Micro-optic Label for 3D Imaging on Blow Molded Containers
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Solution Overview
Problem
Existing methods for achieving three-dimensional imaging on plastic containers, such as raised areas, embossing, holographic labels, and lenticular labeling, face challenges like high costs, difficulty in label registration, susceptibility to damage, and incompatibility with blow molding processes, particularly in creating a consistent and strong container structure.
Innovation Solution
A blow molded plastic container with a micro-optic label that creates a three-dimensional image using a substantially flat label panel, incorporating micro-optics that can be applied during or after molding, allowing for customization without mold modification and providing a strong, thin, and recyclable solution compatible with various container shapes and processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a raised area is created on the container using a word or logo, then product or brand identity is achieved, but the mold requires additional metal removal and cannot be used for multiple customers or products
Solution Approach 1:
The container surface is divided into two functional zones: a raised area for brand identity and a flat label panel for customizable labeling. This segmentation allows the raised area to remain permanent while the flat panel can be re-labeled for different products or customers without mold modification.
Solution Approach 2:
The labeling function is extracted from the mold itself and transferred to a separate flat label panel. This removes the dependency between mold design and labeling, allowing the same mold to be used for multiple customers while maintaining brand identity through the permanent raised area.
2Shape
If a raised area is created on the container, then a three dimensional effect is achieved, but registering a label to the raised area is extremely difficult and costly
Solution Approach 1:
The container surface is segmented into a raised 3D area for aesthetic branding and a separate flat label panel for precise labeling. This segmentation eliminates the registration difficulties by providing a flat surface that is easy to align with standard labeling equipment.
Solution Approach 2:
The flat label panel acts as an intermediary between the raised 3D area and the label material. It provides a stable, flat working surface that facilitates easy and accurate label application while the raised area maintains its 3D aesthetic function.
3Shape
If an embossed area is created on the container, then a three dimensional effect is achieved, but registering a label over the embossed area causes undesirable wrinkling in the label
Solution Approach 1:
The container surface is divided into an embossed 3D area for aesthetic purposes and a flat label panel for labeling. This segmentation prevents label wrinkling by providing a flat surface for label application, while the embossed area maintains its 3D appearance function.
4Shape
If a release coating is applied to the rear of the label to prevent adhesion in certain areas, then the label can lift in certain areas to create a 3D appearance, but items can rub or catch on the raised area and tear the raised area, causing the label to be defaced
Solution Approach 1:
The container surface is segmented into a raised 3D area that remains intact for aesthetic purposes and a flat label panel where the label is applied. This segmentation prevents items from rubbing or catching on the raised area, eliminating the risk of tearing and label defacement while maintaining the 3D appearance.
5Shape
If lenticular labeling is used on blow molded containers, then a three dimensional image is achieved, but the thickness of the label creates a weak area around the label causing container failure
Solution Approach 1:
A thin flat label panel is used instead of thick lenticular labeling. This thin film approach provides the necessary 3D image capability through micro-optics while maintaining container strength by avoiding the thickness-related weakness that causes container failure.
Solution Approach 2:
The thick lenticular mechanical structure is replaced with a thin flat label panel incorporating micro-optics. This substitution achieves the same 3D imaging function through optical means rather than mechanical thickness, preserving container structural integrity.
6Shape
If holographic labels are used to give a dimensional appearance, then a three dimensional effect is achieved, but the labels are extremely susceptible to atmospheric conditions creating curl and making them difficult to apply
Solution Approach 1:
The holographic label system is replaced with a flat label panel incorporating micro-optics. This substitution eliminates the curling and application difficulties associated with holographic labels while maintaining the 3D appearance function through a more stable flat substrate.
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 micro-optic label provides a cost-effective and durable three-dimensional image that enhances product identity, is compatible with blow molding, and allows for customization without additional mold costs, while maintaining container integrity and recyclability.
Implementation Method 1
micro-optics included as at least part of the label to create an image of depth in the micro-optic area
Implementation Method 2
micro-optics included as at least part of the label to create an image of depth in the micro-optic area
Data Source
AI summary
A plastic container with the sidewall thereof including a label panel and a label adhered to the label panel. The label includes micro-optics as at least part of the label to create an image of depth in the micro-optic area.