Tag for Labeling an Article Cast From Molten Material, Method Therefore and Article

1. Field of the Invention

The present invention relates to a tag structure for attachment to an article cast from molten material, to a method for labeling an article cast from a molten material and to an article cast from molten material including a tag having human or machine readable markings relative to the article, such as article identification.

Upon completing the manufacture of an article cast from a molten material, there is a need to provide the subsequent user with a clear identification and other information relating to the article. For example, if the article is in its usable final form, product information such as price and weight may be useful. If the article is utilized in combination with various other items, a clear description of its individual function may be required. Further, production schedules may require inventory information to be displayed on the article. If the article is simply in an intermediate form to be subjected to further processing, information regarding the individual article's composition may be required for the final processing steps.

2. Description of The Prior Art

Certain methods are known for providing a display of information on articles in general. One method, perhaps the most common method, includes the application of a label coated with an adhesive backing which is adhered to the article. Unfortunately, many of these labels lack sufficient adherence to provide a reliable bond between the label and the article for extended periods of time.

Another method includes the attachment of a label in the form of a structural tag to the article by physically driving retaining projections which are integral with the tag into the article. An example of such a tag and process is disclosed in U.S. Pat. No. 3,673,717. Use of tags with these projections in such a process may subject the article to unwanted damage or at least create stresses within the article. Further, the hardness of the article to be labeled may preclude use of this method. This is especially likely in articles which are cast from molten material, such as aluminum, for example.

Another method, specific to cast molten material articles, includes the attachment of a label or tag before solidification of the molten material. An example of such a process is disclosed in U.S. Pat. No. 1,561,427. The process disclosed in this patent includes assembling individual characters on a strip to form a number or word, embedding the entire strip into a mold and casting the metal in the mold.

Regarding this process, it should be noted that a number of individual characters must be arranged to create the marking. This may be time consuming and laborious, especially if much information is to be conveyed. Further, computer bar codes which are often used in many of today's products cannot be embedded in this manner. Also, repeated impression of the markings into the mold may eventually cause damage to the mold surface.

Stenciling and riveting are also known methods used with cast articles after the articles are made.

It can be seen that labeling an article can proceed during the making of the article or after the article is made, with the latter being the predominate mode.

According to the present invention the former mode is preferred. The present invention has proven to be advantageous as it does not interfere with production of the article, is made separate from the article, but made such that it can adhere effectively to the article, and retain its adherence for an indefinite period of time.

The label according to the present invention has the form of a structural member and will accordingly be referred to as a tag. The tag has structural integrity and is arranged so that it will not be damaged when it is joined to the molten material from which the cast article is being made during the production of the cast article. It possesses the capability of being joined to the molten material during the production of the cast article so that a bond or attachment arises between the tag and the article as the article is made.

According to the present invention, the tag is not attached to a mold. Instead it is floated on the surface of the molten material from which the cast article is formed prior to solidification of the material, i.e., while the material of the article is in a molten state. A portion of the tag is submerged in the molten material and another portion engages the surface of the molten material. In this condition, the tag floats on the molten material and the submerged portion is essentially surrounded by molten material for better adherence. A portion of the tag bears identification information and this portion does not submerge and is clearly visible when the tag is floating. In the process of solidification, the submerged portion of the tag forms a bond with the material of the article and is consequently adhered thereto.

The finally formed article is unique because it bears a tag which has been uniquely joined thereto and is non-removable therefrom.

A number of advantages result from the present invention. Among these are: the avoidance of any mold preparation prior to article formation; the elimination of any post article formation working; minimal effort in achieving adherence of the tag and cast article; and an effective bond resulting in a permanent attachment without damage to the article.

Twelve figures have been selected to illustrate a preferred embodiment of the present invention. These figures are schematic in nature. Nevertheless, they are sufficiently detailed so that those skilled in the art will be able to practice the invention and fully comprehend the scope of the invention. Included are:

FIG. 1, which is a top plan view of a tag in accordance with one variant of the present invention;

FIG. 2, which is a front elevation view of the tag of FIG. 1;

FIG. 3, which is a side elevation view of the tag of FIG. 1;

FIG. 4, which is a top plan view of a tag in accordance with another variant of the present invention;

FIG. 5, which is a front elevation view of the tag of FIG. 4;

FIG. 6, which is a side elevation view of the tag of FIG. 4;

FIG. 7, which is a top plan view of a tag in accordance with another variant of the present invention;

FIG. 8, which is a front elevation view of the tag of FIG. 7;

FIG. 9, which is a side elevation view of the tag of FIG. 7;

FIG. 10, which illustrates a bath of cast material with the tag according to the present invention floating in the bath;

FIG. 11, which is a top view of the bath of cast material illustrating a preferred location of the tag; and

FIG. 12, which is a partial perspective view which focuses on one end of the floating tag and its submerged attachment projection.

According to a preferred form of the present invention, the tag is made from anodized aluminum sheet having strips each preferably drawn into a smooth loop from the edges of the tag. The article comprises cast aluminum metal units, such as ingots formed in a conventional manner. The tag is dropped onto the molten aluminum and the strips sink into the molten aluminum where they become embedded during the final stages of the casting process, i.e., the tag when dropped onto the surface of the molten aluminum, floats on the surface while the strips are submerged in the molten aluminum. As the molten aluminum solidifies (freezes) into an ingot, the strips are bonded or adhered to the ingot.

Preferably, the tag structure of the present invention includes a planar rectangular sheet 10, with a top surface 12 and a bottom surface 14. The sheet may be constructed of any material suitable to display human or machine readable markings (FIGS. 1, 4 and 7) that will also withstand the heat of the molten material from which the labeled article will be formed. The anodization serves as one means of insulating the tag so that the tag withstands the heat of the molten material.

At least one, but preferably two strips serving as attachment projections 16 are formed, preferably by drawing in a known manner, from the sheet 10 and project outwardly from the bottom surface 14 of the sheet. The attachment projections 16 are preferably smooth, and according to one variant, are formed as semicircular loops along the periphery of the sheet 10.

As shown in the variant embodiment of FIGS. 1-3, the article attachment projections 16 are formed along the width edge of the rectangular sheet 10 but do not extend the entire width of the rectangular sheet. In another variant embodiment shown in FIGS. 4-6, the attachment projections 16 are formed inboard of the outer edge of the sheet 10 toward the sheet center but remain parallel to that edge. In both variants shown in FIGS. 1-6, the attachment projections 16 are, as noted, formed as semicircular, continuous loops, whereas in the variant shown in FIGS. 7-9, the attachment projections 16 are formed as discontinuous loops having a somewhat flattened surface 18 with a passage 20. According to all the variants, the attachment projections 16 define an opening 22.

When attaching the tag to an article cast from molten material, such as molten aluminum, the tag is dropped onto the surface of a molten material bath 24 to be solidified in a mold 26, as shown in FIG. 10. Preferably the tag is dropped at the imaginary intersection A or B, between the 1st and 2nd or 3rd and 4th sectors, respectively, of the top surface of the molten material bath, as illustrated in FIG. 11, because of the inherent depression formed in the center region of solidifying aluminum material (aluminum ingot). The weight of the tag under gravity causes the attachment projections 16 to locally break the surface tension at the top surface of the molten material bath and sink into the molten material until the bottom surface 14 of the tag engages the top surface of the molten material bath 24. When the bottom surface 14 engages the top surface of the molten material bath 24 the surface tension at the top surface allows the tag to float on the top surface. The result is that the tag floats while the attachment projections 16 are submerged. By dropping the tag from an appropriate height splashing of the molten material onto the top surface 12 of the tag, which might damage or at least conceal the markings thereon, is avoided as is sinking of the tag itself. As the attachment projections 16 sink, the molten material flows through the openings 22 (FIGS. 1-9, 8-10, and 12) as well as passage 20 (FIGS. 7-9). The molten material, therefore, surrounds the attachment projections 16 thereby stabilizing, along with the surface tension at the top surface 12, the location of the tag. Upon solidification of the molten material, the attachment projections 16 are adhered to the solidified material.

It will be appreciated by one of ordinary skill in the art that density and other physical properties of the molten material bath 24 will be determinative of the material and physical dimensions of the tag so that the result noted above can be achieved.

For example, three tags were made from 0.062 in. gauge anodized aluminum sheet having the following dimensions: L=5.0 in.; W=1.5 in; P.sub.L =1.0 in; P.sub.W =0.375 in.; P.sub.D =0.375 in. The top surface of the tags were provided with printed matter as shown in FIG. 1, while the bottom surface of the tags and all surfaces of the attachment projections 16 were given a 0.3 mil thick anodization layer (not shown).

The tags so constructed were dropped onto a bath of molten 2024 alloy aluminum which was subsequently solidified to form an aluminum ingot. The tags were dropped with their top and bottom surfaces situated substantially parallel to the bath surface, from approximately 4 in. above the bath surface and at the center of a quadrant as shown in FIG. 11. From this height, and with this orientation, it was found that the tags caused negligible disturbance to the molten material bath surface. So that, as noted above, splashing was effectively prevented. The attachment projections 16 sank quickly followed by contact and wetting of the bottom surface 14. A stable floating condition ensued with almost no noticeable movement of the tags in the bath, do perhaps in part, as noted above, to the holding forces exerted by the molten material on the attachment projections 16, as schematically illustrated by the arrows in FIG. 12. Adherence of the attachment projections 16, with casting material surrounding the loop surfaces, was complete. Minimal, if any, fading of the printed matter occurred on the tags tested, ingot cracking at the tag ingot interface was not found, and removal of the tags was impossible without physically chiseling the tags from their ingots.

In other tests conducted, it was observed that some tags experienced a thermal shock on their anodized layer causing "crazing", i.e., break down of the anodozied layer, which adversely affects the bar code on the surface 12 as well as the tag itself because the heat of the molten material bath will as a result have access to the tag material causing melting of the tag. One solution to this problem would be to spray a lacquer on the top surface of the tag after it is dropped. Another solution was found to be the timing related to the solidification cycle of the molten material. A time period of 4 to 5 min. prior to solidification was found acceptable for dropping the tags to avoid break down of the anodized layer.

The number and exact location of the projections 16 is arbitrary. Two attachment projections 16 are shown in the variants of FIGS. 1-3, 4-6 and 7-9. In FIGS. 4-6, the location of the attachment projections 16 are spaced inboard of the outer width edges of the sheet 10, whereas as shown in FIGS. 1-3, and FIGS. 7-9, the outer width edges of the sheet 10 form part of the projections 16.

While the preferred embodiment in its variants has been described in conjunction with the labeling of an aluminum ingot, it should be understood that the invention is not so limited. For example, if the article is steel the tag could be made of, for example, ceramic material having similar dimensional characteristics to that of the preferred embodiment.

The important consideration is that the attachment projections 16 must allow the sheet 10 to reach a floating condition without submerging the information on the surface 12, and must be capable of adequately adhering the tag to the solidified article.