Silicone Release Coating for Linerless Labels
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Solution Overview
Problem
Water-based release coatings in linerless labels restrict the use of aggressive adhesives due to unwinding issues and risk of damaging the substrate, limiting the label's application to less aggressive surfaces.
Innovation Solution
Manufacturing linerless labels using a non-top coated (NTC) substrate with a silicone release coating on the front side and an adhesive coating, including aggressive adhesives, on the back side, allowing for improved unwinding and adhesion without substrate damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a water-based release coating is used on the front side of the substrate, then the release coating allows adhesive to separate during unwinding, but the adhesive becomes less aggressive which limits the types of surfaces the label can adhere to
Solution Approach 1:
The patent changes the chemical composition parameter of the release coating from water-based to silicone-based. This parameter change allows the adhesive to maintain higher aggressiveness (higher tack) while still enabling proper unwinding, thereby resolving the contradiction between ease of operation and adaptability.
2Adaptability or versatility
If an aggressive adhesive is used on the backside of the substrate, then the label can adhere to a wider range of surfaces including recycled materials, but the adhesive may pull the release coating off the substrate causing damage
Solution Approach 1:
The patent changes the release coating material parameter from water-based to silicone-based, which increases the bonding strength parameter of the release coating to the substrate. This allows aggressive adhesives to be used without compromising substrate integrity, resolving the contradiction between adaptability and reliability.
3Quantity of substance
If a non-top coated (NTC) substrate is used instead of top coated substrate, then the substrate is more porous allowing ink to be absorbed, but ink soaks into the paper causing smearing or smudging
Solution Approach 1:
The patent segments the substrate structure by adding a top coating layer over the NTC substrate. This creates distinct functional layers: the NTC substrate provides ink absorption for customization, while the top coating layer prevents smearing and provides a smooth surface for thermal printing. The silicone release coating is then applied over the top coating, creating a multi-layered structure that resolves the contradiction between ink absorption and print 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 use of a silicone release coating with NTC substrates enables the use of aggressive adhesives while preventing unwinding issues and substrate damage, expanding the label's application to a wider range of surfaces, including recycled materials.
Implementation Method 1
a release coating applied to the front side of the substrate that allows an adhesive coating on the backside of the substrate to release from the front side and separate when the substrate is wound into a roll and subsequently unwound
Implementation Method 2
an adhesive coating on the backside of the substrate
Data Source
AI summary
A roll of linerless labels are manufactured from a non-top coated (NTC) substrate. A front side of the NTC substrate is coated with silicone and a backside of the NTC substrate is coated with adhesive. A web of the NTC substrate is wound into a roll. In an embodiment, the silicone is coated on top of a direct thermal (DT) coating disposed on the front side of the web of the NTC substrate.