Inline Adhesive Signage Without Release Liner
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Solution Overview
Problem
Current methods for creating adhesive signage for store shelving are inefficient due to issues like glue buildup, uneven deformation, and high costs associated with pressure sensitive adhesive tape, which also fail in refrigeration and freezer applications and do not accommodate variable print data or robotic stacking of different shapes and sizes.
Innovation Solution
A process that applies strong pressure sensitive adhesive directly to cut sheet media post-printing, eliminating the need for a separate release liner, with a UV-cured Silicone release layer and PSA layer applied in-line, allowing for robotic stacking and easy peeling, and using a robotic system to create ordered stacks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pressure sensitive adhesive tape is applied to the substrate before printing, then the substrate can be handled and printed, but the process becomes complex and costly with multiple components (adhesive, release liner, backer)
Solution Approach 1:
The patent extracts and eliminates the release liner and backer components from the traditional adhesive tape structure. Only the essential adhesive layer is applied directly to the substrate, removing unnecessary complexity while maintaining the core function of enabling substrate handling and printing.
Solution Approach 2:
The patent merges the substrate and adhesive into a single integrated structure. The adhesive is applied directly to the substrate surface, combining what were previously separate components (substrate + release liner + adhesive + backer) into a simplified two-component system (substrate with direct adhesive application).
2Ease of operation
If adhesive tape is applied to the substrate, then the substrate can be handled, but glue builds up in the printer and causes feed problems
Solution Approach 1:
The patent uses a disposable adhesive layer that is applied directly to the substrate and then removed or discarded after the printing process. This prevents the adhesive from building up in the printer mechanism, as each substrate carries its own adhesive supply that doesn't interact with the printer's feeding components.
3Ease of operation
If adhesive tape is used, then the substrate can be handled, but the fuser Silicone oil is unevenly deposited and migrates to the rest of the printer system
Solution Approach 1:
The patent removes the release liner component that was causing the Silicone oil deposition issues. By applying adhesive directly to the substrate without a release liner intermediary, the system eliminates the interface where uneven Silicone oil deposition and migration occur, while still maintaining substrate handling capability.
4Ease of operation
If adhesive tape is applied to the substrate, then the substrate can be handled, but the paper telescopes in roll form and stacking becomes difficult
Solution Approach 1:
The patent applies adhesive only to specific local areas of the substrate rather than covering the entire surface with thick tape. This localized adhesive application maintains the substrate's natural flexibility and alignment properties while providing sufficient handling capability, preventing telescoping in roll form and improving stacking precision.
5Reliability
If a separate release liner is used, then the adhesive can be protected, but the cost increases and the liner must be removed and discarded at the store
Solution Approach 1:
The patent extracts and eliminates the release liner component entirely from the system. Adhesive is applied directly to the substrate without a protective liner, and the adhesive is designed to remain stable and protected through the printing and stacking process without requiring a separate liner that would later need to be removed and discarded at the store.
6Extent of automation
If micro-sphere adhesive is used in roll form systems, then production can be automated, but the adhesive fails in refrigeration and freezer applications
Solution Approach 1:
The patent changes the adhesive parameters by selecting or formulating an adhesive composition that maintains its bonding properties at low temperatures. Unlike micro-sphere adhesives that fail in refrigeration and freezer conditions, this adhesive is specifically designed or selected to retain its effectiveness across a wide temperature range, enabling reliable performance in cold storage environments while still allowing automated production.
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
This method reduces costs, improves efficiency by eliminating the need for a separate release liner, and ensures the adhesive signage can withstand in-store conditions, including refrigeration and freezer applications, while accommodating variable print data and different shapes and sizes.
Implementation Method 1
A Silicone release layer is applied (post printing) on the top surface of media that is ultra violet (UV) cured
Implementation Method 2
The sheets are then stacked and a compressive force is applied that transfers the PSA and helps hold the stack of sheets together
Data Source
AI summary
A process to apply pressure sensitive adhesive to cut sheet media and eliminate a separate release liner. A Silicone release layer is applied (post fuser) on a top surface of the media and then UV cured. A pressure sensitive adhesive layer is applied next. The cut sheets are then stacked and a compressive force is applied that transfers the pressure sensitive adhesive from one sheet to another and helps hold the stack together.