Adhesive Laminate Patches With Integral Applicator Tabs
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Solution Overview
Problem
The production of adhesive laminate patches often results in significant waste material, particularly in transdermal drug delivery devices, due to the conventional stamping or cutting process from a master roll, which also generates drug-containing waste and requires additional converting steps.
Innovation Solution
A method of handling adhesive laminate patches using integral applicator tabs that allows for efficient production with reduced waste by die-cutting in a tight pattern and transferring them to a second release liner, utilizing a web handling apparatus to minimize waste and facilitate easier application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If adhesive patches are produced by stamping or cutting from a master roll, then production efficiency is improved, but significant waste material is generated
Solution Approach 1:
The release liner is segmented into individual tabs that can be separated after the adhesive patch is applied. Each tab remains attached to the patch through a non-adhesive region, allowing the liner to be divided into manageable portions that are easily removed and disposed of, minimizing waste handling complexity while maintaining high production efficiency
Solution Approach 2:
The adhesive patch is extracted from the master roll in a continuous manner without complete separation, maintaining connection through the tab region. This allows the patch to be transferred to the skin while the release liner remains partially attached for easy removal, eliminating the need to cut the entire liner and reducing waste material generation
2Ease of operation
If the release liner has a larger surface area than the adhesive portion, then handling ease is improved, but additional converting steps and waste material are generated
Solution Approach 1:
The release liner is designed with segmented tabs that extend beyond the adhesive patch boundaries, providing extended handling surfaces. These tabs are naturally separated by non-adhesive regions, allowing the liner to be easily divided into individual portions without additional converting steps, thus maintaining simplicity while improving handling ease
Solution Approach 2:
The release liner is pre-configured with tabs and non-adhesive regions during the manufacturing process, so that the extended handling surfaces are already in place before application. This preliminary configuration eliminates the need for additional converting steps to create extended liners, maintaining device simplicity while providing improved handling
3Ease of operation
If adhesive patches are produced with extended release liner, then handling ease is improved, but drug-containing waste is generated
Solution Approach 1:
The adhesive patch is extracted from the master roll while maintaining connection through the tab region, allowing the release liner to be partially removed with the patch. This extraction method ensures that the extended liner portions are naturally separated and can be disposed of as minimal waste, reducing drug-containing waste generation while maintaining extended handling surfaces
Solution Approach 2:
The release liner tabs are designed to be easily discarded after application, with the non-adhesive regions facilitating clean separation. The extended portions of the liner that extend beyond the patch boundaries can be cleanly removed and disposed of as waste, while the essential functional portions remain with the patch, minimizing drug-containing waste
Data Source
Figure 1~2
Figure 3A~3F
Figure 3G~3L
AI summary
Methods of handling adhesive laminate patches. A first article, passed over a first supporting structure, includes disconnected adhesive laminate patches adhered to a first web, each patch being aligned over and adhered to a tab. A second web can be passed over a second supporting structure that is separated from the first supporting structure by a gap. The first article can be passed over the first supporting structure to lift a leading portion of a first tab and a first patch off of the first web together, such that the first tab facilitates transfer of the first patch across the gap. The first patch can then be adhered to the second web; and the second web can be advanced to transfer the first patch, and first tab, onto the second web to form a second article comprising patches aligned over tabs on the second web.