Patterned Overprint Coating for Film Labels
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Solution Overview
Problem
Current film labels, especially clear or solid color ones, do not achieve a satisfactory 'no label' appearance due to scuffing, gas bubbles, and glue voids, and require costly additives for scuff resistance and opacity, which also affect aesthetics.
Innovation Solution
A film label with a reverse-printed design and an overprint coating on the back surface, which can be patterned to provide escape paths for air and water, allowing for high opacity inks without gloss agents and reducing the appearance of bubbles and voids, while also protecting the printed image from abrasion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If clear or solid color film labels are used, then the label is transparent or visually simple, but the 'no label' appearance is not achieved due to visible bubbles and voids
Solution Approach 1:
The patent applies an opaque or translucent coating layer to the film label that can be patterned with varying opacity levels. This coating layer camouflages the bubbles and voids between the label and container surface, making them invisible to the observer while maintaining the overall transparency or visual simplicity of the clear film label.
Solution Approach 2:
The patent varies the opacity parameter of the coating layer across different regions of the label. By creating areas of different opacity levels, the coating effectively masks the harmful visual effects of bubbles and voids while preserving the desired aesthetic appearance of the label.
2Shape
If inks with gloss agents are used to achieve glossy appearance, then the label has desired aesthetic finish, but the opacity of the inks is reduced
Solution Approach 1:
The patent separates the functions of achieving glossy finish and maintaining ink opacity into different layers. The opaque or translucent coating layer applied over the printed surface provides the glossy finish through its own formulation and surface properties, while the ink layer beneath maintains full opacity without needing to incorporate gloss agents.
3Loss of information
If the first surface of the label is printed with text and graphics, then the design is visible, but the printed image is susceptible to scuffing and abrasion
Solution Approach 1:
The patent introduces an opaque or translucent coating layer as an intermediary protective layer between the printed image on the first surface and the external environment. This coating layer acts as a shield that protects the printed graphics and text from scuffing and abrasion during handling and application, while still allowing the design to remain visible through the coating.
4Manufacturing precision
If multiple layers of ink are applied to increase opacity, then the aesthetic quality is maintained, but the production cost increases
Solution Approach 1:
The patent uses a composite structure consisting of a clear film label layer with printed ink and an overlying opaque or translucent coating layer. This composite material approach achieves the desired opacity and aesthetic quality in a single ink layer combined with the coating, rather than requiring multiple expensive ink layers, thereby reducing production costs while maintaining visual quality.
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 provides a cost-effective, scuff-resistant film label that achieves a 'no label' appearance by protecting the printed image and allowing for high opacity inks, reducing the visibility of bubbles and voids, and enhancing the label's integration with the container surface.
Implementation Method 1
The grooves also allow water in a water-based adhesive to wick away to the edges of a cut-and-stack label without the use of a hydrophilic coating or layer.
Implementation Method 2
The grooves can help move entrapped air and other gasses from the back side of the label during the adhesive wipe down process on a labeling machine.
Data Source
AI summary
A film label comprising a film layer with printed material on the front or back surface, where the back surface may be covered with an overprint coating. The overprint coating protects any reverse-printed material, and may be colored or patterned, or both. One exemplary pattern is achieved by alternating coating weights to create a series of lands (i.e., raised areas) and groove (i.e., lower areas). The grooves help move entrapped air and gasses from the back side of the label, and may help water in a water-based adhesive wick away. The pattern can be a series of sinusoidal waves, curves, straight lines, or a variety of other patterns. The coating may also be used on opaque labels to assist in drying the label adhesive.