Linerless Label Coating and Detack Activation
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Solution Overview
Problem
The labeling industry faces challenges in reducing waste generated by pressure sensitive adhesive (PSA) label production, as existing liner-free and activatable labels either retain the release system or introduce additional costly components, failing to achieve a true linerless solution that eliminates both the liner and release system.
Innovation Solution
A method and system for labeling that coats a pressure sensitive adhesive onto a roll of face stock, allowing for sequential coating, singulation, and application of individual labels without a liner or release system, using a detack layer that becomes tacky upon exposure to heat or IR radiation, enabling self-winding and high-speed labeling without the need for a release liner.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a liner and release system are used in PSA label production, then the labels can be easily manufactured and stored, but a waste stream is generated that must be land-filled or reprocessed
Solution Approach 1:
The patent removes the liner and release system from the label structure, extracting the waste-generating components while retaining the essential adhesive and face stock elements. This extraction eliminates the waste stream while maintaining label functionality through alternative storage methods.
Solution Approach 2:
The invention discards the traditional liner-release system approach entirely, replacing it with a linerless design where the adhesive layer itself serves as the storage mechanism. The face stock with adhesive is wound without a liner, and labels are applied directly, recovering material value by eliminating the non-functional liner component.
2Loss of substance
If liner-free labels are manufactured with a release system still coated on the face-stock, then the liner is eliminated, but the release system adds cost and does not deliver full cost potential
Solution Approach 1:
The patent extracts both the liner and the release system from the label construction, removing all components associated with traditional label storage and application. This complete extraction achieves true linerless status and eliminates the associated costs of release coatings and liner materials.
Solution Approach 2:
The invention changes the fundamental parameters of label storage and application by eliminating the liner-release system architecture. The adhesive is formulated and applied directly to the face stock without a release layer, fundamentally altering how the label is stored, handled, and applied, thereby reducing material costs.
3Loss of substance
If a detack layer is applied to the adhesive to prevent sticking during storage, then the labels can be self-wound without a liner, but the detack layer must be removed or activated before application
Solution Approach 1:
The patent employs a detack layer that automatically performs its function of preventing adhesive sticking during storage and handling. The detack layer is designed to be self-activating or easily removable through simple mechanisms such as heat, friction, or chemical reaction at the point of application, eliminating the need for complex activation systems while maintaining linerless benefits.
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 approach eliminates waste streams, reduces material and supply chain costs, and achieves high-speed labeling with a clear, non-tacky adhesive layer, maintaining adhesive properties and clarity, thus providing a true linerless solution.
Implementation Method 1
A method and system for labeling that coats a pressure sensitive adhesive onto a roll of face stock, allowing for sequential coating, singulation, and application of individual labels without a liner or release system, using a detack layer that becomes tacky upon exposure to heat or IR radiation
Implementation Method 2
A method and system for labeling that coats a pressure sensitive adhesive onto a roll of face stock, allowing for sequential coating, singulation, and application of individual labels without a liner or release system, using a detack layer that becomes tacky upon exposure to heat or IR radiation
Data Source
AI summary
According to an embodiment of the present disclosure, a method of labeling a plurality of products includes coating a pressure sensitive adhesive to a roll of face stock, the roll of face stock configured to be converted to a plurality of individual labels aligned in a single lane; singulating an individual label from the roll of face stock; and applying the individual label to a product of the plurality of products, wherein the coating, singulating and applying are conducted sequentially in a single continuous operation with a single continuous web of material.