Direct Thermal Label with UV-Cured Protective Coating

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Solution Overview

Problem

Direct thermal printing labels tend to fade over time and lack resistance to liquids and chemicals, and conventional UV varnishes can heat-activate the direct-thermal material, making them impractical for wide-spectrum UV curing.

Innovation Solution

A label with a direct thermal coating and a cured ultraviolet coating that uses photoinitiators activated by a 315 nm-450 nm wavelength range, allowing for UV printing without heat-activating the direct thermal coating, and an LED UV coating that is cured using UV light-emitting diodes to provide protection from solvents and chemicals.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional UV varnish is applied over direct thermal labels, then the labels gain protection from solvents and chemicals, but the UV curing process heats the direct thermal material causing blackening and rendering the UV varnish impractical

Engineering Contradiction:

Improveresistance to solvents and chemicalsVSAvoidheat activation of direct thermal coating

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the curing parameters of the UV coating by using a specific wavelength range (315 nm-450 nm) that activates photoinitiators without generating sufficient heat to activate the direct thermal coating. This parameter change allows the UV coating to be cured while protecting the underlying direct thermal material from heat activation.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The UV coating acts as an intermediary layer between the direct thermal coating and the external environment. It provides chemical resistance and protection while its specific photoinitiator formulation allows it to be cured through a wavelength range that doesn't transfer harmful heat to the direct thermal coating beneath.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If direct thermal printing is used, then the printing process is cost effective and does not require toner or ink, but the printed areas tend to fade over time and lack durability

Engineering Contradiction:

Improvecost effectiveness of printingVSAvoiddurability and resistance to fading

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent creates a composite structure with multiple layers: a direct thermal coating layer for cost-effective printing and a UV-cured coating layer for durability and protection. This composite material combines the advantages of both technologies - the cost effectiveness of direct thermal printing with the durability and chemical resistance of UV-cured coatings.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent merges two different printing and coating technologies - direct thermal printing and UV-cured coating - into a single label structure. The direct thermal coating provides the printing function while the UV coating provides the protective function, and both work together to create a durable, cost-effective labeling solution.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If a UV coating with photoinitiators activated by wide-spectrum UV is used, then the coating provides comprehensive protection, but the broad wavelength range causes heat activation of the direct thermal coating

Engineering Contradiction:

Improveprotective coverageVSAvoidheat generation during curing

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent narrows and shifts the UV wavelength range to 315 nm-450 nm, which is optimized for activating specific photoinitiators while minimizing heat generation. This parameter change in the spectral distribution allows comprehensive protective coverage without the thermal side effects of broad-spectrum UV curing.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution provides durable and chemically resistant direct thermal labels that maintain print quality and resist fading, while allowing for direct thermal printing without heat-activating the coating, thus enhancing the label's longevity and performance.

Implementation Method 1

a cured ultraviolet coating on the direct thermal coating, the cured ultraviolet coating having photoinitiators with substantial activation at an exposure limited to radiation at a 315 nm-450 nm wavelength range

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Implementation Method 2

a direct thermal coating on the facestock, the direct thermal coating configured to selectively darken by heat activation when direct thermal printed

Methodology Applied

Scientific EffectThermal activation: Heating

Data Source

PatentUS11472214B1Shielded direct thermal label and methods

Publication Date: 2022.10.18 AMBARTSOUMIAN GOURGEN

AI summary

A label comprises a facestock adapted to be adhered or attached to an object. A direct thermal coating is on the facestock, the direct thermal coating configured to selectively darken by heat activation when direct thermal printed. A cured ultraviolet coating is on the direct thermal coating, the cured ultraviolet coating having photoinitiators with substantial activation at an exposure limited to radiation at a 315 nm-450 nm wavelength range, and configured to allow direct thermal printing of the direct thermal coating therethrough. The ultraviolet coating is cured without heat activating the direct thermal coating.