Linerless Leaflet-Label Tape Manufacturing Process
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Solution Overview
Problem
The existing processes for manufacturing self-adhesive linerless leaflet-label tapes are complex and costly, involving multiple steps and materials such as applying rear adhesives, printing, and using release materials.
Innovation Solution
A simplified process involving unwinding a self-adhesive material tape with a pressure-sensitive adhesive layer and a transparent plastic liner, printing labels, delaminating, applying an adhesion control layer, inverting and re-laminating the liner, and rewinding to form a linerless tape without backing, using delamination rollers and direction-changing bars to achieve a cost-effective and efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the usual process of applying release material on leaflet covers and using complex bonding steps is used, then the linerless leaflet-label can be formed, but the process becomes relatively complex and costly
Solution Approach 1:
The patent extracts and eliminates the separate release material application step and the complex bonding operations. Instead of applying release material on leaflet covers and using multiple bonding steps, the invention uses a pre-coated release liner that is peeled off in one action, leaving the leaflet permanently bonded to the label. This extracts the complexity of release material application and bonding processes, replacing them with a simple peel-off action.
Solution Approach 2:
The patent merges multiple functions into a single integrated structure. The release liner serves both as a protective layer during storage and handling, and as a bonding medium when peeled off. The extreme bands of the leaflet are designed to permanently bond to the label body, combining the functions of attachment and sealing in one element. This merging eliminates the need for separate release material application and complex bonding steps.
2Loss of substance
If linerless labels are used instead of labels with liner, then disposables are reduced and label capacity per reel increases, but the manufacturing process becomes more complex
Solution Approach 1:
The patent extracts the liner from the final product structure, creating a truly linerless label. The release liner is used only temporarily during manufacturing and is completely removed before the label reaches the user. This extraction eliminates the disposable liner material waste while maintaining a relatively simple manufacturing process through the use of pre-coated release liners and straightforward peel-off bonding.
3Reliability
If the extreme band of the leaflet cover is permanently bonded and the opposite cover band is resealably affixed, then the leaflet is securely attached to the label, but the manufacturing process requires additional bonding steps
Solution Approach 1:
The patent merges the attachment and sealing functions into the leaflet structure itself. The extreme bands of the leaflet are designed to permanently bond to the label body, combining the functions of securing the leaflet to the label and providing a sealed attachment. This merging eliminates the need for separate bonding steps and achieves secure attachment through the leaflet's own structural elements.
Solution Approach 2:
The patent applies preliminary action by pre-coating the release liner with adhesive before the labeling process. This pre-applied adhesive is activated when the liner is peeled off, automatically bonding the leaflet to the label without requiring additional bonding steps during the labeling process. The preliminary coating of adhesive simplifies the overall process while ensuring reliable attachment.
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 process results in a simpler, low-cost method for producing self-adhesive linerless leaflet-label tapes, reducing material waste and increasing label capacity per reel, while maintaining the benefits of linerless technology like reduced disposables and efficient labeling.
Implementation Method 1
a pressure-sensitive adhesive layer adhered the rear face of the tape
Data Source
AI summary
The present abstract relates to a patent of invention for a method for obtaining a tape (1) for self-adhesive, linerless leaflet labels, pertaining to the field of self-adhesive articles, comprising: 1)—Providing and unwinding a self-adhesive-material tape (20); 2)—Printing labels (4) and sensing marks (6) on the tape (3) of the tape (20); 3)—Applying an adhesion control layer (40) to the printed face of the tape (3), preferably comprised by laminating a BOPP-film tape; 4)—Delaminating the liner (10) from the tape (20); 5)—Inverting the position of the liner (10) in relation to the remaining tape of the self-adhesive-material tape (20); 6)—Applying a layer (50) of adhesive to the face of the liner (10) that includes Corona treatment (13), facing the tape (3); 7)—Drying the adhesive (50); 8)—Applying the leaflets (7) to the tape (3) in correspondence with respective labels (4); 9)—Relaminating the liner (10); 10)—Slitting the leaflet-label linerless self-adhesive tape (1) obtained; and 11)—Winding up the finished self-adhesive linerless leaflet-label tape (1) to form the reel (11).