Linerless Label Applicator with Electrical Heating
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Solution Overview
Problem
Existing devices for printing, separating, and applying self-adhesive labels are limited by their inability to efficiently process labels without a carrier tape, leading to waste and increased costs, and they are not suitable for real-time applications due to restrictions on label placement and heating methods.
Innovation Solution
A device equipped with a heating applicator working on an electrical principle, allowing for controlled heating and real-time use, combined with a pressure device and kinematic axes for flexible application, enabling the use of heat-activated adhesive labels without a carrier tape and allowing for multi-sided labeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a carrier tape is used to hold self-adhesive labels, then labels can be easily applied, but the carrier tape becomes hazardous waste requiring thermal disposal and increases costs
Solution Approach 1:
The invention extracts and removes the carrier tape from the label structure, creating linerless labels that consist only of the necessary functional layers (printable layer, carrier layer, and heat-sealable adhesive layer). This eliminates the hazardous carrier tape waste while maintaining label application functionality through direct heat-activated adhesion to the target surface.
2Ease of manufacture
If a carrier tape is used for label application, then labels can be processed, but additional equipment for rolling up and disposing of carrier tape is required
Solution Approach 1:
The carrier tape is completely removed from the system, eliminating the need for carrier tape handling, rolling up, and disposal mechanisms. The labeling machine only needs to handle the simplified linerless labels, reducing mechanical complexity while maintaining processing capability.
3Ease of manufacture
If conventional heating methods are used for heat-activated adhesive, then labels can be applied, but real-time applications and multi-sided labeling are restricted
Solution Approach 1:
The invention replaces conventional mechanical heating systems with an electrical heating principle implemented in the applicator. This electrical heating system provides precise temperature control and can be integrated into the applicator structure, enabling real-time label activation and multi-sided labeling capabilities while maintaining adhesive activation effectiveness.
4Loss of substance
If labels without carrier tape are used, then waste is reduced, but existing devices cannot process them efficiently
Solution Approach 1:
The invention changes the fundamental parameters of the label structure by removing the carrier tape and implementing heat-activated adhesive with controlled particle size distribution (at least 10% w/w of particles with diameter ≥0.5 μm). This parameter change enables compatibility with existing labeling devices while achieving waste reduction, and the electrical heating applicator further enhances processing efficiency.
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 enables efficient, cost-effective processing of labels without a carrier tape, allowing for real-time applications and flexible label placement, reducing waste and operational costs while maintaining the integrity of RFID tags.
Implementation Method 1
the applicator can be heated by a heating device which works according to an electrical operating principle
Implementation Method 2
a handling device, the negative pressure is removed and an overpressure is generated. This makes it easier to detach the label from the stamp
Data Source
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AI summary
A device (1) for printing, severing and applying self-adhesive flat structures, in particular labels, wherein the device (1) operates with a label material without a carrier strip, which label material has a printable layer, a carrier layer and a heat-sealable adhesive layer, and the device (1) has an applicator (16, 16a, 22, 26), by way of which the label is applied to an object to be labelled, wherein the applicator (16, 16a, 22, 26) can be moved up to the object to be labelled by way of a handling device (18), and the handling device (18) is constructed in accordance with the principle of an open kinematic chain and has at least one translational kinematic axis (19) and/or at least one rotational kinematic axis (20), is distinguished by the fact that the applicator (16, 16a, 22) can be heated by way of a heating device (17) which operates in accordance with an electrical operating principle.