Removable Image Printing on Containers via Layer Segmentation

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Solution Overview

Problem

Reusable containers with non-recyclable labels face challenges in achieving high clarity, abrasion resistance, and easy removability, leading to reduced recycling rates, as existing label materials are not easily separable from the containers.

Innovation Solution

A system and method for printing both permanent and removable images on containers using a single manufacturing line, employing a processor to determine the composition of pre-coat and post-coat layers based on metadata, ensuring the images can be easily removed for recycling while maintaining adhesion and durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional label materials are used to achieve high clarity and abrasion resistance, then the label maintains aesthetic and functional qualities, but the label becomes difficult to remove for recycling

Engineering Contradiction:

Improvelabel adhesion and durabilityVSAvoidlabel removability

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The label structure is segmented into multiple functional layers: a permanent base layer that adheres to the container and maintains durability, and a removable image layer that contains the printed information. This segmentation allows each layer to serve its specific function - the base layer provides reliable adhesion while the image layer enables easy removal for recycling without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The label uses composite material construction with different layers having distinct properties. The base layer is made from materials optimized for adhesion and durability, while the image layer uses materials that facilitate easy removal. This composite approach resolves the contradiction by combining materials with opposing characteristics in a unified structure where each material's properties are optimized for its specific function.

Inventive Principle:

Principle #40Composite materials

2Manufacturing precision

If digitally printed labels are used to achieve sufficient definition and quality, then the visual aesthetics improve, but the removability for recycling becomes problematic

Engineering Contradiction:

Improvedigital image definition and qualityVSAvoidlabel separability from container

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The digitally printed label is segmented into a permanent adhesive base layer and a removable image carrier layer. The digital printing is applied to the image carrier layer, which maintains high definition and quality while being designed for easy removal. This segmentation allows the printed image to achieve manufacturing precision goals while the overall label structure maintains ease of operation for recycling.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The image carrier layer acts as an intermediary between the digital print and the container surface. It provides the high-definition digital image quality while serving as a removable medium that does not permanently bond to the container. This intermediary layer resolves the contradiction by decoupling the printing quality requirements from the adhesion requirements.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If multiple manufacturing lines are used to print permanent and removable images separately, then the printing quality for each type improves, but the handling and tracking complexity increases

Engineering Contradiction:

Improveprinting quality for permanent and removable imagesVSAvoidnumber of manufacturing lines and handling steps

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The manufacturing process merges the production of permanent and removable images into a single integrated label structure that can be applied in one step. The label combines both image types on different layers, allowing them to be manufactured and applied together rather than requiring separate manufacturing lines. This merging reduces device complexity and handling requirements while maintaining the printing quality of both image types through optimized layer design.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The label structure is designed with multi-functionality to serve both permanent and removable imaging needs within a single product. The base layer provides permanent adhesion and background functionality, while the image carrier layer provides removable foreground information. This universal design allows a single label to fulfill multiple functions that would otherwise require separate products or manufacturing processes.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11772400B2Systems and methods for printing of removable and permanent images on an object

Publication Date: 2023.10.03 XEROX CORP

AI summary

Systems and methods for printing a plurality of images on a substrate include, for each of the plurality of images: determining whether that image is a removable image or a permanent image, identifying, based on the determination, at least one layer to be used for printing that image in addition to a marking material layer that forms the image. The at least one layer may be a pre-coat layer applied under the marking material layer and/or a post-coat layer applied over the marking material layer. The marking material layer and the at least one layer are then printed on the object.