Note: Descriptions are shown in the official language in which they were submitted.
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IMPROVED NECK BAND USING STRAIGHT-TEAR FILM
RENAISSANCE MARK, INC., a United States corporation and resident,
applicant for all designated countries except US and Wayne O'Hara, a US
national
and resident, applicant/inventor for US only, are filing this application as a
PCT
application claiming prior to US Provisional Patent Application No. 60/468,435
filed 06 May 2003.
I. FIELD OF THE INVENTION
This invention relates to a neck band' or label for a bottle or other
container
comprising a reservoir, a neck, and a removable cap at the end of the neck.
The neck
band encircles a portion of the cap and the neck of the bottle.
II. BACKGROUND OF THE INVENTION
Neck bands are frequently used on glass or plastic containers having an
elongated "neck" with a closure at the end, such as, a screw cap. For example,
neck
bands are frequently used on "narrow neck" bottles for consumable products
such as
a 2o salad dressing, barbecue sauce, and alcoholic beverages and for
containers of catsup
and over-the-counter medicines. The bands contain graphics and infornlation
for
marketing, product identification and other purposes, e.g., instructions,
product
expiration date, production lot data, etc. For marketing purposes it is highly
desirable
that high quality graphics can be imprinted or otherwise applied to the neck
band and
that the graphics and the band itself are not degraded by handling or
environmental
conditions encountered in shipping and storage.
Neck bands should also help to prevent moisture from entering the container
by enclosing the junction of the cap and the bottle. The neck band should also
provide evidence if tampering has occurred prior to consumer use by opening of
the
cap allowing access to the contents of the container. For these reasons, the
neck
band is securely mounted to both the neck of the container and the skirt of
the cap so
that the cap cannot be moved to an open position without tearing or breaking
the
neck band thereby showing visually that the container has been opened. Neck
bands
may also hide slight variations in fill amounts in the contents of the
containers,
1 , .
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thereby assuring that all of the containers have an equal chance of selection
by a
customer. It is highly desirable that neck bands meeting all of these
conditions be
produced and affixed to containers reliably and efficiently without adding
significant
cost to the price of the product.
Although various forms of neck bands have been employed, none has
successfully met all of these objectives.
For economic reasons, paper is the predominant material for making most, if
not all, commercial neck bands today. A typical prior art paper neck band is
shown
in Figure 1. The band 1 comprises paper imprinted with the appropriate
graphics,
to product identification, information and instructions. The ends of the neck
band 4
and 5 are wrapped around the neck and cap of the container, and the band is
glued so
that the upper portion 2 of the band is adhesively secured to the cap of the
container
and the lower portion 3 is adhesively secured to the neck.
There are problems, however, in applying paper to the necks/caps of bottles,
e.g., curling of the paper after application of the glue in the wrong
direction. In
addition, paper is not very resistant to moisture and does' not significantly
assist the
cap and bottle closure in preventing moisture intrusion. Indeed, in the
presence of
moisture (for example, in direct contact with water), the paper may
deteriorate to the
point that the neck band becomes completely separated from the container or
2o sufficiently separated that it no longer would indicate if tampering has
occurred.
Consumers also find that it is difficult to open paper neck bands. While
directions on
the band frequently advise the consumer to open by twisting the cap, many
consumers cannot open the container in this manner. Typically, a knife or
other
sharp implement must be found and employed to form an incision in the band
adjacent the cap and completely around the neck, before the cap can be twisted
and
removed. This presents the potential for minor injury. At the very least it
results in a
negative customer experience, e.g., delay and fi-ustration, at the very time
the product
i
is to be first enjoyed.
In an attempt at improvement, some paper neck bands are perforated along a
3o line adjacent the cap and encircling the neck of the container. Such a
prior art band
is depicted in Figures lA and 1B. As shown, band 11 comprises upper portion 12
and lower portion 13 and ends 14 and 15. An intermittent line of perforations
16
extends from one end to the other. Figure 1B depicts a container 17 with the
lower
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portion 13 of band 11 attached to the neck 1 g above the shoulder 17, and the
upper
portion 12 attached to the cap 20. While the perforations facilitate opening
of the
container for some users, others still find it necessary to locate a hard
sharp object,
such as a fingernail, knife, etc, to pierce the perforations and separate the
upper and
lower portions of the neck band thereby allowing the cap to be removed.
In addition, the perforations exacerbate problems in applying the band to the
neck of the container. For example, the perforations tend to cause a "doming
effect"
when the band is placed in the magazine of the labeling machine used for
application
to containers. This can result in defects in the placement of neck bands on
to containers, quality control rejects and possible down time of the labeling
production
line. Variability in the depths of the perforations also presents problems.
When the
perforations are too shallow, they fail to facilitate the opening of the
container.
When perforations are too deep, there is a tendency for premature bursting or
cracking of the neck band during transit or stocking of the containers
resulting in
otherwise unnecessary product returns. Regardless of depth, perforations also
substantially reduce any effect of the neck band as a moisture and vapor
barrier.
Alternatively, paper neck bands have also been utilized in which a draw
string is located between the band and the neck of the bottle around its
circumference. In theory, the consumer should be able to pull the end of the
string
2o around the circumference of the container thereby separating the upper and
lower
portions of the neck band so that the cap can be removed. Thus, easier opening
might be accomplished without compromising the neck band's worth as a moisture
barrier. In practice, however, it is both difficult and expensive to properly
locate and
secure the string on the back of the neck band. The draw string has to be
precisely
placed on the neck band and separately glued. If the draw string is not
properly
secured to the neck band, it will separate from the neck band without opening
it,
even if pulled in the proper manner. Moreover, many consumers do not pull the
string correctly -- only causing the string to separate from the neck band
without
opening it. These deficiencies, coupled with additional expense, have
minimized the
3o use of paper drawstring neck bands.
Transparent shrinkable neck bands have also been utilized, either alone or
over a paper neck band, primarily to improve moisture resistance. Shrinkable
neck
bands have not been widely employed commercially, because they still require
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perforations with the defects associated with that design. In addition,
expensive,
specialized equipment must be installed to apply these neck bands.
Thus, a need exists for an improved neck band obviating these deficiencies.
The neck band should be easy to open, should provide a significant moisture
and
vapor barner, should clearly show evidence of tampering, should be capable of
being
applied reliably and efficiently, and should provide a surface for
implementing
superior graphics. These improvements should be obtained without requiring new
equipment or substantial modifications to production lines for manufacturing
neck
bands or affixing them to product containers.
III. SUMMARY OF THE INVENTION
It has now been discovered that an improved neck band can be prepared by
using a straight-tear film that can be manually separated along a line around
the neck
of the bottle. Preferably, the straight-tear film is a polypropylene-based
polymer
film that has been directionally oriented in a single direction. The improved
neck
bands are applied to the neck and cap of the container so that the lines of
weakness
are parallel to the circumference of the neck. A tab is placed on the neck
band
adjacent the skirt of the cap, so that when the tab is pulled, the polymer
material
2o separates along a line around the circumference of the neck. Preferably,
this process
does not just separate the neck band, but removes a piece of neck band
material
around the circumference of the container.
Neck bands prepared in accordance with this invention provide a base for
permanently imprinting or otherwise providing superior graphics. They provide
a
moisture proof barrier far superior to paper neck bands. They are easy to
open.
When the neck band is opened, a piece of the material is visibly removed.
Thus, if
opening occurs prior to use by the purchaser, the evidence of tampering is
clearly
apparent. The neck bands of this invention can be manufactured and applied
reliably
and efficiently with standard, existing equipment.
IV. BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a front view of a prior art paper neck band.
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Figure lA is a front view of a prior art perforated paper neck band.
Figure 1B is a perspective view showing the prior art perforated paper neck
band of Figure lA as installed on a container. The sequence of steps for
opening the
neck band and container are identified.
Figure 2 is a front view of a neck band prepared in accordance with a
preferred embodiment of the invention.
Figure 3 is a perspective view of a bottle with the band of Figure 2 applied
to
it.
Figures 3A through 3C depict a side view of the bottle of Figure 2 as it is
to opened, first by manually removing a piece of the neck band by pulling the
tab as
shown in Figures 3A and 3B and then by twisting and removing the cap as shown
in
Figure 3C.
Figure 4 is a schematic illustrating one typical manufacturing technique
employed in preparing a directionally oriented polypropylene material.
15 Figure 5 is a schematic diagram illustrating a process for manufacturing
neck
bands from directionally oriented film.
Figure 6 is a schematic illustrating the equipment and process employed in
applying neck bands of the present invention to bottles.
Figures 7A through 7C illustrate some alternative designs for neck bands in
20 accordance with the present invention.
IV. DETAILED DESCRIPTION OF THE INVENTION
AND THE PREFERRED EMBODIMENT
25 It has now been discovered that an improved neck band can be prepared by
using a straight-tear film that can be easily separated manually along one or
more
lines around the neck of a bottle. Figure 2 is a front view of a neck band
prepared in
accordance with a preferred embodiment of the invention. The neck band
contains
product information and directions as on the prior art neck band of Figures 1
and lA.
30 However, it is made of a straight-tear material that has the ability of
being torn
manually in a straight line in the direction indicated. As used herein, a
"straight-tear
film" refers to a film that can be torn manually along a straight line.
Typically, this
occurs because it is difficult, if not impossible, to manually tear the film
in the
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perpendicular, direction. In general, a straight-tear film propagates a tear
in the film
along a straight line, with the tear varying by at most only a few millimeters
in the
transverse direction from that line.
Figure 2 shows one embodiment of an improved neck band of the present
invention. As depicted, neck band 101 is the same general shape as neck bands
of
the prior art shown in Figures 1 and lA and comprises upper portion 102 and
lower
portion 103 and ends 104 and 105. Die-cut notches 107 and 10~ define an
intermediate tab 106. When tab 106 is pulled to the left, it initiates tears
shown in
the drawing as lines 109 and 110 in the direction indicated. Unlike the
perforations
on the prior art band depicted in Figures lA and 1B, the lines 109 arid 110 on
band
101 appear as a result of tearing in the direction of the straight-tear
orientation of the
film from which the band was made. When the tab 106 has been pulled completely
to the left end 105, a strip of material 111 is released between the upper
portion 102
of the neck band and the lower portion 103 of the neck band.
Figure 3 shows the neck band 101 of Figure 2 as applied to the neck 114 and
cap 115 of the container 112, in this case a "narrow neck" salad dressing
bottle.
Although not shown in the drawing, the ends of the band 104 and 105 are
wrapped
around the neck and overlap each other on the back of the container and are
secured
by adhesive to one another, except as noted below. The upper portion 102 of
the
2o band is secured by adhesive to the cap 115, and the lower portion 103 of
the band is
secured to the neck, also by adhesive. The band 101 is designed so that the
tab 106
lies below or adjacent the bottom of the cap 115 in an area of the band that
is not
glued to either the cap, the neck or the other end 105 of the band. When the
tab is
pulled, as shown in Figure 3A, the neck band material is torn on straight
lines 109
and 110 around the circumference of the neck. As a result, a piece of film 111
is
removed around the circumference of the neck leaving upper portion 102
attached to
the cap 115 and lower portion 103 attached to the neck 114 as shown in Figure
3B.
The separation of the film can be performed "manually" meaning that the film
can
be separated without having to cut or pierce the neck band, as is the case
with paper.
After the neck band has been separated, the cap can be twisted and removed to
open
the container as shown in Figure 3C.
In the preferred embodiment shown in Figures 2, 3 and 3A though 3C, the
neck band of the present invention employs a tab to separate portions of the
band.
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The tab is formed by cutting two "V"- shaped portions 107 and 108 into the
edge
104 of the neck band. When the tab is pulled, parallel tears in the neck band
are
commenced at the bottom of each "V." As the user continues to pull the tab,
the
tears are completed around the neck band enabling separation of the middle
portion
from the upper and lower portions of the neck band.
While this is a presently preferred embodiment, other types of tabs can be
employed and other forms of tear-initiating features. For example, these could
include the use of slits instead' of "V" slots (for example, as shown in
Figure 7A) or
a single knife slit or "V" slot (for example, as shown in Figure 7B). A tab
could be
to formed as an extension of one end of the band rather than using slits or
grooves.
Other designs for tear-initiating features known to one skilled in the art can
also be
employed.
Indeed, the neck bands of the present invention can be employed without any
tear-initiating feature. While such a construction would retain some of the
benefits of
the present invention, it would not be as easy to open, since the user would
be
required to employ a fingernail, knife or other instrument to initiate the
tear.
The preferred embodiment depicted in Figures 2, 3 and 3A through 3C
comprises a three-section neck band, i.e., opening removes a piece of material
between the portions of the neck band secured to the cap and neck,
respectively. This
2o construction is preferred because of the ease of operation and because the
removal of
a piece of material from the neck band provides clear evidence of potential
tampering. Other numbers of neck band sections can be employed depending on
the
number of tears initiated in the band. For example, a two-section embodiment
can
be utilized as shown in Figure 7B.
Neck band materials suitable for use in this invention include any "straight-
tear films." Obviously, it is preferably that the materials be inexpensive,
that they be
easy to manufacture, attach and handle, that they form a base for high quality
printing and graphics, and that they provide superior water and vapor
resistance.
The selection of the straight-tear film may depend on the composite of
properties
desired for a particular application. However, a presently preferred group of
materials for use in this invention include polypropylene films or any number
of
other polypropylene-based monopolymers, copolymers and blends that are capable
of being directionally oriented so that a straight-tear film is produced.
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One material that has been successfully used to prepare neck bands of this
invention is PR1TMAX~ NA 350 film available from Avery Dennison, 7600 Auburn
Road, Concord, Ohio USA. This material is a corona treated, flexible matte
white
opaque polyolefin (i.e., polypropylene) film having the following properties:
Thickness 3.5 mils
Yield 7,900 sq. in./lb.
Opacity 88.0 maximum
Tensile Modulus MD: 160,000 psi
CD: 60,000 psi
Tensile Elongation MD: 50%
CD: 500%
Gurley Stiffness
(typical value) MD: 30 mg
Dyne
(print surface) Target: 45
Minimum: 40
Another suitable material is "DL2" film, also available from Avery
Dennison.
This material is also a corona treated, flexible matte white opaque polyolefin
(i.e.,
polypropylene) film having the following properties:
Thickness 4.0 mils
Yield 7,400 sq. in./lb.
Opacity 85.0 maximum
Tensile Modulus MD: 200,000 psi
CD: 100,000 psi
Tensile Elongation MD: 60%
8
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CD: 600%
Gurley Stiffness
(typical value) MD: 65 minimum
Dyne
(print surface) Target: 45
~ Minimum:40
Preferably, the-straight-tear film is a polypropylene-based polymer film that
has been directionally oriented in a single direction, usually the "machine
direction."
Such materials are known to have great strength and tear-resistance. However,
those properties are not exhibited in all directions. While the material is
essentially
tear resistant in one direction, the tear strength in the perpendicular
direction is quite
weak, and tearing can be accomplished manually with ease.
However, straight-tear films are not limited to polypropylene films that have
2o been oriented in a single direction. Suitable straight-tear films may be
formed by
careful selection of polymer type, molecular weight and degree of orientation.
The films prepared in accordance with this invention should have sufficient
thickness to produce neck bands that are successfully employed in standard
label
application equipment, but not so thick as to add substantially to material
costs. The
appropriate thickness may vary slightly depending on the specific type of
polypropylene-based polymer employed. Generally, however, the thickness should
be in the range of about 1.0 mil to 6.0 mil, preferably in the range of about
2.0 mil to
5.0 mil, and most preferably in the range of 2.5 mil to 4.0 mil.
Finns suitable for use in the present invention may be employed alone or as a
3o co-extruded composite or laminate with other layers known to those skilled
in the
art. Examples of composites include the PR1IMAX~ NA 350 and DL2 filins
referenced previously.
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The polypropylene materials of the present invention produce neck bands
that are superior to those made of paper in a number of characteristics.
First, neck
bands of polypropylene-based films are stronger physically than paper, with
the
exception that they may be easily torn in a straight line in a single
direction that
facilitates opening. Because the bands may be easily torn for opening when
intended
without any perforations, they do not present the deficiencies of paper bands
(either
perforated or un-perforated) as previously noted. Neck bands made of
polypropylene-based films also provide an improved barrier to water. Because
polypropylene does not absorb water, it is impervious to changes in humidity
and to
1o deterioration from direct contact with water, such as that encountered when
placing
labeled containers in an ice cooler. The absence of perforations further
enhances
water resistance.
Compared to paper, polypropylene-based polymers also provide a much more
attractive base for the presentation and preservation of graphics.
Polypropylene-based films can be prepared by any of the conventional
methods known to one skilled in the art. Generally, these materials are
thermoplastic. While the films are still hot, they may be stretched in the
direction in
which they are moving through the manufacturing process, i.e., the "machine
direction." This is illustrated, for example in Figure 5, where the hot
polypropylene-
2o based film 150 from the extruder is passed between web rollers (not shown)
moving ,
at different speeds, i.e., the "down stream" rollers moving sufficiently
faster than
those "upstream," so that the film is stretched in the "machine direction."
The
stretched film can be "set" in that orientation by annealing. Thus the film
has been
stretched in the machine direction, but not stretched in the transverse
direction. The
continuous film is wound and formed into a roll for ease in delivery to
customers.
Normally polypropylene film is stretched in both the machine direction and
the transverse direction thereby enhancing the strength of the polymer in both
directions. The vast majority of commercial applications require that
polypropylene
film be biaxially oriented. Smaller amounts of polypropylene film are
manufactured
3o where the film is stretched in only the machine direction. Preferably,
films suitable
for use in the present invention are stretched or oriented in only one
direction.
Typically that will be the machine direction for ease of manufacture. Although
bi-
directionally oriented films might be used in the present invention, the
amount of
1o
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orientation in the second direction must be relatively insignificant, i.e., so
that the
film may be easily torn in a straight line.
Similarly, if the polypropylene film is employed in the neck band as a
laminate or otherwise with other layers, the composite must meet the same
criteria,
i.e., that it is capable of being torn in a straight line.
Neck bands may be prepared from the polypropylene film using conventional
technology. One manufacturing sequence is illustrated schematically in Figure
5. A
roll of film 150, such as that produced in the orientation process illustrated
in Figure
4, is fed to the feed table of the neck band manufacturing line. Accordingly,
the film
to feedstock is fed in the machine oriented direction through the label
manufacturing
line. A typical printing line may be employed, such as a "Mark Andy/Comco, MSP
22" Proglide Flexographic Press, Press# 2116D" available from Mark Andy
located
in St. Louis, Missouri. Straight tear film 150 supplied in roll form, is
threaded
through the press and printed in up to nine colors in-line using ultra violet
cured
inks. This may include imprinting of the product identifying information and
trademark and various instructions. After printing, the bands are varnished in
whole
or in part. Normally, certain portions of the band are not varnished, such as
the
portions of the band edges that will overlap one another and be affixed in
that
position by glue and portions of the band that'may be subsequently printed
with
2o additional information, such as, product expiration date and lot number,
just before
the neck bands are affixed to the containers. The printed film 150 then passes
through a rotary die cutting station, which cuts the band to shape and
delivers the
film with printed and cut neck bands for re-rolling and delivery to the label
applier.
As shown schematically in Figure 5, the neck bands are printed on the film and
cut
so that the ends 104 and 105 of each band 101 lie in the machine-oriented
direction.
As mentioned previously, an advantage of the neck bands of the present
invention is that they may be applied to containers using existing equipment
without
structural modifications. In addition, the materials employed in the invention
may be
applied securely with cold, glue applied rather than pressure sensitive
adhesive. For
3o example, Figure 6 depicts a top schematic view of a typical cold glue label
application process. This process depicted is common to cold glue application
systems available in the United States from Krones, Inc. of Franklin,
Wisconsin or
from Jagenberg, Inc. of Enfield, Connecticut. In the first step, adhesive is
circulated
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along a roller at the glue station. A label pallet, which is the exact shape
of the neck
band being applied, is exposed to glue roller, and glue is applied to pallet.
Individual neck bands 101, having been removed from film web 150, are fed from
the label magazine onto the glue pallet, which applies glue to the back of the
neck
bands and transfers the band to gripper wheel. The gripper wheel picks up the
neck
band and exposes the back of the band to the surface of the bottle, which is
traveling
along the bottle conveyer. Bottles are then conveyed through a series of
brushes to
wipe the neck band down smoothly and securely.
Those skilled in the art will know how to design the label pallet so that it
to applies adhesive to the back portions of the neck bands where it is
required. As
previously discussed, the neck bands of the present invention do not generally
contain adhesive behind the portion of the neck band 111 that will be removed
upon
tearing. However, it may be desirable to apply adhesive in the area between
the
notches 107 and 108 to hold the area adjacent the tab 106 in place to avoid
unintended contact of the tab with surfaces, thereby initiating inadvertent
tearing of
the neck band.
Those skilled in the art will also appreciate that there are a number of other
design options that might be employed using "straight-tear" film for a neck
band.
For example:
2o Figure 7A illustrates an alternative neck band embodiment of the present
invention.
In this case, neck band 201 has an upper section 202 and lower section 203 and
ends
204 and 205. The tear initiating feature is similar to that shown in Figure 2,
except
that slits 207 and 208 are employed instead of "V"-shaped notches. A tab 206
is
formed between the slits, which when pulled to the left causes straight line
tearing as
indicated along lines 209 and 210 resulting in separation of intermediate
section 211.
Figure 7B illustrates a two section neck band embodiment of the present
invention. In this case, neck band 301 has an upper section 302 and a lower
section
303 and ends 304 and 305. The tear initiating feature consists of a single "V"-
shaped groove 306 at which a tear can be initiated utilizing the sides and
bottom of
the groove to initiate a tear along line 309 resulting in separation of the
neck band
into the upper and lower portions 302 and 303, respectively.
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Finally, Figure 7C illustrates a neck band embodiment similar to that shown
in Figure 2.
Again, neck band 401 consists of upper portion 402 and lower portion 403 with
ends
404 and 405. The tear initiating feature is similar to that in Figure 2 and
comprises
tab 406 formed by "V"-shaped grooves 407 and 408. Pulling the tab to the left
initiates tearing of the straight-tear film along lines 409 and 410, resulting
in
separation of intermediate material 411. The grooves 407 and 408 are deeper
than
those of the neck band in Figure 2.
These and other embodiments are within the skill of the art without
to departing from the principles of the invention as set forth in the
following claims.
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