Multi-Ply Wrap Label Shear Splice Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current 'wrap around' labels are excessively long, leading to application challenges such as misalignment, buckling, and machine jamming, while 'multi-ply' labels face issues with wrinkling and weak bonding when applied to curved surfaces, and both types lack the ability to combine different materials in a single layer.
Innovation Solution
A label design that transforms into a co-joined single strip during application, featuring a shear-type splice between the base and upper plies, allowing for shorter length without reducing print area, using differing materials, and enhancing stability on curved surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If wrap around labels are made longer to provide sufficient print area, then the available print space increases, but the label becomes prone to misalignment, buckling, and machine jamming during application
Solution Approach 1:
The label is divided into multiple plies (typically two) where the base ply provides structural support and the overlay ply provides the print surface. This segmentation allows the label to achieve sufficient print area without requiring excessive length, as the overlay ply can be shorter while still providing adequate printing surface when wrapped around the container.
Solution Approach 2:
The label uses composite construction with a base ply and an overlay ply that are bonded together. This composite structure combines the structural integrity of the base ply with the printability of the overlay ply, enabling the label to maintain reliability during application while providing sufficient print area through the combined surface of both plies.
2Length of moving object
If multi-ply labels are used to reduce length, then the label stability improves, but wrinkling and weak bonding occur when applied to curved surfaces
Solution Approach 1:
The adhesive properties are modified by applying a release varnish coating to specific portions of the base ply. This parameter change in adhesive strength allows the overlay ply to be temporarily released from the base ply during application to curved surfaces, preventing wrinkling, and then re-bonded to achieve stable adhesion in the final position.
Solution Approach 2:
The release varnish is pre-applied to the base ply in areas where the overlay ply will be separated. This preliminary action prepares the bonding surface to allow easy separation during application without causing wrinkling, and enables the overlay ply to be repositioned before final bonding occurs.
3Device complexity
If single ply wrap around labels are used, then the label construction is simpler, but the label lacks rigidity and is prone to misfeeding and jamming during application
Solution Approach 1:
Multiple plies are merged into a single label construction where the base ply and overlay ply are bonded together through adhesive regions. This merging provides the rigidity and structural strength needed to prevent misfeeding and jamming during application, while the integrated construction remains relatively simple and suitable for standard labeling equipment.
4Ease of operation
If release varnish is applied to enable opening and resealing, then the label can be viewed by end user, but the bonding strength between plies is reduced
Solution Approach 1:
The release varnish is applied selectively to specific portions of the base ply rather than uniformly across the entire surface. This local quality approach creates regions of weak bonding where the overlay ply can be easily separated for viewing, while other regions maintain strong bonding to ensure overall label integrity and proper adhesion to the container.
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 design improves application efficiency, reduces the likelihood of misalignment and buckling, provides stronger bonding, and allows for the use of multiple materials, resulting in a more robust and efficient label application process.
Implementation Method 1
A base ply having a pressure sensitive adhesive coating on its lower surface for application to a container, and an upper ply having a pressure sensitive adhesive coating on its lower surface
Implementation Method 2
A release varnish coating is applied to the upper side of the base ply in those areas that are in contact with the upper ply's adhesive coat
Implementation Method 3
A label design that transforms into a co-joined single strip during application, featuring a shear-type splice between the base and upper plies
Data Source
AI summary
A multi-ply, expanded content wrap label includes a base ply and an upper ply thereon with adhesive applied to the underside of a trailing end of the base ply to form a splice between the base ply and the upper side of the upper ply when the label is applied to a container.