Advantages of

Pattern Coated

Adhesive

Jim Maloney

Senior Engineer, Tapemark

AIMCAL October 25, 2004

Minnesota Weather

Ice Palace

Topics

• Why not full coating?

• Overview of pattern coating

• Technical description

• Advantages and challenges

• Beyond adhesives

• Opportunities

• Q&A

Why not full coating?

Numerous disadvantages

• Adhesive ooze

• Die cutting problems

• Adhesive where you don’t want it

• Thickness variations

• Waste

• Cost

What prompted pattern coating?

• Disadvantages as mentioned

• The need to solve problems for customer applications

• There has to be a better way:

Pattern Coating

• Two patents

• Pattern coating is one step in a process

– Laminating, die cutting, sheeting, packaging

Three Methods of

Pattern Coating

• Gravure

• Flexo

• 100% solids

using hot melt

Three Types of Pattern

Coating Using 100% Solids

• Stripe pattern

• Intermittent stripe pattern

• Screen printing

Heat is Applied

Pattern on Screen

Pattern Appears on Web

• More efficient use of adhesive

Technical Description

• Rotary screens

• Heating

• Air knife

• Servo drive system

• Impression roller

Equipment Graphic

Rotary Screen

Air Knife

Impression

Roll

Web Path

Rotary Screens

• Types

– Galvano

– Lacquer

• Various screen sizes/mesh

– Depending on volume and accuracy of adhesive

laydown

• Intricate patterns to full coverage

• Thickness of laydown

• Process dependent on viscosity

Rotary Screens

Heating

• Heated air blowers

• Screen is heated

• Heated supply die

• Heated air knife

Heating

Air Knife

• Prevents “angel hairs”

Web

ScreenHeated Air

Air Knife

Servo Drive System

• Re-registration

– Can lay adhesive on preprinted web

– Can print to an eye-mark

• Ratio

– Vary pattern size

– Screen can go faster or slower than web

• Pump speed matched to web speed

Impression Roller

• Driven

• Chilled

• More accurate laydown of adhesive

• Prevents smearing

Impression Roller

Advantages of

Pattern Coated Adhesives

• Reduces or eliminates adhesive ooze

• Pattern coating on clear film allows for

cost-effective “no label” look alternative

• Increased cost savings

– Pattern coating rather than full spread

– Put adhesive only where needed

• By using different pattern screen sizes, coat

weight can vary, even on same part

• High run speeds

Challenges of

Pattern Coated Adhesives

• Learning curve

• Time to heat equipment

• Repeats must match screen diameter

• High viscosity adhesive is more of a

challenge

• Cosmetic look of dots

• Capital cost

Beyond Adhesives

• Not just a label application

• Use pattern coating on a range of shapes,

sizes, and materials such as vinyls,

papers, and polyesters

• Consider polymers or other materials

– Opens up a wide range of opportunities

• Pattern coating is a cost-effective way to

create a two-part system

Opportunities

• Using pattern coating instead of full coverage

allows other ingredients to be incorporated

– Fragrance

– Microencapsulation

– Other elements

• Pattern coating on hydrophilic material results in

a system to channel and manage fluids

• Just the beginning

Jim Maloney

Senior Engineer

651-450-8773

maloneyj@tapemark.com

www.tapemark.com/d_coat.htm

Just think of the possibilities!sm

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