Striped Adhesive Linerless Labels for Repositionable Thermal Printing

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Solution Overview

Problem

Existing linerless label products face challenges in providing cost-effective, dependable performance in compact on-demand printers for fast-paced customer service environments, requiring manual handling, repositionability, and sustainability, while maintaining operationality under high print volumes and avoiding adhesive residue issues.

Innovation Solution

A linerless label web with a direct thermal printable face and pressure sensitive adhesive, arranged in machine-direction continuous stripes with limited cross-directional adhesive coverage, is manufactured by applying a water-based adhesive on a carrier, drying it separately, and then transferring it to the face, ensuring low exposure to thermal activation temperatures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If pressure sensitive adhesive is applied in continuous stripes with high cross-directional coverage, then adhesion strength is improved, but adhesive residue and printer contamination increase

Engineering Contradiction:

Improveadhesion strengthVSAvoidadhesive residue

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The adhesive is applied in continuous stripes only in the machine direction with limited cross-directional coverage (10-50%), creating localized adhesive zones. This provides sufficient adhesion for label application while minimizing adhesive residue that could contaminate the printer, resolving the contradiction between adhesion strength and residue reduction.

Inventive Principle:

Principle #3Local quality

2Productivity

If water based adhesive is dried at high temperature, then drying speed is improved, but thermal activation of direct thermal printable face occurs causing premature printing

Engineering Contradiction:

Improvedrying speedVSAvoidpremature printing

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The manufacturing process is segmented into separate stages: adhesive application, low-temperature drying/curing, and subsequent label production. This segmentation allows controlled drying at temperatures below thermal activation threshold, preventing premature printing while maintaining production efficiency through process optimization.

Inventive Principle:

Principle #1Segmentation

3Reliability

If adhesive coverage in cross direction is increased, then label securing is improved, but manual repositionability and removability deteriorate

Engineering Contradiction:

Improvelabel securingVSAvoidrepositionability

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

Adhesive is strategically placed in continuous stripes with limited cross-directional coverage (10-50%), creating localized bonding zones that secure the label during application while leaving non-adhesive areas that enable easy repositioning and removal, thus balancing label securing with operational flexibility.

Inventive Principle:

Principle #3Local quality

4Ease of manufacture

If conventional adhesive application method is used, then manufacturing simplicity is maintained, but sustainability and cost-effectiveness deteriorate due to high material usage

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidadhesive material

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The adhesive application parameters are optimized by limiting cross-directional coverage to 10-50% while maintaining machine-direction continuity. This parameter change reduces adhesive material consumption by 50-90% compared to full coverage, improving sustainability and cost-effectiveness while maintaining adequate label securing through strategic adhesive placement.

Inventive Principle:

Principle #35Parameter changes

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 enables efficient, sustainable, and economical label production suitable for high-speed printing and manual handling, minimizing adhesive residue and maintaining printer functionality, even under heavy use.

Implementation Method 1

drying/curing the water based pressure sensitive adhesive on the carrier

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 2

direct thermal printable face

Methodology Applied

Scientific EffectThermal activation: Phase Change

Data Source

PatentUS12488708B2Linerless label product, manufacturing a linerless label product and use of a linerless label product for delivery of orders

Publication Date: 2025.12.02 UPM RAFLATAC OY

AI summary

This specification relates to a linerless label product intended for end uses having a short label-life and requiring manual handling, repositionability and/or removability together with lean sustainable and economical structure. A linerless label web (631, 741) comprising a direct thermal printable face (210, 630, 740) and a pressure sensitive adhesive (220) is provided. The linerless label web (631, 741) comprises the pressure sensitive adhesive (220) arranged in one or more machine-direction continuous stripes leaving one or more non-adhesive area(s) between said machine-direction continuous stripes in a cross direction of the linerless label web. A total coverage of the pressure sensitive adhesive (220) in the cross direction of the linerless label web is less than 70%, or less than 50%, or less than 30%. Further, a manufacturing method of a linerless label web (631, 741), a linerless label product roll (200) as well use of the linerless label web (631, 741) or the linerless label product roll (200) in on-demand printing for preparation and delivery of orders are provided.