Linerless Label Coating and Singulation Process
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Solution Overview
Problem
The labeling industry faces challenges in reducing waste generated by pressure sensitive adhesive (PSA) labels, as existing liner-free and activatable labels either retain the release system or introduce additional complex 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 directly onto a roll of face stock, singulates individual labels, and applies them to products without a liner or release system, using a detack layer that liquefies upon exposure to heat or IR radiation to render the adhesive tacky, allowing for self-winding and high-speed labeling without the need for a release coating or liner.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a liner and release system are used in PSA labels, then the labels can be easily applied and stored, but waste is generated and material costs increase
Solution Approach 1:
The patent removes the liner and release system from the label structure, extracting only the essential components (face stock and adhesive layer) needed for label functionality. This eliminates the waste stream while maintaining the core labeling capability.
Solution Approach 2:
The label is divided into functional segments: the face stock provides structural support and printing surface, while the adhesive layer provides bonding capability. This segmentation allows each component to perform its specific function without requiring additional liner or release system layers.
2Loss of substance
If liner-free labels are manufactured with release system coated on face stock, then the liner is eliminated, but the release system remains and does not deliver full cost potential
Solution Approach 1:
The patent completely removes the release system from the label structure, extracting not only the liner but also the release coating material. This achieves full linerless potential by eliminating all release system components that would otherwise remain on the face stock.
Solution Approach 2:
Instead of coating release system on the face stock as in conventional liner-free labels, the patent inverts the approach by applying adhesive directly to the face stock without any release coating, thereby eliminating the release system entirely.
3Quantity of substance
If adhesive is coated directly on face stock without liner, then material efficiency improves, but adhesive protection and handling become difficult
Solution Approach 1:
The adhesive is coated on the face stock in a controlled manufacturing environment with proper handling procedures established beforehand. This preliminary action ensures the adhesive is protected during storage and transport, preventing premature activation or contamination while maintaining material efficiency.
Solution Approach 2:
The patent modifies the physical parameters of the adhesive coating process, such as coating weight, drying conditions, and surface preparation, to optimize adhesive performance while eliminating the liner. These parameter changes ensure reliable adhesive protection and handling without requiring additional liner layers.
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 enables high-speed labeling with minimal additional complexity, maintaining adhesive properties and clarity, thus achieving a true linerless solution.
Implementation Method 1
using a detack layer that liquefies upon exposure to heat or IR radiation to render the adhesive tacky
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.