The present disclosure relates to a method for manufacturing an injection-moulded article with an in-mold label. The present disclosure further relates to an injection-moulded article with an in-mold label.

Injection-moulded articles are well-known. In the packaging industry, it is known to provide hollow injection-moulded articles for placing consumables inside. These articles often comprise a base and an openable cover to allow access to consumables stored within. Suitable consumables may be, for example, pastilles or nicotine pouches. For example, the injection-moulded article may be a hollow can having a removable cover portion such as a hinged lid.

Due to the injection-moulding process, there is typically a material irregularity or protrusion on the surface of the injection-moulded article at the position which had been in contact with an injection-hole of the mold during the injection-moulding process. Such material irregularities or protrusions stemming from the injection-moulding process are known as injection point marks. Such injection point marks may be visually unpleasant. Such injection point marks may be haptically irritating.

It is known to apply one or more labels onto surfaces of injection-moulded articles. Such labels may provide a surface area to share information printed thereon.

For example, a top label may be provided for marketing purposes. A bottom label may be provided for providing information on ingredients of a consumable stored within the article. Also, side labels including, for example, health information, branding information, or a tax stamp are known.

The labels may be attached with an adhesive on an outside surface of the article after the injection-moulded article has been filled with consumables and closed.

It would be desirable to provide an injection-moulded article with an enlarged label surface area to allow sharing more information. It would be desirable to provide an article which allows to present information only at certain stages of a user experience.

It would be desirable to provide an injection-moulded article with reduced or avoided visibility of injection point marks from the injection-moulding process. It would be desirable to provide an injection-moulded article with increased perceived quality of the resulting injected part.

It would be desirable to provide an injection-moulded article with a base and a hinged-lid with a durable hinge. It would be desirable to provide an injection-moulded article with a base and a hinged-lid with a space-saving hinge. It would be desirable to provide an injection-moulded article with a base and a hinged-lid with a flexible hinge. It would be desirable to provide an injection-moulded article with a base and a hinged-lid which may be economically manufactured.

According to an embodiment of the invention there is provided a method for manufacturing an injection-moulded article with an in-mold label. The method may comprise providing a first mold comprising a surface with an injection hole. The method may comprise providing an in-mold label comprising a through-hole. The method may comprise applying the in-mold label onto the surface of the first mold such that the through-hole of the in-mold label is aligned with the injection hole of the first mold. The method may comprise providing a second mold in proximity to the first mold such that at least a portion of the in-mold label is arranged between the first mold and the second mold. The method may comprise injecting a molten material through the injection hole of the first mold and through the through-hole of the in-mold label into an empty space between the first mold and the second mold.

According to an embodiment of the invention there is provided a method for manufacturing an injection-moulded article with an in-mold label. The method comprises providing a first mold comprising a surface with an injection hole. The method comprises providing an in-mold label comprising a through-hole. The method comprises applying the inmold label onto the surface of the first mold such that the through-hole of the in-mold label is aligned with the injection hole of the first mold. The method comprises providing a second mold in proximity to the first mold such that at least a portion of the in-mold label is arranged between the first mold and the second mold. The method comprises injecting a molten material through the injection hole of the first mold and through the through-hole of the inmold label into an empty space between the first mold and the second mold. The method steps may be conducted consecutively in accordance to the sequence of mentioning above.

The method may provide an injection-moulded article with reduced or avoided visibility of injection point marks from the injection-moulding process. The method may provide an injection-moulded article with increased perceived quality of the resulting injected part.

By the in-mold label, the method may provide an injection-moulded article with an enlarged label surface area to allow sharing more information. The method may provide an article which allows to present information only at certain stages of a user experience.

The molten material may be a molten plastic material. The molten plastic material may comprise one or more of a thermoplastic polymer and a thermosetting polymer. The molten plastic material may comprise one or more of polypropylene (PP), polyethylene (PE), polyethylene terephthalate (PET), glycol-modified polyethylene terephthalate (PETG), polyvinyl chloride (PVC), polycarbonate PC, and polystyrene (PS). The step of applying the in-mold label onto the surface of the first mold may comprise attaching the in-mold label to the surface of the first mold via one or both of vacuum and glue. The step of applying the in-mold label onto the surface of the first mold may comprise attaching the in-mold label to the surface of the first mold via vacuum. The first mold may comprise one or more vacuum channels to attach the in-mold label onto the surface of the first mold via vacuum.

The surface of the first mold comprising the injection hole and, optionally the one or more vacuum channels, may be a planar surface. The surface of the first mold comprising the injection hole and, optionally the one or more vacuum channels, may be a curved surface.

The in-mold label may be provided on an inner surface, or inside surface, of the injection-moulded article. An article which allows to present information only at certain stages of a user experience may be provided.

As used herein, the terms “inner surface” and “inside surface” are used synonymously and relate to a surface pointing towards an interior of the article. When referring to an openable portion of the article, the terms “inner surface” and “inside surface” refer to a closed configuration.

The injection-moulded article may be used for holding any suitable commodity, for example conventional snus, nicotine-free pouches, and nicotine pouches. As used herein, the term “nicotine pouches” refers to nicotine-containing, tobacco-free or substantially tobacco-free oral pre-portioned products that contain nicotine and typically flavorings and other ingredients, but which do not contain substantial amounts of tobacco. Nicotine pouches are exclusively intended for oral use not involving a combustion process, and for uptake of the nicotine via the oral mucosa.

The injection-moulded article may be a container for storing one or more consumables. The container may be a plastic can. The container may have one or both of openable top cover and an openable bottom cover. One or both of the openable top cover and the openable bottom cover may be reclosable. The reclosable cover may comprise a screw-cap. The reclosable cover may comprise a hinged lid.

The consumables may be pastilles. The consumables may be pouches. The consumables may comprise nicotine. The consumables may be tobacco-free. The consumables may be nicotine pouches.

The container may have a generally cylindrical shape with a diameter of between 5 millimeters and 250 millimeters, preferably between 60 millimeters and 70 millimeters. The in-mold label may comprise a generally cylindrical portion with a diameter which may be about 5 millimeters smaller than the container diameter. The in-mold label may be located at an inside base surface of the container. Thereby, the label may become successively visible on successive depletion of the consumables. For example, a disposal information may become visual at the base of the container after depletion of the consumables. An article is provided which may allow to present information only at certain stages of a user experience.

The in-mold label may be located at an inside surface of a lid portion of the container. An article is provided which may allow to present information only after opening of the container. For example, a lottery ticket bar code may be printed onto the in-mold label.

The method may further comprise a step of placing the one or more consumables into the container and, optionally, closing the container filled with one or more consumables.

The in-mold label may comprise a generally circular part. A diameter of the generally circular part may be between 45 millimeters and 75 millimeters, preferably between 55 millimeters and 65 millimeters.

The in-mold label may comprise a first end portion comprising the through-hole, an intermediate portion, and a second end portion. The second mold may be provided in proximity to the first mold such that the first end portion of the in-mold label is arranged between the first mold and the second mold. The method may further comprise steps of, providing a third mold comprising an injection hole, providing a fourth mold in proximity to the third mold such that the second end portion of the in-mold label is arranged between the third mold and the fourth mold, and injecting a molten material through the injection hole of the third mold into an empty space between the third mold and the fourth mold.

The intermediate portion of the in-mold label may serve as a flexible link connecting two moulded parts of the injection-moulded article. The flexible link may be a hinge of a hinged lid of the injection-moulded article.

An injection-moulded article with a base and a hinged-lid with a durable hinge may be provided. An injection-moulded article with a base and a hinged-lid with a space-saving hinge may be provided. An injection-moulded article with a base and a hinged-lid with a flexible hinge may be provided. A method for economically manufacturing an injection-moulded article with a base and a hinged-lid may be provided.

The container may have a first storage portion accessible via an openable top cover and a second storage portion accessible via an openable bottom cover. One or both of the openable top cover and the openable bottom cover may comprise a hinged-lid. Both the hinge of the hinged lid of the openable top cover and the hinge of the hinged lid of the openable bottom cover may be formed from one single in-mold label. The in-mold label may comprise a first end portion, a first intermediate portion, a center portion, a second intermediate portion, and a second end portion. The first intermediate portion may form the hinge of the hinged lid of the openable top cover. The second intermediate portion may form the hinge of the hinged lid of the openable bottom cover. The first end portion, the center portion, and the second end portion of the in-mold label may be included in moulded parts of the article.

The in-mold label may comprise one or more of polypropylene, polyethylene, and plastic based laminates.

The intermediate portion of the in-mold label may be additionally treated. The intermediate portion of the in-mold label may be coated. The treating or coating may improve the wear resistivity of the intermediate portion. The coating may comprise one or more of acrylonitrile butadiene styrene (ABS), polyethylene (PE), and polypropylene (PP). The treated or coated intermediate portion of the in-mold label may serve as a hinge in the finished article. By the treating or coating of the intermediate portion, a hinge with improved resistivity against wear due to multiple opening and closing of the hinged lid may be provided.

According to an embodiment of the invention there is provided an injection-moulded article obtainable by the method as described herein.

According to an embodiment of the invention there is provided an injection-moulded article, comprising an in-mold label. The in-mold label comprises a through-hole. The article comprises an injection point mark provided at a surface of a wall of the injection-moulded article. The through-hole of the in-mold label is aligned with the injection point mark. The inmold label may circumscribe the injection point mark.

The injection point mark of the article may be at least partially masked by the in-mold label. Thereby, the visibility of the injection point mark may be reduced. Thereby, the tactility of the injection point mark may be reduced.

The injection point mark may be optically included into a graphic printed on the inmold label. A thickness of the in-mold label may be equal to or greater than a height of a protrusion of the injection point mark.

According to an embodiment of the invention there is provided a method for manufacturing an injection-moulded article with an in-mold label comprising steps of, providing a first mold comprising a surface with an injection hole and one or more vacuum channels; providing an in-mold label; applying the in-mold label onto the surface of the first mold such that the in-mold label covers the one or more vacuum channels; attaching the in-mold label onto the surface of the first mold by applying vacuum to the one or more vacuum channels; providing a second mold in proximity to the first mold such that at least a portion of the in-mold label is arranged between the first mold and the second mold; and injecting a molten material through the injection hole of the first mold into an empty space between the first mold and the second mold.

By having a surface of the first mold comprising both the injection hole and the one or more vacuum channels, the in-mold label may be positioned adjacent to the injection hole on the same surface which also comprises the injection hole. Thereby, it may be avoided that the molten material is injected directly against a surface that comprises the in-mold label. Slipping or misaligning of the in-mold label during the injection process may advantageously be reduced or avoided.

Below, there is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

Example E1 : A method for manufacturing an injection-moulded article with an inmold label comprising steps of, providing a first mold comprising a surface with an injection hole; providing an in-mold label comprising a through-hole; applying the in-mold label onto the surface of the first mold such that the through-hole of the in-mold label is aligned with the injection hole of the first mold; providing a second mold in proximity to the first mold such that at least a portion of the in-mold label is arranged between the first mold and the second mold; and injecting a molten material through the injection hole of the first mold and through the through-hole of the in-mold label into an empty space between the first mold and the second mold.

Example E2: The method according to Example E1, wherein the molten material is a molten plastic material, preferably wherein the molten plastic material comprises one or more of a thermoplastic polymer and a thermosetting polymer.

Example E3: The method according to Example E2, wherein the plastic material comprises one or more of PP, PE, PET, PETG, PVC, PC, and PS.

Example E4: The method according to any of the preceding examples, wherein the step of applying the in-mold label onto the surface of the first mold comprises attaching the in-mold label to the surface of the first mold via one or both of vacuum and glue.

Example E5: The method according to Example E4, wherein the first mold comprises one or more vacuum channels to attach the in-mold label onto the surface of the first mold via vacuum. Example E6: The method according to any of the preceding examples, wherein the in-mold label is provided on an inner surface of the injection-moulded article.

Example E7: The method according to any of the preceding examples, wherein the injection-moulded article is a container for storing one or more consumables, preferably wherein the container is a plastic can.

Example E8: The method according to Example E7, wherein the consumables are pastilles or pouches.

Example E9: The method according to Example E7 or Example E8, wherein the consumables comprise nicotine.

Example E10: The method according to any of Examples E7 to E9, wherein the consumables are tobacco-free.

Example E11: The method according to any of Examples E7 to E10, wherein the container has a generally cylindrical shape with a diameter of between 5 millimeters and 250 millimeters, preferably between 60 millimeters and 70 millimeters.

Example E12: The method according to any of Examples E7 to E11, wherein the inmold label is located at an inside base surface of the container.

Example E13: The method according to any of Examples E7 to E12, wherein the inmold label is located at an inside surface of a lid portion of the container.

Example E14: The method according to any of Examples E7 to E13, wherein the container has a first storage portion accessible via an openable top cover and a second storage portion accessible via an openable bottom cover, preferably, wherein one or both of the openable top and bottom covers comprises a hinged-lid.

Example E15: The method according to any of Examples E7 to E14, wherein the method further comprises a step of placing the one or more consumables into the container.

Example E16: The method according to any of the preceding examples, wherein the in-mold label comprises a generally circular part, and wherein a diameter of the circular part is between 45 millimeters and 75 millimeters, preferably between 55 millimeters and 65 millimeters.

Example E17: The method according to any of the preceding examples, wherein the in-mold label comprises a first end portion comprising the through-hole, an intermediate portion, and a second end portion, wherein the second mold is provided in proximity to the first mold such that the first end portion of the in-mold label is arranged between the first mold and the second mold, and wherein the method further comprises steps of, providing a third mold comprising an injection hole; providing a fourth mold in proximity to the third mold such that the second end portion of the in-mold label is arranged between the third mold and the fourth mold; and injecting a molten material through the injection hole of the third mold into an empty space between the third mold and the fourth mold.

Example E18: The method according to Example E17, wherein the intermediate portion of the in-mold label serves as a one or both of a flexible link and a hinge of a hinged lid of the injection-moulded article.

Example E19: The method according to any of the preceding examples, wherein the in-mold label comprises one or more of polypropylene, polyethylene, and plastic based laminates.

Example E20: An injection-moulded article obtainable by the method according to any of the preceding examples.

Example E21: An injection-moulded article, comprising an in-mold label comprising a through-hole; and an injection point mark provided at a surface of a wall of the injection-moulded article, wherein the through-hole of the in-mold label is aligned with the injection point mark.

Example E22: The injection-moulded article according to Example E20 or Example E21 , wherein an injection point mark of the article is at least partially masked by the in-mold label.

Example E23: The injection-moulded article according to Example E22, wherein the injection point mark is optically included into a graphic printed on the in-mold label.

Example E24: The injection-moulded article according to any of Examples E20 to E23, wherein a thickness of the in-mold label is equal to or greater than a height of a protrusion of the injection point mark.

Features described in relation to one embodiment may equally be applied to other embodiments of the invention.

The invention will be further described, by way of example only, with reference to the accompanying drawings in which:

Figs. 1a to 1c show steps of a method for manufacturing an injection-moulded article with an in-mold label;

Figs. 2a to 2c show steps of a method for manufacturing an injection-moulded article with an in-mold label;

Fig. 3 shows a surface of an article with an in-mold label;

Figs. 4a to 4c show a method for manufacturing an injection-moulded article with an in-mold label; and Fig. 5 shows an article with an in-mold label.

Fig. 1 and 2 show a method for manufacturing an injection-moulded article with an inmold label.

Fig. 1a shows a first mold 10 in cross-sectional view. The first mold 10 comprises a surface 12 with an injection hole 14. The injection hole 14 is in fluid communication with an injection channel 16. The first mold 10 may further comprise one or more vacuum channels 18.

Fig. 1b shows a subsequent method step, where an in-mold label 20 comprising a through-hole 22 has been applied onto the surface 12 of the first mold 10 of Fig. 1a such that the through-hole 22 of the in-mold label 20 is aligned with the injection hole 14 of the first mold 10. The in-mold label 10 may be attached onto the surface 12 of the first mold 10 via glue. Alternatively or addition, the in-mold label 10 may be attached onto the surface 12 of the first mold 10 via vacuum, for example via applying vacuum to the one or more vacuum channels 18.

Fig. 1c shows a subsequent method step, where a second mold 24 has been provided in proximity to the first mold 10 such that the in-mold label 10 is arranged between the first mold 10 and the second mold 24.

Arrows in Fig. 2a indicate a subsequent step of injecting a molten material through the injection channel 16 and the injection hole 14 of the first mold 10, and further through the through-hole 22 of the in-mold label 20 into an empty space 26 between the first mold 10 and the second mold 24.

Fig. 2b indicates the situation after injecting the molten material to form an injection- moulded article 28.

Fig. 2c indicates the resulting injection moulded-article 28 after removal of the first and second molds 10, 24 in Fig. 2b. The article comprises the in-mold label 20 on an inner surface of the article. The through-hole 22 of the in-mold label 20 coincides with an injection point mark which may be present at the position 30 of the article 28 which had been in contact with the injection-hole 14 of the first mold 10 during the injection-moulding process (see Fig. 2b). Thereby, a reduced or avoided visibility of the injection point mark from the injection-moulding process is achieved.

Fig. 3 shows a surface of an injection-moulded article 28 with an in-mold label 20 in top view. The in-mold label 20 allows to provide a label printing 32 in close proximity to the through-hole 22 of the in-mold label 20. It is thus made possible to provide the label printing 32 with a graphic to optically include and further mask the injection point mark. Figs. 4a to 4c show a method for manufacturing an injection-moulded article with an in-mold label.

Fig. 4a shows an intermediate step of the injection-molding method similar to the step shown in Fig. 2a. Molten material is injected through the injection channel 16 as indicated by arrows. However, the method of Fig. 4 comprises an in-mold label different to the in-mold label 20 of the method of Figs. 1 and 2. Only a first end portion 42 of the in-mold label of the method of Figs. 4a to 4c is arranged between the first mold 10 and the second mold 24. An intermediate portion 44 and a second end portion 46 of the in-mold label are not arranged between the first mold 10 and the second mold 24.

After injection of the molten material and removal of the first and second molds 10, 24, a semi-finished article 48 is provided as shown in Fig. 4b.

Fig. 4c shows a subsequent step, where a third mold 50 comprising an injection hole 52 and a fourth mold 54 have been provided such that the second end portion 46 of the inmold label is arranged between the third mold 50 and the fourth mold 54. As indicated by an arrow in Fig. 4c, molten material is then injected through the injection hole 52 of the third mold 50 into an empty space 56 between the third mold 50 and the fourth mold 54.

Fig. 5 shows an injection-moulded article as obtainable by the method of Fig.4 in perspective view. The article comprises two moulded portions. A first moulded portion 58 is provided by the moulded portion of the semi-finished article 48 shown in Fig. 4b. A second moulded-portion 60 is formed from the molten material injected to the empty space 56 shown in Fig. 4c. The intermediate portion 44 of the in-mold label serves as a hinge 62 of a hinged lid of the injection-moulded article and thereby connects the two moulded portions 58, 60 of the article.