Product Description and Manufacturing Process of PVC Rope badge Bracket
1、 Product Description
1. Product name
Multi functional PVC lanyard badge bracket (including regular, printable, and expandable series)
2. Core positioning
Specially designed for scenarios such as employee badges, exhibition passes, campus student IDs, event medals, scenic spot tickets, etc., with the durability and flexible adaptability of PVC material as the core, integrating the advantages of convenient wearing, personalized printing, stable load-bearing, and balancing practicality, safety, and brand display function, meeting the mass customization and daily use needs of enterprises, institutions, and event organizers.
3. Key characteristics
• Material quality: Made of food grade environmentally friendly PVC raw materials (in accordance with GB/T 20266-2006 standard), with no odor, no heavy metal precipitation, strong flexibility, wear resistance, and not easily aged. Under normal use environment (-10 ℃~60 ℃), it can maintain for more than 3 years without brittleness or deformation; The surface is smooth and easy to clean, and stains can be directly wiped off.
• Structural design:
· Hanging rope part: PVC rope diameter 3mm/5mm optional, tensile strength ≥ 15kg, not easy to break; The length can be
customized (regular 45cm/50cm/60cm), paired with a rotating hook (360 ° free rotation), and there is no entanglement problem when wearing;
· Badge holder: Adopting integrated injection molding, the
Card slot size is precise (suitable for conventional badge sizes such as 5cm × 8cm/6cm × 9cm, and can be customized with special specifications), with strong clamping force, making it difficult for the badge to fall off after insertion, and reserving a disassembly gap for easy replacement of the badge;
· Function upgrade: The telescopic model has a built-in spring telescopic mechanism, with a stretching length of up to 80cm. The retraction is smooth and without jamming, making it convenient to display badges up close; The printable surface reserves a flat printing area, compatible with silk screen printing, heat transfer printing and other processes, and supports customization of brand logos, text, and patterns.
• Safety guarantee: The hanging rope is designed with a built-in safety buckle, which automatically disconnects when subjected to a tensile force of ≥ 5kg, avoiding safety hazards caused by accidental entanglement; All edges and corners have been smoothed, without burrs or sharp edges, making it comfortable to wear without scratching clothing or skin.
• Adaptation scenarios:
· Corporate Office: Employee ID tags can be hung with ropes, and the company logo can be printed to showcase the brand image;
· Exhibition activity: Attendee pass holder, customized exclusive patterns in bulk to enhance event recognition;
· Campus/Scenic Area: Student ID card, ticket hanging rope, lightweight and durable, easy to carry;
· Event Celebration: Medal lanyard stand, with strong load-bearing capacity, can be paired with medals for long-term storage.
4. Specification parameters
| Series | lanyard diameter | lanyard length | bracket slot size | load-bearing capacity | core functions |
| Regular model | 3mm | 45cm/50cm | 5cm × 8cm | ≥ 5kg | basic wear,stable clamping |
| Printable | 5mm | 50cm/60cm | 6cm × 9cm | ≥ 8kg | supports LOGO/pattern customization |
| Expansion piece | 4mm | contraction 45cm/stretch 80cm | 5cm × 8cm | ≥ 6kg | spring expansion, convenient display |
2、 Production process
1. Raw material selection
• PVC raw materials: high-purity polyvinyl chloride resin (PVC purity ≥ 99%) is selected, and environmentally friendly plasticizers (dioctyl phthalate content ≤ 0.3%) are added to ensure material flexibility and environmental friendliness, and RoHS environmental certification is obtained;
• Auxiliary materials: spring (stainless steel material, rust and corrosion resistant), safety buckle (ABS environmentally friendly plastic), printing ink (environmentally friendly screen printing ink/heat transfer ink ribbon, free of harmful substances such as formaldehyde and benzene).
2. Core production process
• Raw material pretreatment: PVC resin is mixed with plasticizers and stabilizers in precise proportions (resin: plasticizer: stabilizer=100:30:2), and stirred at high speed (speed ≥ 2500r/min) to form a uniform mixture. It is then placed in a drying oven (80 ℃) for 4 hours to remove moisture and avoid the formation of bubbles during molding.
• Hanging rope extrusion molding: The dried mixture is fed into an extruder, with the barrel temperature controlled at 150-180 ℃ and the die temperature at 170-190 ℃. The PVC hanging rope with a set diameter (3mm/4mm/5mm) is extruded through a customized mold, and the traction speed is synchronized with the extrusion speed (10-15m/min) to ensure uniform thickness of the hanging rope; After extrusion, it is cooled and shaped in a water cooling tank (water temperature of 20-30 ℃), and then stretched by a traction machine (stretching ratio of 1:1.2) to enhance the tensile strength of the hanging rope.
• Bracket injection molding:
· Mold preparation: Design injection molds according to the slot size, with a mold accuracy of ≤ 0.02mm and surface polishing treatment to ensure smooth and burr free finished brackets;
· Injection molding process: Put PVC particle raw materials into the injection molding machine, with a barrel temperature of 160-190 ℃, an injection pressure of 80-100MPa, an injection time of 2-3 seconds, a holding time of 5-8 seconds, and a cooling time of 10-15 seconds to ensure that the bracket is formed in one go, with a complete structure and no shrinkage holes;
· Corner processing: After injection molding, the bracket is taken out by a robotic arm and placed in a polishing machine (120 mesh grinding wheel) to process the burrs on the corners, ensuring smooth edges.
• Component assembly:
· Hanging rope cutting: Accurately cut according to the set length (45cm/50cm, etc.), with a smooth and burr free cut and a length error of ≤± 0.5cm;
Assembly of accessories: Connect the hanging rope to the safety buckle, rotating hook, and bracket body through ultrasonic welding process (welding temperature 280-320 ℃, welding time 0.5-1 second), ensuring that the connection is firm and the tensile strength meets the standard;
· Expansion assembly: Stainless steel springs and expansion mechanisms are embedded in the hanging rope to adjust the smoothness of expansion and contraction, ensuring that there is no jamming during stretching and retraction, and the spring fatigue test is ≥ 1000 times without failure.
Printing process (printable):
· Screen printing process: For simple logos/text, screen printing is used to create a dedicated screen (300-400 mesh). Environmentally friendly screen printing ink is evenly applied and transferred to the surface of the hanging rope/bracket through scraper pressure. After drying at 60 ℃ for 10 minutes, the ink adhesion is ensured to be strong (no peeling after friction testing ≥ 50 times);
· Heat transfer printing process: For complex patterns/gradient colors, heat transfer printing technology is used to print the pattern onto a heat transfer film. The pattern is transferred to the surface of the product through a heat transfer machine (temperature 150-180 ℃, pressure 0.3-0.5MPa, time 5-8 seconds), with high color reproduction and no glue marks.
• Finished product inspection packaging:
· Quality inspection: Each batch of products is sampled and tested for tensile strength, environmental indicators, printing adhesion, and slot clamping force. Unqualified products are immediately reworked;
· Packaging and warehousing: individual products are packed in independent OPP bags, batch packed into corrugated boxes, filled with buffer foam, to avoid damage during transportation.
3. Quality control standards
• Environmental standards: formaldehyde emission ≤ 0.05mg/m ³, heavy metal (lead, cadmium, etc.) content ≤ 0.01%, in compliance with RoHS certification requirements;
• Physical properties: The tensile strength of the hanging rope is ≥ 15kg, the clamping force of the bracket slot is ≥ 3kg, and the breaking force of the safety buckle is controlled at 5-8kg;
• Printing quality: The clarity of the silk screen pattern is ≥ 95%, with no omissions or ghosting; Heat transfer printing color reproduction degree Δ E ≤ 3, no fading after 50 rubs;
• Appearance standard: The surface is free of bubbles, scratches, and burrs, the color is uniform and consistent, and the size error is ≤± 0.5mm.
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