WO2025074306A1 - Adhesive article with patterned microstructure release - Google Patents

Abstract

This disclosure generally relates to a self-wound laminate structure comprising a facestock layer; an adhesive layer; and a silicone free release surface on top of the facestock layer; wherein the release surface comprises a plurality of microstructures with a space between each microstructure greater than 50 micrometer.

Description

ADHESIVE ARTICLE WITH PATTERNED MICROSTRUCTURE RELEASE

TECHNICAL FIELD

[0001] This disclosure generally relates to a patterned microstructure release surface. Specifically, this disclosure generally relates to a patterned microstructure release surface along a substrate.

BACKGROUND

[0002] Pressure sensitive adhesive backed films may be imaged and adhered to a variety of substrates. For example, large graphics or smaller decals may be placed on vehicles or may be used as signs for identification, promotional or decorative objectives. However, the tacky and aggressive pressure sensitive adhesives used in these applications cause considerable handling and application problems. Ideally, the film is adhered conformably and evenly on the application substrate. Adhesive articles that adhere with the slightest contact can often be particularly difficult to apply if they inadvertently adhere to the substrate in an undesired position. In addition, even if one section of the adhesive article is properly positioned on a substrate, and the film is firmly adhered, air or other fluids may be trapped under the article. The trapped air forms a bubble under the article, and cannot be easily removed without debonding or perforating the article.

[0003] Structured adhesive layers may be utilized to overcome some of the difficulties associated with the application and repositioning of adhesive articles. Structured adhesive layers can be prepared by coating a structured release liner with a suitable adhesive composition. Upon removal of the release liner, a structured adhesive surface is exposed, which then can be adhered onto a substrate. The structured surface geometry of the release liner, however, can limit the speed at which the liner can be coated. If a structured release liner is coated at too high a coating speed, air bubbles can become trapped between the surface of the release liner and the adhesive. Trapped air bubbles can compromise both the performance and appearance of the adhesive article.

SUMMARY

[0004] Therefore, novel constructions with patterned release coatings and methods of construction of the same that allow for improved performance while maintaining high levels of conformability are needed. Exemplary embodiments relate to a laminate structure comprising: a facestock layer; an adhesive layer; and a silicone free release surface on the facestock layer; wherein the release surface contains a plurality of square pyramid shapes with a base and a height in a regular pattern; wherein the base has a length between about 15 and about 300pm, and the height is between about 10pm and about 80pm. Other exemplary embodiments relate to a laminate structure comprising: a facestock layer; an adhesive layer; and a silicone free release surface on the facestock layer; wherein the release surface contains a plurality of square pyramid shapes with a base and a height in a regular pattern; wherein the base has a length between about 15pm and about 300pm, and the height is between about 10pm and about 80pm and the distance between the base of a first square pyramid and a second square pyramid is between about 25pm and about 150pm. Other exemplary embodiments relate to a laminate structure comprising: a facestock layer; an adhesive layer; and a silicone free release surface on the facestock layer; wherein the release surface contains a plurality of square pyramid shapes with a base and a height in a regular pattern; wherein the base has a length between about 15pm and about 300pm, and the height is between about 10pm and about 80pm and there is no distance between the base of a first square pyramid and a second square pyramid. Other exemplary embodiments relate to a method comprising: providing a facestock layer; providing an adhesive layer; and providing a silicone free release surface on the facestock layer; wherein the release surface contains a plurality of square pyramid shapes with a base and a height in a regular pattern; wherein the base has a length between about 15pm and about 300pm, and the height is between about 10pm and about 80pm. Other exemplary embodiments relate to a method comprising: providing a facestock layer; providing an adhesive layer; and providing a silicone free release surface on the facestock layer; wherein the release surface contains a plurality of square pyramid shapes with a base and a height in a regular pattern; wherein the base has a length between about 15pm and about 300pm, and the height is between about 10pm and about 80pm and the distance between the base of a first square pyramid and a second square pyramid is between about 25pm and about 150pm. Other exemplary embodiments relate to a method comprising: providing a facestock layer; providing an adhesive layer; and providing a silicone free release surface on the facestock layer; wherein the release surface contains a plurality of square pyramid shapes with a base and a height in a regular pattern; wherein the base has a length between about 15pm and about 300pm, and the height is between about 10pm and about 80pm and there is no distance between the base of a first square pyramid and a second square pyramid. Other exemplary embodiments relate to a facestock layer comprising high density polyethene (HDPE), a mixture of HDPE and low density polyethylene (LDPE), LDPE, polypropylene (PP), polyethylene terephthalate (PET), polyolefin (PO), mixtures of PP and polyethylene (PE), paper, and combinations thereof; an adhesive layer, wherein the adhesive layer is a pressure sensitive adhesive; and a silicone free release surface on the facestock layer; wherein the release surface contains a plurality of square pyramid shapes with a base and a height in a regular pattern; wherein the base has a length between about 15 and about 300pm, and the height is between about 10pm and about 80pm. This embodiment or another embodiment may provide for a laminate structure comprising: a facestock layer comprising high density polyethene (HDPE), a mixture of HDPE and low density polyethylene (LDPE), LDPE, polypropylene (PP), polyethylene terephthalate (PET), polyolefin (PO), mixtures of PP and polyethylene (PE), paper, and combinations thereof; an adhesive layer, wherein the adhesive layer is a pressure sensitive adhesive; and a silicone free release surface on the facestock layer; wherein the release surface contains raised portions allowing about 15% to about 70% contact to an opposing surface. This embodiment or another may provide for a laminate structure comprising: a facestock layer comprising high density polyethene (HDPE), a mixture of HDPE and low density polyethylene (LDPE), LDPE, polypropylene (PP), polyethylene terephthalate (PET), polyolefin (PO), mixtures of PP and polyethylene (PE), paper, and combinations thereof; an adhesive layer, wherein the adhesive layer is a pressure sensitive adhesive; and a silicone free release surface on the facestock layer; wherein the release surface contains raised portions allowing about 15% to about 70% contact to an opposing surface and is free of any silicon containing compound.

[0005] Additional exemplary embodiments relate to a laminate structure comprising: a self-wound laminate structure comprising: a facestock layer; an adhesive layer; and a silicone free release surface on top of the facestock layer; wherein the release surface comprises a plurality of microstructures with a space between each microstructure greater than 50pm, the release surface has ink coverage value greater than 80%, wherein the ink coverage value is measured by depositing an ink all over the release surface and measuring a surface area of the substrate covered by ink divided by the total area of the measured substrate of the ink after the ink dries, and a release force less than 200 cN/inch when the adhesive is in contact with the release surface in the self-wound configuration. This embodiment or another can provide for the release force is less than 30 cN/inch. This embodiment or another can provide for the release force is less than 20 cN/inch. This embodiment or another can provide for the ink coverage value greater than 90%. This embodiment or another can provide for the ink coverage value greater than 95%. This embodiment or another can provide for the plurality of microstructures approximate square pyramids. This embodiment or another can provide for the square pyramids have a height greater than 20pm and a base of greater than 80pm. This embodiment or another can provide for the spacing of the plurality of microstructures is greater than 75pm. This embodiment or another can provide for the release surface is selected from the group consisting of: high density polyethene (HDPE), a mixture of HDPE and low density polyethylene (LDPE), LDPE, polypropylene (PP), polyethylene terephthalate (PET), polyolefin (PO), mixtures of PP and polyethylene (PE), and combinations thereof. This embodiment or another can provide for the facestock layer is selected from the group consisting of: wherein the release surface is selected from the group consisting of: high density polyethene (HDPE), a mixture of HDPE and low density polyethylene (LDPE), LDPE, polypropylene (PP), polyethylene terephthalate (PET), polyolefin (PO), mixtures of PP and polyethylene (PE), and combinations thereof. This embodiment or another can provide for greater than 50% air between the release surface and the adhesive layer when in the self-wound configuration. This embodiment or another can provide for less than 30% contact between the release surface and the adhesive layer when in the self-wound configuration. This embodiment or another can provide for the plurality of microstructures approximate right cones. This embodiment or another can provide for the plurality of right cones are in a staggered formation.

[0006] Yet additional embodiments are directed towards a method comprising: providing a layer with no silicone; creating a microstructure on the layer resulting in an structured layer, wherein the structured layer has a ink coverage value greater than 80%, wherein the ink coverage value is measured by depositing an ink all over the release surface and measuring the a surface area of the substrate covered by ink divided by the total area of the measured substrate of the ink after the ink dries of the ink after the ink dries; laminating the structured layer with a facestock layer resulting in a laminated body; applying an adhesive to the facestock layer at a first side of the facestock layer resulting in a laminate structure; and winding the construction so that the structured layer is in contact with the adhesive layer, resulting in a self-wound configuration, wherein the structured layer has a release force less than 200 cN/inch when the adhesive is in contact with the structured layer in the self-wound configuration. This embodiment or another can provide for printing indicia on the layer prior to creating a microstructure. This embodiment or another can provide for printing indicia on the layer after creating a microstructure. This embodiment or another can provide for breaking partially the laminate structure by creating perforations along a length. This embodiment or another can provide for dispensing the construction by exposing the laminated structure; cutting entirely through the perforations on the laminated structure; and applying the laminated structure to an article. This embodiment or another can provide for dispensing the laminated structure; and applying the laminated structure to an article.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1 shows a 2D representation of one embodiment of an exemplary embodiment of the structural representation.

[0008] Figure 2 shows a 3D representation of one embodiment of an exemplary embodiment of the structural representation.

[0009] Figure 3 shows a diagram with exemplary measurements of a square pyramidal release coating as described herein. [0010] Figure 4A shows a representation of an exemplary embodiment consistent with Example 1 discussed herein.

[0011] Figure 4B shows a representation of an exemplary embodiment consistent with Example 2 discussed herein.

[0012] Figure 4C shows a representation of an exemplary embodiment consistent with Example 3 discussed herein.

[0013] Figure 4D shows a representation of an exemplary embodiment consistent with Example 4 discussed herein.

[0014] Figure 4E shows a representation of an exemplary embodiment consistent with Example 5 discussed herein.

[0015] Figure 4F shows a representation of an exemplary embodiment consistent with Example 6 discussed herein.

[0016] Figure 4G shows a representation of an exemplary embodiment consistent with Example 7 discussed herein.

[0017] Figure 4H shows a representation of an exemplary embodiment consistent with Example 8 discussed herein.

[0018] Figure 41 shows a representation of an exemplary embodiment consistent with Example 9 discussed herein.

[0019] Figure 41 shows a representation of an exemplary embodiment consistent with Example 9 discussed herein.

[0020] Figure 5A is an image of ink spread on an exemplary embodiment consistent with Example 1 discussed herein.

[0021] Figure 5B is an image of ink spread on an exemplary embodiment consistent with Example 2 discussed herein.

[0022] Figure 5C is an image of ink spread on an exemplary embodiment consistent with Example 3 discussed herein.

[0023] Figure 5D is an image of ink spread on an exemplary embodiment consistent with Example 4 discussed herein.

[0024] Figure 5E is an image of ink spread on an exemplary embodiment consistent with Example 5 discussed herein.

[0025] Figure 5F is an image of ink spread on an exemplary embodiment consistent with Example 6 discussed herein. [0026] Figure 5G is an image of ink spread on an exemplary embodiment consistent with Example 7 discussed herein.

[0027] Figure 5H is an image of ink spread on an exemplary embodiment consistent with Example 8 discussed herein.

[0028] Figure 51 is an image of ink spread on an exemplary embodiment consistent with Example 9 discussed herein.

[0029] Figure 6 is a graph showing summary of heights and other characteristics.

[0030] Figure 7 is a graph which summarizes results for the various patterns with respect to zippiness and release for PE80/PET50.

[0031] Figure 8 is a graph which summarizes results for the various patterns with respect to zippiness and release for PP/PET50.

DETAILED DESCRIPTION

Definitions

[0032] As used herein, "regular pattern" means the evenness, consistency, and/or balance in shape, arrangement, and/or pattern orientation variation and homogeneity that is repeating.

[0033] As used herein, "repeat pattern" means the pattern is regular in terms of shape, arrangement and/or pattern orientation and heterogeneity is repeating.

[0034] As used herein, "irregular pattern" means not even or balanced in shape, arrangement, and/or pattern orientation variation and heterogeneity that is non-repeating.

[0035] As used herein, "discontinuous" means that one or more regions, portions, parts, or spaces is not covered by a pattern.

[0036] As used herein, "continuous" means that all of one surface is covered by the pattern at some level.

[0037] As used herein, the term "laminate" or "laminate structure" means, with respect to construction, at least one adhesive coated material, generally with one or more additional layers. Nonlimiting examples of such layers to make up the multilayer include protective layers, spacing layers, adhesive layers, optical component-containing layers, metallic layers, barrier layers, release liners, tie coat layers, clear layers, color layers, white layers, reflective layers, fluid transfer layers, strength promoting layers, topcoats, print receptive layers, print containing layers, indicia layers, functional layers, and the like as well as combinations thereof. The resultant multilayer laminate construction described herein can be used for a variety of applications including, but not limited to, graphics applications, such as automobile and architectural wraps; reflective applications, such as road and traffic signs, trains and other commercial vehicles, etc.; and label and packaging applications.

Adhesives

[0038] The laminate structures described herein contain one or more adhesives. The adhesive(s) can be a pressure sensitive adhesive (PSA), a non-pressure sensitive adhesive, a hot-melt adhesive, or combinations thereof. In some embodiments, the adhesive is a PSA. The PSA may be any known PSA. In some embodiments, the PSA is a solvent type adhesive, an emulsion type adhesive, or non-emulsion type adhesive. In some embodiments, the PSA is an emulsion adhesive. Hot melt PSAs may also be used. The adhesive may be acrylic or any other useful adhesive which has the hardness and adhesive properties needed for the laminates and/or adhesive coated facestocks. In certain embodiments, the adhesive should have a hardness sufficient to prevent the adhesive squeezing out of the laminate or article during processing.

[0039] Exemplary PSAs may be found in (1) Encyclopedia of Polymer Science and Engineering, Vol. 13, Wiley-lnterscience Publishers (New York, 1988); (2) Polymer Science and Technology, Vol. 1, Interscience Publishers (New York, 1964); (3) those described in U.S. Pat. Nos. 5,164,444; 5,183,459; and 5,264,532, all issued to Bernard, and U.S. Pat. No. 5,385,965, issued to Bernard et al; and (4) combinations thereof. In some embodiments, the PSAs may be a solvent based or may be a water based adhesive. Conventional PSAs, including acrylic-based PSAs, rubber-based PSAs and silicone-based PSAs may be used in the laminates/constructs described herein. In some embodiments, the pressure sensitive adhesive contains an acrylic emulsion adhesive.

[0040] In exemplary embodiments, the coat weight of adhesives can be between 1 and 100 gsm.

Release Surface and Release Properties

[0041] The laminate structure further includes a silicone free release surface. The release surface can be provided by any suitable substrate such as for example a film. In some embodiments, the release surface is provided by a release film. In some embodiments, the release film is a release liner. In some embodiments, the release film can be any appropriately configured carrier film and other member instead of a release liner. Additionally, the release film may be the same material as the facestock, merely structured as discussed herein. [0042] In some embodiments, the release film may be patterned with a microstructure. Such a pattern can be in the shape of a square pyramid with a height and a base length, in some embodiments. This pattern may be repeated along the entirety of the release film and coating. In some embodiments, the height of the square pyramid may be between about 10pm and about 80pm. Further, in some embodiments, the base of the square pyramid may have a distance between about 15 and about 300pm. Additionally, in some embodiments there may be a space between the base of one pyramid and the start of an additional pyramid. In this instance, the space may be between about 25 and about 150pm. In other embodiments, there is no space between the square pyramids base. While exemplary embodiments discuss a pyramidal shape, it will be known to those in the art, that in some embodiments, the top of a pyramidal shape or other such three-dimensional shapes that come to a sharp point may not come to a sharp point and instead has a curved surface and hence has a larger surface area. Ideally, the contact surface area percentage in which acceptable release performance can be achieved can be between about 15% and about 70%. The less of a contact, the better release properties that may be obtained.

[0043] In other embodiments, the release film may be structured with a discontinuous and irregular pattern. In such a design, the contact area still can be between about 15% and about 70% on the surface. The less of a contact, the better release properties that may be obtained. In these embodiments, the ultimate shape and distribution of said shapes is dependent on the desired implementation with sufficient release properties. For example, depending on the use of the material, it may be desired to have a higher or lower release value based on the implementation. The release film is intended to promote release from a surface placed opposite itself in a self wound configuration. In all such embodiments, the release film is completely free of silicone or silicon containing compounds. This can be done to promote ease of recyclability of the end product.

[0044] In an exemplary embodiment, the laminate structure is a self-wound roll (i.e., without a liner adhered to itself around a roll) with release properties while being 100% silicone free as a result of the structures structured onto the layer. As a result, the adhesive layer may be overlaid onto the release surface, in a completed roll.

[0045] In other embodiments, the release liner may be structured with a discontinuous and irregular pattern. In such a design, the contact area still can be between about 15% and about 70% on the surface. The less of a contact, the better release properties that may be obtained. In this embodiment, the ultimate shape and distribution of said shapes is dependent on the desired implementation with sufficient release properties as will be discussed later. The release liner is intended to promote release from a surface placed opposite itself. In all such embodiments, the release liner is completely free of silicone or silicon containing compounds. This can be done to promote ease of recyclability of the end product.

[0046] In an exemplary embodiment, the construction is a self-wound roll with release properties while being 100% silicone free as a result of the structures structured onto the layer. As a result, the adhesive layer may be overlaid onto the release surface, in a completed roll.

Facestock

[0047] Suitable facestocks include, but are not limited to, synthetic papers such as polyolefin type and polystyrene type; various plastic films or sheets such as polyolefin, polyvinyl chloride, polyethylene terephthalate, polystyrene, polyurethane, polymethacrylate and polycarbonate. Additional examples of suitable facestocks include paper and cardboard. The facestock may be, or may include, a multilayer polymeric sheet. The multi-layers may be coextruded, or the multi-layers may be laminated together. In some embodiments, the facestock includes both co-extruded multi-layers and laminated multi-layers. In addition, a white opaque film may be formed by adding a white pigment to one or more of the aforementioned synthetic resins and used as the facestock. In some embodiments, a foamed film is used as the facestock. The foamed film may be formed by a conventional foaming operation. In another embodiment, the facestock may be a laminated body formed by combining a plurality of single layered sheets composed of the above listed materials. Examples of such a laminated body may include the combination of cellulose fiber paper with synthetic paper, and a laminated body of combined cellulose fiber paper with a plastic film or sheet. In another suitable embodiment, the facestock includes coated and uncoated papers, metalized papers, aluminum foil, laminated paper and paper with a polymeric material extruded onto the surface of the paper. In certain versions, the facestock can be coated with a liquid absorbent material. The selected facestock may be porous or semi-porous. The facestock may exhibit certain visibility characteristics such as opaqueness, color, and/or brightness. The facestock may include water or other liquid absorbency properties. The facestock may be electrically conductive and/or include electrically conductive coatings or regions. A wide array of commercially available facestocks can be used such as for example those available under the designation TESLIN (commercially available from PPG).

[0048] The thickness of the facestock is optionally determined with reference to application specific criteria. Such criteria may include the desired end use. In some embodiments, the sheet thickness is in a range of from about 10 pm to about 300 pm. In another embodiment, the sheet thickness is in a range of from about 20 pm to about 200 pm. In still another embodiment, the sheet thickness is in a range of from about 30 pm to about 150 pm. Optionally, a primer treatment or a corona discharging treatment or a plasma treatment may be used on the facestock to increase a bonding strength between the facestock and a dried topcoat composition to be formed on a surface of the facestock.

[0049] In certain embodiments described herein, the facestock exhibits one or more functions or functional characteristics. For example, the facestock may be selected to enable or promote an indication such as a visual indication of a liquid, outgassing such as directing or allowing flow of air or gas across a thickness of the facestock, water or liquid retention within the facestock, electrical discharge or conductivity of the facestock, chemical delivery across a thickness of the facestock, passage of sound across a thickness of the facestock, and/or combinations of these functions or characteristics.

Optional Layers

[0050] The adhesive coated facestock layer and/or laminate structures described herein can include one or more additional layers or components. Non-limiting examples of such layers include protective layers, tie coat layers, clear layers, color layers, white layers, reflective layers, fluid transfer layers, strength promoting layers, topcoats, print receptive layers, print containing layers, indicia layers, functional layers, and the like.

Laminate Properties

[0051] The laminate structures described herein may have specific and useful properties or functionalities. In some embodiments, the techniques described herein enable formation of laminates in which transfer, propagation, and/or migration of liquid, gas, sound waves, electrical current, and/or other agents or elements can occur and can be controlled across or through the laminate in a Z-direction. The reference to "Z-direction" as made herein refers to a direction across a thickness dimension of a laminate or portion thereof, and thus references to "X-direction" and/or "Y-direction" refer to directions perpendicular to the Z-direction and correspond to width and length dimensions of the laminate.

[0052] Non-limiting representative examples of laminates having certain functionalities which are provided by the present subject matter include liquid indicator laminates, outgassing laminates, water absorbent laminates, sound channeling laminates, electrically conductive laminates, and laminates having combinations of these functionalities and/or laminates having combinations of one or more of these functionalities and additional functionalities.

[0053] For example, a liquid indicator laminate can be produced such that the speed of the indicator color change is linked to the facestock selection and porous adhesive properties. A discontinuous structure, such as resulting from pores in the adhesive layer or region(s), can allow, for example, liquid to channel through the discontinuous adhesive from one side of the adhesive to the other side and create a permanent discoloration when a dye or other agent in a functional coating in the laminate is dissolved.

[0054] In some embodiments, a liquid indicator laminate is provided. The speed or rate of the indicator color change is linked to the facestock properties such as for example absorbency of liquid, and porosity of the pattern adhesive in the Z-direction. The indication typically is irreversible and can be measured by color change or by a simple visual comparison.

[0055] The discoloration of a face or region of the laminate can be measured and quantified by optical change, such as by CIE Lab or by a simple visual comparison. The discoloration can be permanent or nonpermanent. The discoloration can also be temporary and revert to an initial state after passage of a period of time. In some embodiments, the period of time is predetermined.

[0056] This phenomenon of transport through discontinuities in an adhesive in the Z-direction can be implemented in other label applications and particularly pressure sensitive adhesive labels, such as for example, labels for outgassing substrates such as by air channeling in the Z-direction, moist substrate labeling such as by liquid channeling in the Z-direction, electrical discharge in the Z-direction, chemical delivery from one layer to another in the Z-direction, and/or sound channeling in the Z-direction. This phenomenon enables passage, transfer, and/or migration of a medium or agent from one side of an adhesive region of a laminate, to another side of the adhesive region. Although medium penetration or transport is noted as being in the Z-direction, it will be understood that the present subject matter is not limited to such and may also include penetration/transport in the X-direction and/or Y-direction.

[0057] In some embodiments, the laminates described herein include a layer or region of a secondary adhesive. The secondary adhesive is typically utilized to adhere the laminate to a substrate of interest. The secondary adhesive may contain one or more adhesives which are the same or different than the adhesive of the patterned or porous adhesive. Description of representative examples of secondary adhesives are provided herein. In such an adhesive configuration, the primary adhesive may be coated onto the facestock, the secondary adhesive may be coated onto the release liner, and the coated adhesive and release liner may be laminated together such that the primary and secondary adhesives are in direct contact with each other. Alternatively, or additionally, both the primary and secondary adhesive may be coated on the facestock or the release liner, then laminated together. It is contemplated that the layering of the primary and secondary adhesive relative to the facestock and the release liner may be either facestock, primary adhesive, secondary adhesive, and release liner or facestock, secondary adhesive, primary adhesive, release liner. Regardless of the order of primary and secondary adhesive, it is contemplated that in some embodiments, at least one of the primary and secondary adhesive is patterned, taking into consideration that the other adhesive may be continuous.

[0058] In some embodiments, an array of different arrangements of layers and components may be utilized. In some embodiments using a patterned adhesive, e.g., the layer of discontinuous adhesive, that layer is disposed between a functional facestock and a liner or functional layer. And in the liquid indicator laminates, the patterned adhesive may be disposed between the functional facestock and the layer or region of functional agent that is sensitive to liquid passing through the laminate. And, in the liquid indicator laminates, the layer or region of the functional agent may be disposed between the patterned adhesive and the carrier layer.

[0059] Utilization of the techniques and features described herein enable production of adhesive laminates and/or adhesive coated facestocks with fluid/air management characteristics, controlled removability, and/or unique thermal and/or electrical conductivity. In addition, use of these techniques and features enable reductions in materials, e.g., adhesives, and thus enable cost savings. However, it will be understood that the present subject matter includes the adhesive coated facestocks and laminates described herein which are formed by other methods than the methods described herein.

Top Coat Formulation and Application

[0060] As noted hereinabove, in some embodiments, a topcoat is present on the surface of the facestock. The top coat coating can be deposited on the any layer by any suitable method. In embodiments, the suitable method includes any suitable coating technology. Embodiments include depositing the coating on the any layer via liquid deposition method. Without limitation, examples of suitable methods include bath coating, spray coating, slot coating, spin coating, curtain coating, gravure coating, reverse gravure print coating, reverse roll coating, knife over roll (i.e., gap) coating, metering (Meyer) rod coating, air knife coating, or any combinations thereof. Bath coating includes immersion or dip in the aqueous solution. In an embodiment, the coating is deposited by bath in the aqueous solution. In other embodiments, the coating is deposited by spray of the aqueous solution.

Exemplary Laminate Structures

[0061] Exemplary laminate structures are illustrated generally by the exemplary Figures 1-3. Figure 1 shows an example 2-dimensional construction 100 with a patterned release surface 102, an exemplary facestock layer 104, and an exemplary adhesive layer 106. While for the purpose of illustration, there is shown as a gap between the facestock 104 and the pattern 102, this is not necessarily the case and in another embodiment the pattern 102 is structured into the facestock 104 allowing the pattern 102 to be an extension of the facestock 104. In Figure 2, an exemplary square pyramid is shown. In this view, a height h can be shown along with a base of the pyramid length b and a distance between pyramids d. Similarly, one can see in Figure 3 a microscopic look of an exemplary construction 100 where the patterned release surface 102 is seen on an exemplary facestock 104. In some embodiments the patterned release surface 102 can be the same material as the exemplary facestock 104. In other embodiments, the patterned release surface can be separately patterned and adhered or otherwise attached to the facestock.

[0062] A roll was constructed in order to emboss the release liner with various patterns of height h, along with a base of the pyramid length b and a distance between pyramids d. While these patterns are made, limitations of the material used to construct the roll, tool error, and the release liner with its elastic properties and thicknesses lead to slightly different heights of the pyramids. This will be discussed as actual results versus some of theoretical considerations. Figure 6 shows a summary of these results.

Methods

[0063] Having discussed various components of the apparatus, exemplary methods and methodologies of operation will be discussed.

[0064] The laminate structures can be prepared by any suitable method. In some embodiments, the method includes providing a layer with no silicone and creating a pattern on the layer, thereby providing a structured release surface. In some embodiments, the pattern is created by passing the layer over an engraved roll; and embossing the layer through contact with the engraved roll resulting in a structured layer. In some embodiments, the patterned release surface can be created by means other than embossing. This can include known disposition techniques including but not limited to inkjet printing, aerosol jet printing, screen printing, physical vapor deposition, chemical vapor deposition, atomic layer deposition, and other coating techniques. In some embodiments, after printing the patterned release surface has an ink coverage value greater than 80%, wherein the ink coverage value is measured by depositing an ink all over the release surface and measuring a surface area of the substrate covered by ink divided by the total area of the measured substrate of the ink after the ink dries. In some embodiments the ink coverage is greater than 85%. In some embodiments the ink coverage is greater than 90%. In some embodiments the ink coverage is greater than 95%.

[0065] The method can further include laminating the structured layer with a facestock layer resulting in a laminated body; and applying an adhesive to the facestock layer at a first side of the facestock layer resulting in a laminate structure. The method can further include winding the construction so that the structured layer is in contact with the adhesive layer. In some embodiments, the method results in a self-wound configuration, wherein the patterned release surface layer has a release force less than 200 cN/inch when the adhesive is in contact with the patterned release surface in the self-wound configuration. In some embodiments, the method comprises: providing a layer with no silicone; passing the layer over an engraved roll; embossing the layer through contact with the engraved roll resulting in an patterned release surface, wherein the patterned release surface has an ink coverage value greater than 80%, wherein the ink coverage value is measured by depositing an ink all over the release surface and measuring the a surface area of the substrate covered by ink divided by the total area of the measured substrate of the ink after the ink dries; laminating the structured layer with a facestock layer resulting in a laminated body; applying an adhesive to the facestock layer at a first side of the facestock layer resulting in a construction; and winding the construction so that the structured layer is in contact with the adhesive layer, resulting in a self-wound configuration, wherein the structured layer has a release force less than 200 cN/inch when the adhesive is in contact with the structured layer in the self-wound configuration. In some embodiments the ink coverage is greater than 85%. In some embodiments the ink coverage is greater than 90%. In some embodiments the ink coverage is greater than 95%. Additionally, in some embodiments, the release force can be less than 30 cN/inch. In some embodiments the release force can be less than 20 cN/inch.

[0066] The method can further include printing indicia on the layer prior to embossing the layer. Alternatively, the method can further comprise printing indicia on the layer after embossing the layer. The method can further include breaking partially the laminated body by creating perforations along a length. This can further be modified by dispensing the construction by exposing the laminated body; cutting entirely through the perforations on the construction; and applying the construction to an article. The method can culminate in dispensing the construction; and applying the construction to an article.

[0067] In some embodiments, are directed towards printing using flexographic printing. This type of printing is a versatile printing technique that utilizes a flexible relief plate. It's a popular choice for printing on various materials, including paper, plastic, cellophane, and metallic films. This makes it ideal for packaging, labels, and other applications where flexibility and durability are crucial. The process involves creating a raised image on a flexible plate, typically made of photopolymer. This plate is then wrapped around a rotating cylinder. Ink is applied to the raised areas of the plate and transferred directly to the substrate (the material being printed on). One of the key advantages of flexo printing is its adaptability. It can accommodate a wide range of inks, including water-based, solvent-based, and UV-curable inks, allowing for printing on various surfaces with different adhesion and drying requirements. Flexo printing is known for its high speed and efficiency, making it suitable for large print runs. It's particularly well- suited for printing large areas of solid color and intricate designs. Additionally, flexo presses can be configured with multiple printing stations, enabling inline processes like varnishing, laminating, and diecutting, streamlining production.

[0068] Other printing techniques that could be used include offset printing. This common method involves transferring inked images from a plate to a rubber blanket and then onto the printing surface. It's known for high-quality images, versatility, and cost-effectiveness for large print runs. Another is digital printing. This involves printing directly from digital files without the need for printing plates. It's ideal for quick turnaround times, short runs, and variable data printing (e.g. personalized items). Alternatively, gravure could be utilized through using engraved cylinders to transfer ink onto the printing surface.

[0069] In some embodiments are directed towards printing using flexographic printing for printing ink. This type of printing is a versatile printing technique that utilizes a flexible relief plate. It's a popular choice for printing on various materials, including paper, plastic, cellophane, and metallic films. This makes it ideal for packaging, labels, and other applications where flexibility and durability are crucial. The process involves creating a raised image on a flexible plate, typically made of photopolymer. This plate is then wrapped around a rotating cylinder. Ink is applied to the raised areas of the plate and transferred directly to the substrate (the material being printed on). One of the key advantages of flexo printing is its adaptability. It can accommodate a wide range of inks, including water-based, solvent-based, and UV- curable inks, allowing for printing on various surfaces with different adhesion and drying requirements. Flexo printing is known for its high speed and efficiency, making it suitable for large print runs. It's particularly well-suited for printing large areas of solid color and intricate designs. Additionally, flexo presses can be configured with multiple printing stations, enabling inline processes like varnishing, laminating, and die-cutting, streamlining production.

[0070] Other printing techniques that could be used include offset printing. This common method involves transferring inked images from a plate to a rubber blanket and then onto the printing surface. It's known for high-quality images, versatility, and cost-effectiveness for large print runs. Another is digital printing. This involves printing directly from digital files without the need for printing plates. It's ideal for quick turnaround times, short runs, and variable data printing (e.g., personalized items). Alternatively, gravure could be utilized through using engraved cylinders to transfer ink onto the printing surface. Examples

Example 1

[0071] A square pyramid of pattern was engraved onto a roll. The pattern engraved is shown on Figure 4A. The square pyramid has a height of 25.0 pm, a base length of 100 pm. There was no distance between the pyramids, in that the square bases of the pyramids touched with the base of another pyramid. The roll was then pressed against a facestock to form a three-dimensional structure on the facestock. Various facestock and release surface substrates along with subsequent releasably tests were then performed. These facestocks and release surface substrates included, but were not limited to, high density polyethene (HDPE), a mixture of HDPE and low density polyethylene (LDPE), LDPE, polypropylene (PP), polyethylene terephthalate (PET), polyolefin (PO), any combination of PP and polyethylene (PE), paper, and combinations thereof. When embossing the release surface, various factors inform the ultimate depth of the structures. These include, but are not limited to the modulus of the material being embossed, the temperature at which embossing occurs, the pressure at which embossing occurs, the contact time of the embossing, and the humidity when the embossing occurs. Thus, actual heights can differ from the theoretical heights on the engraved pattern as materials may relax or partially relax. Thus, the actual height of the pyramids when embossed on cPP/PET (cPP/PET sample was cPP coated on PET substrate and the embossed structure was on the cPP side) was approximately 18 pm. Further, the actual height of the embossed PE80/PET50 was approximately 18 pm.

[0072] The sample was then tested with release properties and print ink coverage. Print ink coverage results are shown on Figure 5A.

Example 2

[0073] A square pyramid of pattern was engraved onto a roll. The square pyramid has a height of 50.0 pm, a base length of 100 pm. The pattern engraved is shown on Figure 4B. There was no distance between the pyramids. In that the square bases of the pyramids touched with the base of another pyramid. The roll was then pressed against a facestock to form a three-dimensional structure on the facestock. Various facestock and release surface substrates along with subsequent releasably tests were then performed. These facestocks and release surface substrates included, but were not limited to, HDPE, a mixture of HDPE and LDPE, PET, LDPE, PP, PO, combinations of PP and PE, paper and combinations thereof. Actual height of the pyramids when embossed on cPP/PET was approximately 25 pm. Further, the embossed PE80/PET50 was approximately 31 pm. [0074] The sample was then tested with release properties and print ink coverage. Print ink coverage results are shown on Figure 5B.

Example 3

[0075] A square pyramid of pattern was engraved onto a roll. The pattern engraved is shown on Figure 4C. The square pyramid has a height of 25.0 pm, a base length of 250 pm. There was no distance between the pyramids, in that the square bases of the pyramids touched with the base of another pyramid. The roll was then pressed against a facestock to form a three-dimensional structure on the facestock. Various facestock and release surface substrates along with subsequent releasably tests were then performed. These facestocks and release surface substrates included, but were not limited to, but were not limited to, HDPE, a mixture of HDPE and LDPE, PET, LDPE, PP, PO, combinations of PP and PE, paper and combinations thereof. Actual height of the pyramids when embossed on cPP/PET was approximately 22 pm. Further, the embossed PE80/PET50 was approximately 19 pm.

[0076] The sample was then tested with release properties and print ink coverage. Print ink coverage results are shown on Figure 5C.

Example 4

[0077] A square pyramid of pattern was engraved onto a roll. The pattern engraved is shown on Figure 4D. The square pyramid has a height of 50.0 pm, a base length of 250 pm. There was no distance between the pyramids. There is no distance between the pyramids. In that the square bases of the pyramids touched with the base of another pyramid. The roll was then pressed against a facestock to form a three-dimensional structure on the facestock. Various facestock and release surface substrates along with subsequent releasably tests were then performed. These facestocks and release surface substrates included, but were not limited to, HDPE, a mixture of HDPE and LDPE, PET, LDPE, PP, PO, combinations of PP and PE, paper and combinations thereof. Actual height of the pyramids when embossed on cPP/PET was approximately 45 pm. Further, the embossed PE80/PET50 was approximately 40 pm.

[0078] The sample was then tested with release properties and print ink coverage. Print ink coverage results are shown on Figure 5D. Example 5

[0079] A square pyramid of pattern was engraved onto a roll. The pattern engraved is shown on Figure 4E. The square pyramid has a height of 25.0 pm, a base length of 100 pm. There was 100 pm distance between the sides of the base of the pyramids. The roll was then pressed against a facestock to form a three-dimensional structure on the facestock. Various facestock and release surface substrates along with subsequent releasably tests were then performed. These facestocks and release surface substrates included, but were not limited to, HDPE, a mixture of HDPE and LDPE, PET, LDPE, PP, PO, combinations of PP and PE, paper and combinations thereof. Actual height of the pyramids when embossed on cPP/PET was approximately 21 pm. Further, the embossed PE80/PET50 was approximately 19 pm.

[0080] The sample was then tested with release properties and print ink coverage. Print ink coverage results are shown on Figure 5E.

Example 6

[0081] A square pyramid of pattern was engraved onto a roll. The pattern engraved is shown on Figure 4F. The square pyramid has a height of 50.0 pm, a base length of 100 pm. There was 100 pm distance between the pyramids. The roll was then pressed against a facestock to form a three- dimensional structure on the facestock. Various facestock and release surface substrates along with subsequent releasably tests were then performed. These facestocks and release surface substrates included, but were not limited to, HDPE, a mixture of HDPE and LDPE, PET, LDPE, PP, PO, combinations of PP and PE, paper and combinations thereof. Actual height of the pyramids when embossed on cPP/PET was approximately 30 pm. Further, the embossed PE80/PET50 was approximately 26 pm.

[0082] The sample was then tested with release properties and print ink coverage. Print ink coverage results are shown on Figure 5F.

Example 7

[0083] A square pyramid of pattern was engraved onto a roll. The pattern engraved is shown on Figure 4G. The square pyramid has a height of 25.0 pm, a base length of 250 pm. There was 100 pm distance between the pyramids. The roll was then pressed against a facestock to form a three- dimensional structure on the facestock. Various facestock and release surface substrates along with subsequent releasably tests were then performed. These facestocks and release surface substrates included, but were not limited to, HDPE, a mixture of HDPE and LDPE, PET, LDPE, PP, PO, combinations of PP and PE, paper and combinations thereof. Actual height of the pyramids when embossed on cPP/PET was approximately 21 pm. Further, the embossed PE80/PET50 was approximately 23 pm.

[0084] The sample was then tested with release properties and print ink coverage. Print ink coverage results are shown on Figure 5G.

Example 8

[0085] A square pyramid of pattern was engraved onto a roll. The pattern engraved is shown on Figure 4H. The square pyramid has a height of 50.0 pm, a base length of 250 pm. There was 100 pm distance between the pyramids. The roll was then pressed against a facestock to form a three- dimensional structure on the facestock. Various facestock and release surface substrates along with subsequent releasably tests were then performed. These facestocks and release surface substrates included, but were not limited to, HDPE, a mixture of HDPE and LDPE, PET, LDPE, PP, PO, combinations of PP and PE, paper and combinations thereof. Actual height of the pyramids when embossed on cPP/PET was approximately 45 pm. Further, the embossed PE80/PET50 was approximately 41 pm.

[0086] The sample was then tested with release properties and print ink coverage. Print ink coverage results are shown on Figure 5H.

Example 9

[0087] A square pyramid of pattern was engraved onto a roll. The pattern engraved is shown on Figure 41. The square pyramid has a height of 37.5 pm, a base length of 175 pm. There was 50 pm distance between the pyramids. The roll was then pressed against a facestock to form a three-dimensional structure on the facestock. Various facestock and release surface substrates along with subsequent releasably tests were then performed. These facestocks and release surface substrates included, but were not limited to, HDPE, a mixture of HDPE and LDPE, PET, LDPE, PP, PO, combinations of PP and PE, paper and combinations thereof. Actual height of the pyramids when embossed on cPP/PET was approximately 33 pm. Further, the embossed PE80/PET50 was approximately 26 pm.

[0088] The sample was then tested with release properties and print ink coverage. Print ink coverage results are shown on Figure 51.

[0089] The optimal microstructure for a printable release surface is the pattern that can minimize the contact with adhesives which does not affect the printability. Printability is measured as an ink coverage value. This ink coverage value is related to the percentage of a surface covered by ink after the ink dries. In this case, the ink coverage value is measured by depositing an ink all over the release surface and measuring a surface area of the substrate covered by ink divided by the total area of the measured substrate of the ink after the ink dries. General spreading is driven by type of polymer and pattern (namely the shape and height) and any release depends on the percentage of contact area (by calculation and release value). Generally continuous contact yields smooth release while discontinuous contact yields "zippy" release. Exemplary embodiments provide for an adhesive thickness which is lower than the depth of the structure. Figure 7 summarizes these results based on release properties and zippiness for the various patterns for PE80/PET50 while Figure 8 summarizes it for PP/PET50.

[0090] Based on the height parameter and modeling, a contact area can be defined as a percentage where the adhesive would be in contact with the structured release surface, a contact area is able to be calculated based on the adhesive on top of the structured surface. For example, a non-structured surface would have 100% contact area. Lower percentages help to provide better release properties as less adhesive is in contact. However, a minimal level of contact must still be maintained to allow for adhesion. The contact area was calculated in one example of the adhesive layer of about 15pm thickness (~15gsm), under the pressure of self-winding, the compression of 10pm depth of the peak of the structure into the adhesive layer. Assume x is the total height of the structure that x-h is the portion that is compressed with h remaining uniform. Therefore, it is 10pm from the peak of pyramid uniform everywhere, the total area that is in contact with the adhesive is then calculated in two-dimensional space and expressed as a percentage. In a repetitive selected area (for example of 4 units of pattern), the percentage of the contact area is a ratio of total surface area. This contact area is a function proportional to the release values as greater adhesive contact leads to greater adhesion. In one such embodiment the adhesive is coated at 15gsm with approximately 10 pm compression.

[0091] Additionally, a percentage of air was calculated. This is the percentage of air volume compared to the total volume of structured layer. Higher percentages promote release properties, while lower percentages promote adhesion. Similarto the contact area above, the air percentage was calculated in one example of the adhesive layer of about 15pm thickness (~15gsm), under the pressure of selfwinding, the compression of 10pm depth of the peak of the structure into the adhesive layer. Thus, in this instance, the volume, rather than total area was considered. The air percentage is the total volume, less the contact volume, expressed as a percentage. Air percentage may vary depending on the specific substrate and specific thickness of said substrate in which both the adhesive is applied to and the facestock when the construction is self-wound.

[0092] Release was then measured based on experimental data in accordance with the FINAT FTM4 Test at lOm/min. Finally, ink coverage percentage was obtained. This percentage basically refers to the level of spread, or lack thereof of the ink when it is deposited onto the structured release surface. A value of 100% is given to a flat surface. A given surface area with ink was chosen. The ink coverage in percentage of the selected area is the ratio of the total black area (ink) divided for total area (black and white area without ink). This area and amount of total black area was calculated by imaging software of the microscope.

[0093] Summary results can be found in Table 1 below.

Table 1

[0094] Examples 2, 4, 8, and 9 all showed insufficient ink coverage. As a requirement for this project, the ink coverage must be paramount as there is ink to be dispersed on top of the patterned release so as to allow for a fully self-wound product. Further, the release properties of Example 1, 3, 5, and 7 were all much too high of values, making release difficult, for the structure to be used effectively without risking marring the printed ink. Therefore, Example 6 is the only pattern that performed adequately for a selfwound decorative linerless product. However, other such patterns could be appropriate depending on the desired implementation. For example, the release properties must only be sufficient to reliably unwind given desired parameters and material composition. A more robust material that may have greater deformation properties without delaminating or failing when unwinding may allow for a higher release when possible or appropriate as separation would be able to occur without material failure or deformation.

[0095] Additionally, while this disclosure generally focuses on regular patterns, it is of note that regular patterns can offer some form of visual limitation. Specifically, a moire pattern is a visual phenomenon that occurs when two repetitive patterns are overlaid, creating a new, often unintended, pattern. These patterns are typically grids of lines or dots, but can also be more complex shapes. In this instance, it is possible to observe a moire pattern when viewed. As such, other patterns, such as cone structures have been hypothesized as solutions to this problem. The cone structure approximating a right cone is capable of diffusing such a pattern so that a moire pattern is not perceived by the human eye. Other possibilities include using different shapes that can include but are not limited to, oblique pyramids with an apex that is not directly above the center of the base, unlike right pyramids, triangular pyramids (Tetrahedrons) which are pyramids have a triangular base and three triangularfaces, pentagonal pyramids or pyramids with a pentagonal base and five triangular faces, prisms with two congruent bases, but the lateral faces of a prism are rectangles, right cones, cones, half circles, ovals or ellipsoidal. In the instance of a right cone, this structure has a flat, circular base, a pointed tip called the vertex (or apex) and the line connecting the vertex to the center of the circular base (called the axis) is perpendicular to the plane of the base. This means it forms a right angle (90 degrees) with the base, thus a right cone.

[0096] Alternatively, a random pattern or pseudo random pattern can be used in some embodiments. In the instance of a pseudo random pattern, unlike true randomness (which is inherently unpredictable), pseudo randomness is generated by a deterministic algorithm. This means that if you know the algorithm and its starting conditions (called the "seed"), you can perfectly reproduce the entire sequence. The pseudo randomness is a carefully crafted imitation of randomness, useful in situations where true randomness isn't necessary or is difficult to obtain. It offers the benefits of seeming random while also being reproducible. By having microstructures be embossed, deposited, or structured onto a release surface with printed text and graphics, this offers another solution in order to best suppress a potential moire pattern.

[0097] Other techniques to print the ink as discussed above could also be used in order to remove any problematic pattern.

[0098] All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and/or ordinary meanings of the defined terms.

[0099] The articles "a" and "an," as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to mean "at least one." The phrase "and/or," as used herein in the specification and in the claims (if at all), should be understood to mean "either or both" of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with "and/or" should be construed in the same fashion, i.e., "one or more" of the elements so conjoined. Other elements may optionally be present other than the elements specifically identified by the "and/or" clause, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to "A and/or B", when used in conjunction with open-ended language such as "comprising" can refer, in some embodiments, to A only (optionally including elements other than B); in another embodiment, to B only (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); etc. As used herein in the specification and in the claims, "or" should be understood to have the same meaning as "and/or" as defined above. For example, when separating items in a list, "or" or "and/or" shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as "only one of" or "exactly one of," or, when used in the claims, "consisting of," will refer to the inclusion of exactly one element of a number or list of elements. In general, the term "or" as used herein shall only be interpreted as indicating exclusive alternatives (i.e. "one or the other but not both") when preceded by terms of exclusivity, such as "either," "one of," "only one of," or "exactly one of." "Consisting essentially of," when used in the claims, shall have its ordinary meaning as used in the field of patent law.

[0100] As used herein in the specification and in the claims, the phrase "at least one," in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements may optionally be present other than the elements specifically identified within the list of elements to which the phrase "at least one" refers, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, "at least one of A and B" (or, equivalently, "at least one of A or B," or, equivalently "at least one of A and/or B") can refer, in some embodiments, to at least one, optionally including more than one, A, with no B present (and optionally including elements other than B); in another embodiment, to at least one, optionally including more than one, B, with no A present (and optionally including elements other than A); in yet another embodiment, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other elements); etc.

[0101] An embodiment is an implementation or example of the present disclosure. Reference in the specification to "an embodiment," "some embodiments," "one particular embodiment," or "other embodiments," or the like, means that a particular feature, structure, or characteristic described in connection with the embodiments is included in at least some embodiments, but not necessarily all embodiments, of the invention. The various appearances "an embodiment," "some embodiments," "one particular embodiment," or "other embodiments," or the like, are not necessarily all referring to the same embodiments.

[0102] If this specification states a component, feature, structure, or characteristic "may", "might", or "could" be included, that particular component, feature, structure, or characteristic is not required to be included. If the specification or claim refers to "a" or "an" element, that does not mean there is only one of the element. If the specification or claims refer to "an additional" element, that does not preclude there being more than one of the additional element.

[0103] As used herein in the specification and claims, including as used in the examples and unless otherwise expressly specified, all numbers may be read as if prefaced by the word "about" or "approximately," even if the term does not expressly appear. The phrase "about" or "approximately" may be used when describing magnitude and/or position to indicate that the value and/or position described is within a reasonable expected range of values and/or positions. For example, a numeric value may have a value that is +/-0. % of the stated value (or range of values), +/-!% of the stated value (or range of values), +/-2% of the stated value (or range of values), +/- % of the stated value (or range of values), +/- 10% of the stated value (or range of values), etc. Any numerical range recited herein is intended to include all sub-ranges subsumed therein.

[0104] Additionally, any method of performing the present disclosure may occur in a sequence different than those described herein. Accordingly, no sequence of the method should be read as a limitation unless explicitly stated. It is recognizable that performing some of the steps of the method in a different order could achieve a similar result.

[0105] In the claims, as well as in the specification above, all transitional phrases such as "comprising," "including," "carrying," "having," "containing," "involving," "holding," "composed of," and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases "consisting of" and "consisting essentially of" shall be closed or semi-closed transitional phrases, respectively, as set forth in the United States Patent Office Manual of Patent Examining Procedures.

[0106] In the foregoing description, certain terms have been used for brevity, clarity, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed. [0107] Moreover, the description and illustration of various embodiments of the disclosure are examples and the disclosure is not limited to the exact details shown or described.

Claims

CLAIMS We claim:

1. A self-wound laminate structure comprising: a facestock layer; an adhesive layer; and a silicone free release surface on top of the facestock layer; wherein the release surface comprises a plurality of microstructures with a space between each microstructure greater than 50pm, the release surface has ink coverage value greater than 80%, wherein the ink coverage value is measured by depositing an ink all over the release surface and measuring a surface area of the substrate covered by ink divided by the total area of the measured substrate of the ink after the ink dries, and a release force less than 200 cN/inch when the adhesive is in contact with the release surface in the self-wound configuration.

2. The self-wound laminate structure of claim 1, wherein the release force is less than 30 cN/inch.

3. The self-wound laminate structure of claim 1, wherein the release force is less than 20 cN/inch.

4. The self-wound laminate structure of claim 1, wherein the ink coverage value is greater than 90%.

5. The self-wound laminate structure of claim 1, wherein the ink coverage value is greater than 95%.

6. The self-wound laminate structure of claim 1, wherein the plurality of microstructures approximate square pyramids.

7. The plurality of microstructures of claim 6, wherein the square pyramids have a height greater than 20pm and a base of greater than 80pm.

8. The self-wound laminate structure of claim 1, wherein the spacing of the plurality of microstructures is greater than 75pm.

9. The self-wound laminate of claim 1, wherein the release surface is selected from the group consisting of: high density polyethene (HDPE), a mixture of HDPE and low density polyethylene (LDPE), LDPE, polypropylene (PP), polyethylene terephthalate (PET), polyolefin (PO), mixtures of PP and polyethylene (PE), and combinations thereof.

10. The self-wound laminate of claim 1, wherein the facestock layer is selected from the group consisting of: wherein the release surface is selected from the group consisting of: high density polyethene (HDPE), a mixture of HDPE and low density polyethylene (LDPE), LDPE, polypropylene (PP), polyethylene terephthalate (PET), polyolefin (PO), mixtures of PP and polyethylene (PE), and combinations thereof.

11. The self-wound laminate of claim 1, wherein there is greaterthan 50% air between the release surface and the adhesive layer when in the self-wound configuration.

12. The self-wound laminate of claim 1, wherein there less than 30% contact between the release surface and the adhesive layer when in the self-wound configuration.

13. The self-wound laminate structure of claim 1, wherein the plurality of microstructures approximate right cones.

14. The microstructures of claim 13, wherein the plurality of right cones are in a staggered formation.

15. A method comprising: providing a layer with no silicone; creating a microstructure on the layer resulting in a structured layer, wherein the structured layer has an ink coverage value greater than 80%, wherein the ink coverage value is measured by depositing an ink all over the release surface and measuring a surface area of the substrate covered by ink divided by the total area of the measured substrate of the ink after the ink dries of the ink after the ink dries; laminating the structured layer with a facestock layer resulting in a laminated body; applying an adhesive to the facestock layer at a first side of the facestock layer resulting in a laminate structure; and winding the construction so that the structured layer is in contact with the adhesive layer, resulting in a self-wound configuration, wherein the structured layer has a release force less than 200 cN/inch when the adhesive is in contact with the structured layer in the self-wound configuration.

16. The method of claim 15, further comprising: printing indicia on the layer prior to creating a microstructure.

17. The method of claim 15, further comprising: printing indicia on the layer after creating a microstructure.

18. The method of claim 15, further comprising: breaking partially the laminate structure by creating perforations along a length.

19. The method of claim 18, further comprising: dispensing the construction by exposing the laminated structure; cutting entirely through the perforations on the laminated structure; and applying the laminated structure to an article.

20. The method of claim 15, further comprising; dispensing the laminated structure; and applying the laminated structure to an article.