For low-static-electricity applications, the label can be manually charged. For automated systems, there are two methods to charge the label.
Method 1
Directly Pick Up Label and Place in Mold
1) The vacuum suction cup on the robotic arm picks up the label;
2) The label is transferred into the mold cavity, and after touching the contact surface, the suction cup blows back;
3) At the same time, the electrostatic generator generates static electricity, which charges the charging plate, IML foam pad, and label for a short time through the electrostatic discharge head;
4) The robotic arm withdraws, and the label is adsorbed inside the mold cavity.
Some robotic arm suction cup grippers are conical or cylindrical rather than flat, which facilitates placing labels into mold cavities such as cup-shaped molds.
1) Use an air nozzle to blow the label to the edge of the gripper, where it is adsorbed on the gripper through vacuum suction;
2) The label is transferred into the mold, and after touching the contact surface, the suction cup blows back;
3) At the same time, charge the charging plate, IML foam pad, and label for a short time;
4) The robotic arm withdraws, and the label is adsorbed inside the mold.
Method 2
Blow Label into Mold
Use the electrostatic discharge head to charge the label, and the charged label is attached inside the mold by air force.
1) The robotic arm uses vacuum suction to pick up the label;
2) The suction cup blows air to send the label while the electrostatic discharge head charges the label;
3) The mold is grounded, and the robotic arm should not come into contact with the mold.
For some cup-shaped or similar mold labeling, the label needs to be attached to a press-in male mold (core), rather than inside the mold cavity as in Method 1.
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