Use of Electrostatics for In-Mold Label Applications

Author: Scott E. Shelton Simco Industrial Static Control Hatfield, Pennsylvania

Introduction
The use of in-mold labeling (IML) for injection molding has been around for perhaps 25 years or more but has been gaining interest and serious consideration in the production environment most recently. The advantages are obvious. Applying the label during the molding process eliminates a secondary step and, more importantly, the end result is permanent. This makes IML especially attractive for product liability and instructional information, UPC codes, logos and decoration. Significant benefits include: eliminates screen printing, label application or pad printing on product no corona or flame treating higher quality graphics rapid changing of graphics recyclable with label material same as molded product less storage space, press to final packaging less handling, cleaner, more sanitary

Holding the Label in the Die with Vacuum

The molding die can be specially designed and machined with integral vacuum ports to hold the label in the desired location. The robot picks up the label from a magazine, places it in the proper position in the die, the vacuum is turned on and the mold is shot. When developing this process using vacuum, some important aspects should be considered. In addition to material and heat compatibility, the label should be substantial enough to prevent it from being drawn into the vacuum port causing a deformed image or pimples on the surface of the finished product resulting in less than ideal cosmetics. It is important that the robot does not miss the label. Injecting the mold without a label in place can result in very time consuming and costly downtime to remove the die and clean out all of the vacuum ports and passages. Therefore, a means of detecting the vacuum and stopping injection of the polymer into the die must be devised to prevent this. The Use of vacuum passages in the molding die may also result in non-uniform die temperatures. The cost of designing and machining the die to incorporate vacuum should be considered as this can add significant cost to the tooling.

The use of vacuum may be a benefit, however, when the shape of the molded product requires complex preformed labels, or when the molded part and/or label is required to have a textured surface.

Holding the Label in the Die with Electrostatics

The use of electrostatics in the IML process can be a reliable and cost effective means of holding the label in its proper location in the die. When a static charge is placed on a label of suitable material and construction, it will electrostatically attract and adhere to the grounded metal surface of the die and may stick with excellent adhesion for up to several minutes. The need for vacuum hold-down in the die is eliminated. Although some have attempted to manually charge the label and manually place it in the die, experience has shown this to be labor intensive, unreliable and slows down the press cycling time. Using electrostatics to its full advantage requires the following components: robot with suitably designed end-of-arm tool label magazine high voltage dc charging power supply with 30kV adjustable output capability charging applicator/s label of proper material and construction to accept and maintain a static charge In this process, the robot picks up the label from the magazine with suction. Depending upon the layout of the charging apparatus, as the end-of-arm tool with the label approaches the press or as the label approaches the die surface, a high static charge is placed on the label. The robot places the label in the desired position, releases the vacuum and the label is transferred to the surface of the die. No vacuum in the die or adhesive on the label is needed.

Methods for Applying the Charge

Conventional Method, Charging Applicator on End-of-Arm Tool This method offers a high degree of reliability and repeatability but presents somewhat of a challenge for the designer of the end-of-arm-tooling. The charging applicator/s is designed into the end-of-arm fixture and becomes an integral part. The applicator may be a straight static charging bar of some specified length having a row of emitter pins or it may be a series of individual emitter modules. The style and number of applicators required depends upon the size and shape of the label and contours of the die surface where the label is to be placed; therefore, each end-of-arm fixture may require its own unique charging applicator setup. When the label is being held by the suction cups on the end-of-arm tool, the charging applicators are located directly behind the label (see Figure 1). The emitter pins are typically about one inch from and facing the back of the label. When the robot places the label against the die surface, the charging power supply is fired

Label

Non-Conductive Support Fixture on End-of-Arm Tool Vacuum

Molding Die

Charging Applicator

High Voltage Charging Power Supply (DC) Vacuum

Electric Field "Power Supply "ON"

Figure 1. Conventional method, charging applicator on end-of-arm tool.

on for a period of approximately 2 to 4 seconds. This places a static charge on the label and the label instantly adheres electrostatically to the grounded metal die. The vacuum is turned off and the robot extracts the end-of-arm tool from the press ready for the next cycle. When designing the end-of-arm tool to incorporate the charging applicator, a few guidelines should be considered to assure optimum performance of the label charging process. If the emitters are to be placed 1 inch behind the label, for example, any metal parts of the end-of-arm tool should be grounded and at least 1 inches from the emitters. Metal any closer than this will attract some of the field from the charging applicator, resulting in less charge on the label. If individual emitters are to be mounted into a plate also housing the vacuum suckers, the plate must be made of a nonconductive material such as polyethylene, Teflon, PVC, UHMW, or acrylic. Any component on the end-of-arm tool in proximity of the charging applicator that can be made of a nonconductive material without sacrificing strength and structural integrity is a benefit. Any component that is electrically conductive (metal) must be grounded. When selecting the type of charging applicator, there are two types to consider: current limited and non-current limited. The current limited types are available in the straight static bar style or individual emitter modules and contain a resistor which is in series with the high voltage supply. The advantage is that this applicator will not hard arc if it gets too close to metal and offers a high degree of safety if personnel should accidentally touch it while energized. A non-current limited applicator will arc to metal such as the die if it gets too close or the charging voltage is set too high. This can eventually lead to resurfacing of the die due to pitting caused by the arcing. Some of the newer technology

power supplies contain arc sensing protection circuitry that cuts off or holds back the output voltage when an arc condition exists in an effort to protect itself against overload. The arc-resistant current limited applicator prevents the power supply from going into this mode while maintaining uninterrupted maximum capable charging efficiency for the conditions. The high voltage cable from the charging applicators to the power supply must be supported along the robot arm with sufficient slack to allow for the required movement and with the least physical stress possible. These cables should be inspected on a weekly basis and replaced if fracture, abrasion or weakness of the cable is detected. Simplified Method, Remote Mounted Charging Applicator This is the easiest method requiring little modification of the end-of-arm tooling and is relatively easy to set up and can satisfy the requirements of many different sizes and shapes of labels with the same charging applicator. This means of charging will work for most film labels for relatively flat surfaces. A charging applicator bar is mounted on a permanent fixture between the molding press and the label magazine. The charging power supply can be turned on manually and left on during the duration of the work in progress, or it can be turned on and off remotely by the robots PLC. The fixture on the end-of-arm tool requires a grounded conductor such as a metal plate. The conductive surface should be at least as large as the label and mounted to inch directly behind the label. The suction cups used should be as small in diameter as possible while providing as much holding power as necessary to prevent the label from slipping in the suction cups and attracting to the grounded conductive surface of the fixture. All conductive components of the robot fixture must be grounded and all should have radiused edges and corners and no sharp edges or corners should be within 1 inch of the label. In this charging process, the robot picks up the label at the magazine, orients the label and passes it by the charging bar. The ground reference surface behind the label attracts the electric field from the charging bar and the label becomes charged. The robot places the label in position against the surface of the molding die, releases the vacuum to the suction cups and the label stays in place on the surface of the die. In some cases the label may not readily release from the suction cups and may slightly skew due to mutual electrostatic attraction due to static charges building on the surfaces of the suction cups. In this case, a static neutralizing bar can be mounted in the robots path between the charging bar and the label magazine. Each time the robot returns to pick up a new label, the suction cups will be neutralized. Smaller diameter suction cups will decrease the charged surface area, which may also help minimize the problem. Another version of this simplified method provides even better physical support and uniform transfer of the label from the end-of-arm fixture to the die. This process

functions the same as described above but requires the addition of a piece of antistatic foam mat material bonded to the metal ground reference plate on the end-of-arm tool. This material should ideally have a thickness of approximately 3/8 and should have an electrical surface and volume resistivity of approximately 109 to 1010 ohms. (This type of material is available from most static control distributors who service the electronics circuit board assembly industry). Most of this material is manufactured with an embossed textured surface and may require sanding to achieve a uniform smooth surface. Sanding of the surface also enhances charging of the label. The suction cups are incorporated into the foam material and should be flush with the surface. See Figure 2. With this method, since the foam pad has a high electrical resistance compared to the grounded metal mold surface, the charged label has a greater affinity to the mold and transfers from the foam pad to the mold when the vacuum is switched off. Figure 3 is an example of how this may be accomplished for 360 labels on round containers. Refer also to Figures 4A through 4D.

Neutralizing Power Supply (AC)

Robot Tool

Tool with Charged Label

Mold

Vacuum Anti-Static Foam Label Air Nozzle for Easy Label Separation Charging Applicator

Label Magazine

High Voltage Charging Power Supply (DC)

Figure 2. Simplified Electrostatic I.M.L. for Flat Containers

Label Properties
The physical and electrical characteristics of the label are extremely important to the success and reliability of using static charges to adhere the label to the mold. The surface of the label that is to contact the mold cavity must be a good insulator to accept and maintain the static charge. Ideally, this surface should have a surface resistivity of 1012 ohms/square or greater. The higher this value, the better the label will

accept and maintain the charge without bleeding the charge to ground when it contacts the metal mold cavity. If the charge is not maintained when in contact with the die, adhesion is lost and the label will slip from its intended position. This measurement can be performed using a commercially available surface resistivity meter.
High Voltage Charging Power Supply (DC)

Neutralizing Power Supply

Charging Applicator Label

Vacuum Suction Cups Mandrel on End-of-Arm Tool

Air Nozzle for Easy Label Separation

Label Magazine Anti-Static Foam

Figure 3. Simplified Electrostatic IML for Round Containers

Male Mold

Female Mold

Charging Bar Grounded Anti-Static Foam High Voltage Charging Power Supply Vacuum On Label Mandrel on Robot End-of-Arm

Label Magazine Figure 4a. Mandrel with suction cups in antistatic foam rotates to pick up label from magazine while high voltge charging applicator applies static charge to label.

Male Mold

Female Mold

Figure 4b. Mandrel with charged label inserted into mold cavity

Figure 4c. Vacuum in mandrel is switched off, label transfers to mold cavity and mandrel is retracted from press for next cycle

If conductive inks, coatings or foil laminations are used, these must be on the back side of the label, opposite the surface that is to contact the mold. In this case, the best method for charging the label is with the charging applicator external to the press and the conductive surface of the label against the vacuum ports on the end-of-arm tool. If the

charging applicator is mounted on the end-of-arm tool behind this label, the high voltage field cannot penetrate the conductive layer and sufficient charge will not result on the surface that is to contact the mold cavity. As a word of caution, a charged foil or conductive layer will most likely discharge in the form of an arc as it approaches the mold surface. A result of this arcing is RFI (Radio Frequency Interference) which may cause problems with microprocessor controls, especially if unshielded sensors or cables are nearby. Ongoing arcing over a long period of time may also result in pitting of the die cavity.

Figure 4d. Mold clamps and is shot with label in place.

Physical properties such as label thickness, curl and surface texture are also variables affecting adhesion. A label of substantial thickness that may have some curl due to lamination or storage and is to adhere to a flat surface, may break lose from the die surface as the electrostatic forces may not be able to overcome the physical forces of the label. Likewise, preformed labels may be required for compatibility with contoured die surfaces. A textured label or a textured die surface can also result in poor adhesion due to the reduction in intimate surface contact between the label and die surface. Ultimately, a relatively thin non-textured label with high dielectric properties on a non-textured die surface will produce the best adhesion. Obviously, other label properties such as molding temperature and polymer compatibility are critical as well as gate location and material flow when the die is injected. When developing labels for IML much time and frustration can be eliminated by consulting a label supplier with IML experience.

Conclusion
Using static charges to adhere the label to the mold cavity during the IML process can provide distinct benefits to the molder as well as the molders customer and the end user. Applying the label during molding can streamline and simplify the production process by eliminating secondary steps and related machinery such as corona or flame treating, screen printing, pad printing and label application. The end result is a label or decoration that is homogeneous with the product affording permanence and wear resistance while maintaining the aesthetics of the graphics for the life of the product.