Note: Descriptions are shown in the official language in which they were submitted.
2 ~ 0 0 ~
DE-TA~K~;I~ CONTINUOUS EXTRUSION PROCESS
APPLIED INTEGRATED LABEL PRODUCT
BACKGROUND AND SUMMARY OF THE INVENTION
Business forms in cut sheet format having at least one label (with
pressure sensitive adhesive) and suitable for variable printing in a non-impact
printer (such as a laser printer or other printer using a heat-curable toner) are
0 referred to as integrated labels, and are exemplified by U.S. patent 5,129,682.
In current m~nuf~cturing processes a hot melt extrusion die adhesive
application method is utilized in which a continuous stream of pressure
sensitive hot melt adhesive is applied to a release web, the release web is
l~min~tt~d to a paper web, one or more labels are die cut, and a continuous
form format is cut into individual sheets. The paper face sheet typically
comprises 20-28 lb. [per 500 sheets of paper per ream with dimensions of 17 x
22 inches] bond paper, while the release sheet is typically 25-50 lb. [per 500
sheets of paper per ream with dimensions of 22 x 36 inches] weight material.
While this technique is extremely efficient and cost effective, the integrated
20 label produced has pres~ule sensitive adhesive extending to at least one, andtypically to two opposite cut edges of each form. This presents a significant
cont~min~tion problem in non-impact printers for variably printing indicia on
the integrated labels, such as laser printers or other non-impact p~ s
utilizing a heat curable toner to apply indicia. Cont~min~tion can occur in the
25 nip rolls for the laser printer, or in other printer paper guiding and feed system
components, and the build up of adhesive can eventually cause poor
pe~ rOl l~lance of the printer or terminate its operation altogether, the adhesive
building up due to the tacky nature thereof.
One-way in which the above ~lle~liolled problem can be avoided is to
30 apply the a&esive in a pattern rather than in a continuous strip. When applied
in a pattern, the pattern includes a hiatus at the edges where the continuous
web will be cut into sheets. However this m~nllf~rt-lring method is slower and
more costly than the extrusion die continuous strip method. Therefore it is
desirable to be able to solve the problem of the adhesive cont~min~ting laser
5 printers which act upon the integrated labels while at the same time allowing
m~nllf~ctllre using the continuous strip application of pfessllle sensitive
adhesive.
According to the present invention the desired results of preventing
printer cont~min~tion as a result of adhesive built up, while still allowing
o production of the integrated labels ~ltili7ing the continuous strip method, are
provided. The invention accomplishes these desired goals by utili7ing as the
pressure sensitive adhesive an a&esive that becomes de-tackified by direct
exposure to a sufficient type and dosage of electromagnetic radiation.
Typicaily this is accomplished utilizing a specially formulated hot melt
adhesive that is sensitive to ultraviolet energy so that when exposed to, e.g.,
about 3000 mj/cm2 total dosage of ultraviolet radiation, the edges of the
integrated labels (where the release and bond sheet overlap) is rendered de-
tackified, and therefore will not ill~e~rere with operation of, or otherwise
cont~min~te, a non-impact printer. There are several aspects of the present
20 invention employing this basic concept.
According to one aspect of the present invention a method of producing
a sheet having at least one label and suitable for variable printing in a non-
impact printer, is provided. The method comprises the steps of: (a) Applying
a continuous strip- of pressu-e sensitive adhesive, that is de-tackified by direct
25 exposure to a sufficient type and dosage of electromagnetic radiation, to a
release sheet. (b) Applying the release sheet to a first face of a web of paper
so that the release sheet covers only a portion of the first face and the adhesive
is attached to the web. (c) Forming at least one label in each of a plurality ofpredetermined lengths of the web at the portion of each web predetermined
30 length covered by the release sheet. (d) Cutting the web into individual sheet
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lengths, each sheet having at least a first edge of the paper at which the release
sheet is provided. (e) Exposing the first edge to the sufficient type and dosageof the electromagnetic radiation that de-tackifies the adhesive so that the
adhesive at the first edge becomes de-tackified. And, (f) subsequently using
5 the sheet in a heat-curable toner non-impact printer.
The adhesive is preferably rendered de-t~rl~ifie~l by ultraviolet
radiation, and step (e) is practiced by exposing a sheet to ultraviolet radiation,
e.g. exposing hot melt adhesive to about 3000 mj/cm2 total dosage of
ultraviolet radiation.
o The first edge may be a common edge of the paper and release sheet,
and there may be the further step (g), between steps (d) and (e) of stacking a
plurality of sheets in a stack with subst~nti~lly aligned first edges. Step (e) is
then practiced with the sheets in the stack (although alternatively step (e) maybe practiced on individual sheets). Step (g) may be further practiced by
placing chip board material on the top and the bottom of the stack.
Steps (a) through (d) may be practiced so that opposite first and second
edges are commonly formed by the paper and release sheet, and step (e) may
be practiced to apply electrom~gnPtir radiation to the first and second edges
one immediately after the other. Steps (a) through (d) may also be practiced
20 so that a third edge, perpendicular to and extending between the first and
second edges, is also commoniy formed by the paper and release sheet, in
which case there is the further step -- either before or after step (e) -- of
exposing the third edge to a sufficient type and dosage of the electromagnetic
radiation that the adhesive at the third edge becomes de-tackified.
There may also be the further steps, prior to step (f) of st~r'l ing a
plurality of sheets in a stack, wrapping the stack in p~ ging, transporting the
p~cl~ging to t'ne site of the non-impact printer, and llnp~c~ging the stack at
the site of the non-impact printer.
According to another aspect of the present invention there is provided a
30 method of acting upon a sheet comprising a first ply of paper and a second ply
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of a pressure sensitive adhesive release material overlapped with the first ply,with a pressure sensitive adhesive in a continuous strip between tne first and
second plies and holding them together in overlapped position, the second ply
adjacent the first ply at at least a first edge of the first ply, the pressure
s sensitive adhesive being capable of being rendered de-t~ ifiPd when directly
exposed to a sufficient type and dosage of electrom~gn~tic radiation, and at
least one label formed by the first ply where the first and second plies overlap,
the method comprising tne step of (a) applying to the first edge the type of
electromagnetic radiation witn sufficient intensity and duration so that it de-
o tackifies the adhesive, so that the adhesive at the first edge becomes de-
tackified. The detailed operations and steps, as described above, may also be
utilized in the practice of this aspect of the invention.
The invention also comprises an integrated label. The integrated label
of the invention has the following components: A first paper ply having a
1J quadrate configuration and four edges and a first area. A second quadrate plycomprising a pressure sensitive adhesive release sheet having four edges. The
first and second plies overlapping, including a first edge of the first ply aligned
with or overlapped by the second ply. A continuous strip of pressure sensitive
adhesive disposed betueen the overlapping portions of the first and second
20 plies, releasably holding them together. At least one label formed in the first
ply at the overlapping portions of the first and second plies. And, the adhesiveat the first edge being de-tackified so that it will not stick to or interfere with
continued operation of component parts of a heat-curable toner non-impact
printer if the integrated label is passed tnrough the printer, and the adhesive is
2s tacky at the at least one label.
The second ply may have a second area signific~ntly smaller than the
first- area, and the first edge of the first ply may be aligned with the first edge
of the second ply and a second edge of the first ply aligned with a second edge
- of the second ply. In this case the adhesive at the second edge is also de-
30 t~c~ified so that it will not stick to component parts of or i~ rrere with
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continued operation of a heat-curable toner non-impact printer if the integratedlabel is passed through the printer. The integrated label may be in a stack witha plurality of i~Pntic~l inlegraled labels having aligned edges, and the pressure
sensitive adhesive may be a hot melt adhesive that becomes de-tackified when
5 exposed to ultraviolet radiation.
According to another aspect of the invention there is provided apparatus
for h~n-lling multi-ply sheets with ples~u,e sensitive adhesive between the plies
which is rendered de-tackified by direct exposure to ultraviolet radiation. The
apparatus comprises: A stacker for stacking a plurality of sheets into a stack
o having aligned edges, and at least one ultraviolet radiation source emitting
ultraviolet radiation that renders the adhesive de-t~kif~ A first conveyor
may also be operatively ~soci~ted with the stacker for conveying sheets in a
first direction, and having first and second sides generally parallel tc the first
direction. The at least one ultraviolet radiation source preferably is adjacent to
one of the first and second sides of the first conveyor for emitting ultravioletradiation so that it is directed upon at least one edge of the sheets in the stack
when the stack is on the first conveyor.
Each source of ultraviolet radiation may be a 300 nanometer nominal
frequency, 300 watt/inch ultraviolet radiation source. The at least one source
20 may comprise first and second sources mounted adjacent to the first and
second sides of the first conveyor, respectively, and the first source may be
mounted for movement toward and away from the second source to readily
accommodate different size sheet edges between them. A third ultraviolet
radiation source associated with a second conveyor extending perpendicular to
25 the first conveyor also may be provided. P~ck~gin~ means, a 90 conveyor, a
turn table, and like co~ olle~ may also be associated with the apparatus, and
a stacker may be provided either upstream or dow~llearn of the first conveyor
in the first direction.
It is the primary object of the present invention to provide for the quick
30 and inexpensive extrusion die continuous strip method production of integrated
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labels, which labels do not have active adhesive at the edge portions thereof sothat they will not in~r~ele with continued operation of non-impact printers.
This and other objects of the invention will become clear from an inspection of
the ~e~iled description of the invention, and from the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGURE 1 is a schematic illustration of an exemplary method
according to the present invention, also illustrating various components of the
0 exemplary apparatus utilized according to the invention, in schematic form,
and schem~tir~lly illustrating a stack of integrated labels according to the
present invention;
FIGURE 2 is a view like that of FIGURE 1 only showing a modified
form of the apparatus for de-tackifying the adhesive adjacent the edges of the
integrated labels produced according to the invention;
FIGURE 3 is a view like that of FIGURE 1 only showing a modified
form of the app~a~us for de-tackifying the adhesive adjacent the edges of the
20 integrated labels produced according to the invention;
FIGURE 4 is a detail rear view of an exemplary integrated label
according to the invention, with the corner of the release sheet peeled back forclarity of illustration;
FIGURE 5 is a view like that of FIGURE 4 only of a modified form of
the invention;
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_
FIGURE 6 is a front perspective view of the integrated label of
FIGURE 4, with the release sheet in exploded form for clarity of illustration;
and
FIGURE 7 is a side detail view of a corner of another configuration of
integrated label according to the invention.
DETAILED DESCRIPTION OF THE DRAWINGS
FIGURE 1 sr-hrm~tir~lly illustrates an exemplary method and apparatus
according to the present in~ention. Box 10 illustrates conventional web
printing of bond paper, such as 20-28 lb. bond paper with up to eight colors,
typically six colors. As in~ tr~ schem7tir~lly by box 12, release liner (e.g.
25-50 lb.) is unwound from a roll in web form, pos.itioned in the press, and
UV sensitive hot melt a&esive is applied using a continuous slot die process
(which process is conventional and highly desirable per se), essentially
producing transfer tape. The release liner may also be provided with printing
before or after being coated with ~dhesive. The a&esive coated release liner
is then l~min,.ted to the paper web, as-in~i~te~l at box 13, and labels are die
20 cut as in(lir~trd at 14. In a separate operation, or at the same time that the
labels are die cut, the wçb may be cut into sheets as in~ir~red by box 15 in
FIGURE 1.
The cut sheets from sheeter 15 are then -- in the embodiment of
FIGURE 1 -- stacked or batched as in-~ir~terl by box 16, utili~ing a
25 conventional stacker or batcher, with edges of the sheets ~ n~d For example
the sheets may be batched in 125 sheet q~l~ntitirs with chip board material
applied both on top of and under the stack, the application of the chip board
material being done in a conventional manner. The stack is then conveyed to
the apparatus 17 for exposing edges of the paper at which the release sheet is
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provided to a sufficient type and dosage of electrom~gnetic radiation so that the
adhesive becomes de-tackified at the edges.
In the embodiment illustrated in FIGURE l, stacks of sheets indicated
by reference numeral 19 are conveyed on a conveyor 18 in direction A past an
- 5 ultraviolet radiation source 20 so that the adhesive at the edges of each sheet of
each stack 19 closest to the source 20 becomes de-tackified. The source 20
may comprise a 300 nanometer nominal frequency, 300 watts/inch ultraviolet
radiation source. The conveyor 18 conveys the sheets in the stacks 19 in
direction A at a speed of about 10-20 feet per minute so that about 3000
n mj/cm2 total dosage of ultraviolet radiation is applied, which is sufficient to
render the adhesive de-t~c~ifi~d at the edges between the paper and release
sheets, yet significant energy is not wasted.
In the embodiment illustrated in FIGURE 1, after treatment by
ultraviolet radiation source 20, the stacks 19 are conveyed to the 90 conveyor
21 (which is conventional) and then subsequently conveyed by conveyor 22 in
direction B, perpendicular to direction A. When moving in direction B the
edges of all sheets of the stacks 19 parallel to direction B move past one or the
other of the ultraviolet radiation sources 23, 24, which typically have the samerating as the source 20, so that all edges at which there may be adhesive
20 between the release and bottom sheets have the adhesive de-tackified. The
sources 23, 24 are provided one after the other on opposite sides of conveyor
22 so that one side of stack 19 is bombarded with UV radiation substantially
imm~ tely after the other (i.e. typically not at the same time since excessive
heat build-up could occur).
After discharge from conveyor 22 the stacks 19 may be shrink wrapped
in plastic, as indicated at box 26, utili7ing conventional equipment to produce
packages 27, illustrated schem~tir-~lly-in FIGURE 1. The package 27
comprises the stacks 19, wrapped in plastic 28, with the chip board top and
bottom sheets as in~ tto~cl by reference numeral 29 for the top sheet for the
30 package 27. Packages 27 are then transported, as intii/~ted at box 31, to the
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site of a non-impact printer, they are Imr~rl~ed as inflir~ted at 32 (by removing
the plastic 28 and the chip board 29), and they are subsequently used in the
laser printer 33 in which a heat curable toner is applied to the integrated
labels, to apply variable im~ging thereon.
FIGURE 2 illu~ a~s a modified form of apparatus according to the
invention for de-tackifying adhesive at the integrated label edges, again
utilizing sheeter 15, batcher 16, and stacks 19. In the FIGURE 2 embodiment
instead of using two different sets of UV sources, as in FIGURE 1, to render
tne adhesive at three separate edges de-t~r~ifi~l, a single set of UV sources iso utilized.
FIGURE 2 illustrates a conveyor 35 which can convey the stacks 19 in
the dimension 36, that is in both directions in the dimension 36. This may be
accomplished utilizing end rollers 37, one or both of which are powered by
motors 38; one or both of which the motors 38 may be reversible. UV
sources 39, 39' (of the same rating as the sources 20, 23, 24) are disposed on
opposite sides of the conv~yor 35, and the source 39 is movable by any
suitable movement mech~ni.~m 40 (such as a linear screw, hydraulic or
pneumatic cylinder, etc.) in the dimension 41, perpendicular to tne dimension
36. This allows adJustment of the spacing between the sources 39, 39', and/or
20 between the source 39 and the conveyor 35, to accommodate stacks 19 of
different widths (dimensioned in the direction 41).
Downstream of the conveyor 35 is a conventional rotating conveyor 42,
which can rotate the stack 19 delivered thereto 90 about a vertical axis (as
i~ir.~t~d by the arrow 43), the conveyor 42 powered by motor 44 or the like.
25 In a typical operation of the apparatus of FIGURE 2, after the stack 19 is
conveyed by the conveyor 35 past the sources 39, 39' in the direction 45, the
stack 19 would be rotated to a 90 orientation--as in(lir~t~ by dotted line
stack 19 in FIGURE 2. Then the conveyor 35 would be reversed and would
convey the stack 19 again past the source 39, the source 39 having been moved
30 by the mrçh~ni.~m 40 so that it had the proper position to de-tackify adhesive at
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the edge of each sheet of the stack 19 closest to the UV source 39. Then the
conveyor 35 would be reversed again, and again convey the stack in the
direction 45 to the conveyor 46 which would convey the stack 19 to a
conventional shrink wrap or other packager 26, or the like. Another UV
5 source 39" could be used adjacent conveyor 46 too.
FIGURE 3 in{~ tes yet another modification of the apparatus of
FIGURE 1. In this case the batcher 16 is downstream of the conveyor 48 and
the UV sources 49, 50 in the direction of conveyance 47, and adhesive only at
the two edges parallel to the direction 47 are rendered de-tackified before
o shrink wrapping by shrink wrapping apparatus 26. In this case individual
sheets 51 are exposed to the UV scurces 49, 50 rather than stacks as in the
FIGURES 1 and 2 embodiments.
An exemplary integrated label 51 may be utiliæd with the apparatus of
FIGURE 3 is shown in more detail in FIGURE 4, FIGURE 4 showing the rear
face of the integrated label 51, while FIGURE 6 showing the front face. The
integrated label 51 comprises a first paper ply 53, e.g. of 20-28 lb. bond
paper, having a quadrate configuration and four edges and a first area. A
second quadrate ply 54 comprises a pressure sensitive adhesive release sheet
having four edges. The press~lle sensitive adhesive is shown at 55 in FIGURE
20 4, and adheres to the bond ply 53 after being brought into contact therewith by
the release sheet 54, while the release sheet 54 releases from the adhesive 55
(as shown by the peeled back corner in FIGURE 4). The first and second
plies 51, 54 overlap, including first and second edges 56, 57 of the first ply
aligned with or overlapped by the second ply 54. The continuous (that is not
25 patterned) strip of pless-lre sensitive adhesive 55 is disposed between the
overlapping portions of the plies 53, 54, releasably holding them together.
The a&esive 55 is of the type that will become de-t~rkified when
directly exposed to a sufficient type and dosage of electromagnetic radiation.
Preferably the adhesive 55 is a hot melt adhesive which is sensitive to
30 ultraviolet radiation. For example a suitable adhesive for this purpose is
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commercially available from Ecomelt Adhesives of Paramount, California,
under the name T2 Ex731UV.
The adhesive 58, 59 at the edges 56, 57 is de-tackified, so that it will
not stick to or hl~lrele with continued operation of component parts of a laser
5 or like non-impact printer. As described earlier with reference to FIGURES 1
through 3, the de-tackified edge portions 58, 59 are formed by exposure of the
integrated label 51 to about 3000 mJ/cm2 of ultraviolet radiation.
As illustrated in FIGURE 5, which shows one alternative exemplary
construction, a wide variety of other configurations may also be provided for
o the integrated label. In FIGURE 5 components comparable to those in
FIGURE 4 are shown by the same reference numeral only followed by a "'".
In the FIGURE 5 embodiment, there is a significant area 60 of bond paper 53'
between the edge 56' and the release sheet 54', so that de-t~r'~ifi~tion at the
edge 56' is not n~cecc~ry. Rather only de-tackified adhesive 59' at the edge
57' is provided.
FIGURE 6 illustrates the front of the integrated label 51, with the
release sheet 54 shown in exp'oded format only for clarity of illustration.
FIGURE 6 shows, for example, a plurality of labels 62 which have been die
cut from the paper ply 53 (box 14 in FIGURES 1 and 3), as well as indicating
20 indicia 63 which, for example, may be variably printed by a laser printer (box
33 in FIGURE 1), or it may be non-variable printing applied to the original
paper web (box 10 in FIGURES 1 and 3). Various lines of weakness, such as
pe,ro,alions, also may be provided, for example to defme a receipt or like
detachable portion 64. The integrated label 51 has a multitude of uses, such as
25 for pharmacies.
FIGURE 7 illustrates a slightly différent configuration of integrated
label 70 according to the present invention. In this em'nodim~nt t'ne release
sheet ply has an edge 71, with the paper ply 72 o~ellapping it, and an edge 73
therebetween, the adhesive at the edge 73 being de-t~rl~ifiPr~, according to the30 present invention.
.,
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12
It will thus be seen that according to the present invention an
advantageous method of producing integrated labels, a method of acting upon
multi-ply sheets to render exposed adhesive de-tackified, an integrated label,
and an apparatus for h~n-lling multi-ply sheets, have been provided which
5 utilize the low cost and high speed extrusion die continuous strip method of
integrated label production, yet avoid the problem of adhesive cont~min~ting
laser or like non-impact printers with which the sheets are utilized. While the
invention has been herein shown and described in what is presently conceived
to be the most practical and preferred embodiment thereof it will be apparent
n to those of ordinary skill in the art that many mo-lifir~ions may be made
thereof within the scope of the invention, which scope should be accorded the
broadest hlLer~,reL~tion of the appended claims so as to encompass all
equivalent processes, products, and apparatus.
