Note: Descriptions are shown in the official language in which they were submitted.
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PRESSURE-SENSITIVE LABEL
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a PCT of, and claims priority to, U.S. Patent
Application Serial No.
16/871,694, entitled "Pressure-Sensitive Label," filed on May 11, 2020, which
is a continuation-
in-part of U.S. Patent Application Serial No. 16/269,943, entitled "Pressure-
Sensitive Label,"
filed on February 7, 2019 (now U.S. Patent No. 10,650,706, issued on May 12,
2020), which is a
continuation of U.S. Patent Application Serial No. 15/094,443, entitled
"Pressure-Sensitive
Label," filed April 8, 2016 (now U.S. Patent No. 10,325,528, issued on June
18, 2019), which is
a continuation-in-part of U.S. Patent Application Serial No. 14/724,021,
entitled "Pressure-
Sensitive Label," filed May 28, 2015 (and published on December 1, 2016, as
U.S. Patent
Application Publication No. 2016/0351082), the disclosures of all of which are
incorporated by
reference herein in their entireties.
FIELD OF THE INVENTION
[0002] The present invention relates generally to labels for various
articles, and relates
more specifically to pressure sensitive labels for articles, such as
containers.
BACKGROUND OF THE INVENTION
[0003] This section is intended to introduce the reader to various aspects
of art that may be
related to various aspects of the present invention, which are described
and/or claimed below.
This discussion is believed to be helpful in providing the reader with
background information to
facilitate a better understanding of various aspects of the present invention.
Accordingly, it
should be understood that these statements are to be read in this light, and
not as admissions
of prior art.
[0004] Pressure sensitive labels are multi-layered constructions that
include a pressure-
sensitive adhesive, and are used to label articles by applying pressure to the
label when it is in
contact with an article to adhere the label to the article via the pressure-
sensitive adhesive.
Such pressure sensitive labels are popular because, among other
characteristics, they are
versatile, and allow for a high level of printability with bright colors
printed on surfaces. Further,
they can be printed onto a large spectrum of materials such as paper, foil,
metal, plastic, and
other synthetic materials. They are also compatible with a wide array of
finishing processes,
including (but not limited to) perforating, embossing, and hot stamping.
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[0005] Referring to Fig. 1, a typical prior art pressure sensitive label 1
is shown. When
labeling an article with a pressure sensitive label, one generally acquires a
base pressure
sensitive label stock 2 from a separate supplier. The base pressure sensitive
label stock 2
usually includes at least four laminated layers: (1) a carrier 3 (sometimes
referred to as a
"liner"), (2) a release layer 4 disposed onto one surface of the carrier, (3)
an adhesive layer 5
(including a pressure-sensitive adhesive) disposed onto the release layer, and
(4) a face stock 6
disposed onto the adhesive layer.
[0006] The typical base pressure sensitive label stock 2 can thus be
thought of as having a
support portion 7 (carrier 3 and release layer 4) and a transfer portion 8
(adhesive 5 and face
stock 6). The release layer 4 is used to allow the portion that will transfer
to an article to peel
away and release from the carrier 3 during label application.
[0007] The face stock 6 is typically made from a web or sheet of paper,
film, or foil, and is
applied or laminated to the adhesive layer 5 sequentially at some time after
the adhesive layer 5
has been laid down. Once the base pressure sensitive label stock 2 is acquired
from a supplier,
the face stock 6 may then be printed on with an ink layer 9 or layers (text,
graphics, indicia, etc.)
to create the label decoration and information. The conventional pressure
sensitive label
construction is then applied to an article surface by removing the carrier 3
and release layer 4 to
expose the adhesive layer 5 and placing the adhesive layer 5 into contact with
the desired
surface and applying pressure, to transfer the adhesive 5, face stock 6, and
ink layer 9 to the
article (the "ink layer" as described herein may include more than one ink to
create the
appearance of the label decoration and information).
[0008] While these pressure sensitive labels are well known, there are many
drawbacks to
the use of the above-described pressure-sensitive labels. As described above,
the initial base
pressure sensitive label stock (carrier, release layer, adhesive layer, and
face stock) is generally
provided by a third party with the label design (i.e., ink graphics, text,
indicia, etc) being added
thereafter. This does not allow for the construction of an entire label (e.g.,
carrier, release layer,
adhesive layer, face stock, and ink layer) at one location and/or time. And
so, present pressure
sensitive labels require a multi-location, multi-step process for their
production, thereby
lengthening the amount of time needed to manufacture a completed pressure
sensitive label.
(When the "construction of a label," or the like, is referenced herein, it is
intended to refer to
both the construction of an individual label and/or to the construction of a
web of multiple
individual labels.)
[0009] Further, the supplier of the base pressure sensitive label stock
does not know ahead
of time what size shape, contour, etc. of ink layer indicia will be printed on
the base stock to
create the final web of labels (the "web of labels" being a length of base
pressure sensitive label
stock with multiple individual labels printed via ink/indicia along its
length). Thus, the base
pressure sensitive label stock is created with a flood coating of adhesive and
a face stock that
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matches or generally closely matches the area of the carrier (to accommodate
any size, shape,
contour, etc. of ink layer or layers that may be printed, and any size, shape,
and/or contour of
label or labels). Because of this, following printing of the ink design, the
web of labels must be
die cut to produce the final web (carrier/release with individually cut labels
thereon). This
process requires that the carrier be made of a strong material ¨ such as a
polyester ¨ so that it
can withstand the die cut process without being cut itself (as only the ink
layer, face stock,
adhesive, and release gets cut). The cut matrix that does not include labels
is then removed
and discarded. The use of the strong material (e.g., polyester) of the carrier
presents the
problem that the carrier cannot be recycled, as the material cannot be placed
into the recycle
stream for label web materials. While the carrier is commonly polyester, that
does not prevent
the use of other materials for the carrier (such as a paper liner, glassine,
polypropylene, or
blends of such materials).
[0010] Further, because the base pressure sensitive label stock needs to be
provided by a
third party with printing of the ink layer occurring thereafter, it is
required that the layers of the
final label be ordered in such manner that the adhesive is proximal to the
carrier (e.g., adjacent
to the release layer) with the ink disposed distal from the carrier. This
configuration results in
further drawbacks to the pressure sensitive labels of the prior art. First,
the fact that the
adhesive is proximal to the carrier requires a release layer or coating
between the carrier and
the adhesive to allow the adhesive, face stock, and ink layer to release from
the carrier during
application to an article. The need for this release layer adds materials, and
thus cost, to these
conventional pressure sensitive labels. Second, the positioning of the ink
layer distal to the
carrier means that the ink layer will be the outer surface of the label once
it is applied to an
article. This means that the ink layer can be easily scuffed or damaged ¨
disrupting the
aesthetic appearance of the article. This also means that metallics cannot be
used as inks in
these conventional pressure-sensitive labels (due to their ease of damage).
Thus, the inks that
can be used in these labels are limited, and the designs are subject to
damage. One could add
a protective layer to the label (to the outside of the ink layer) but, like
the release layer described
above, this adds yet another layer, and cost, to the label.
[0011] Further, where the label is to be adhered to a contoured or
irregular surface, and
where a high degree of flexibility is desired, the rigidity of the face stock
(and any rigidity due to
the multiple layers of the label) may interfere with the application and the
adherence of the label.
[0012] Further still, one common occurrence in the application of a
pressure sensitive label
is to have various defects, such as wrinkles and blisters. These defects occur
when the label
becomes misaligned to the article to which it is applied, and/or entrapment of
air between the
label and the article. The result is less than optimum visual appeal (poor
aesthetics), label
failure due to scuffing or tearing of the unsupported label, or even
unsellable products.
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[0013] In view of many of the drawbacks of pressure sensitive labels, as
described above,
(particularly the many layers that are needed, the use of a third party base
construction, and the
damage that can occur to the label indicia), many have often turned to heat
transfer labels as an
alternative type label. Heat transfer labels are desirably resistant to
abrasion and chemical
effects in order to avoid a loss of label information and desirably possess
good characteristics of
adhesion to the articles to which they are affixed.
[0014] Heat transfer labels are multilayered constructions, with each layer
having its own
function. For example, heat transfer labels generally include an adhesive
layer, an ink layer,
and a release layer. The release layer may be a wax release layer, and is
often directly
adjacent a carrier sheet, such as on a roll or web of labels. Thus, in such an
example, the label
may be thought to include a "support portion" (e.g., carrier sheet and release
layer and a
"transfer portion" (i.e., ink layer and adhesive layer). When subjected to
heat, the wax release
layer melts, thereby allowing the transfer portion to be separated from the
carrier sheet, and the
adhesive layer adheres the ink layer to an article being labeled.
Alternatively, all or part of the
wax release layer may transfer as well, to provide protection to the ink
layer. Additionally or
alternatively, the labels may include a separate protective layer overlying
the ink layer to protect
the ink layer from abrasion.
[0015] More specifically, in the heat transfer labeling process, the label-
carrying sheet is
subjected to heat, and the label is pressed onto an article with the ink layer
making direct
contact with the article. As the paper sheet is subjected to heat, the wax
layer begins to melt so
that the paper sheet can be released from the ink layer. (And, as described
above, a portion of
the wax layer may be transferred with the ink layer and a portion of the wax
layer may remain
with the paper sheet.) After transfer of the ink layer to the article, the
paper sheet is removed,
leaving the ink layer firmly affixed to the article. In an alternate
embodiment, where the wax
layer also transfers, the wax layer thus may serve two purposes: (1) to
provide release of the
ink layer from the sheet upon application of heat to the sheet, and (2) to
form a protective layer
over the transferred ink layer. After transfer of the label to the article,
the transferred wax
release layer may be subjected to a postf laming technique which enhances the
optical clarity of
the layer (thereby enabling the ink layer therebeneath to be better observed)
and which
enhances the protective properties of the transferred wax layer.
[0016] However, the primary drawback to the use of the heat transfer label
is the
requirement of heat to be applied during the labeling process, which may not
be desirable. It is,
therefore, desirable that a pressure sensitive label construction be
constructed for use as a
label, for example, which avoids the need to use a conventional face stock
formed from paper,
film, or foil. It is further desirable that the pressure sensitive label
construction have printability,
convertibility and dispensability properties that are better than or equal to
that of pressure
sensitive label constructions of the prior art (as described above). It is
also desirable that such a
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pressure sensitive label construction be designed in a manner that reduces the
amount of
manufacturing time needed to complete same, when compared to a pressure
sensitive
construction of the prior art. Further, it would be desirable to reduce and/or
eliminate wrinkles
and/or blisters that may form during label application. Further, it would be
desirable for such a
pressure sensitive label construction to have reduced layers, and thus cost,
increase
recyclability, increase ease of application to an article being labeled, and
reduce the incidence
or likelihood of damage to the ink layer.
SUMMARY OF THE INVENTION
[0017] Certain exemplary aspects of the invention are set forth below. It
should be
understood that these aspects are presented merely to provide the reader with
a brief summary
of certain forms the invention might take and that these aspects are not
intended to limit the
scope of the invention. Indeed, the invention may encompass a variety of
aspects that may not
be explicitly set forth below.
[0018] Various aspects of the present invention address any and/or all of
the drawbacks
described above with pressure sensitive labels of the prior art by providing
pressure sensitive
labels that, among other characteristics, have reduced layers, reduced cost,
increased
recyclability, increased ease of application to an article being labeled, and
reduced incidence or
likelihood of damage to an ink layer (as compared to pressure sensitive labels
of the prior art, as
described in the Background). To accomplish this, one aspect of the present
invention provides
a pressure sensitive label comprising: (a) a support portion including at
least a carrier layer;
and (b) a transfer portion including at least a printable layer in contacting
relationship with the
carrier layer. In general, the transfer portion may overlie the support
portion for transfer of the
transfer portion from the support portion to an article upon application of
pressure to the transfer
portion while the transfer portion is in contact with the article. In one
aspect of the present
invention, the carrier layer does not include any release layer between the
carrier layer and the
printable layer. This eliminates a layer of the labels of the prior art, thus
reducing the cost of the
label.
[0019] Further, in another aspect of the present invention, the printable
layer may be
applied in a softened, molten, thixotropic, liquid, etc. form that allows it
to be applied as a
pattern (such as in the shape, size, contour, etc. of a label image -- i.e.,
graphics, text, indicia,
etc. -- that is to be produced) rather than being provided as a face stock
that matches (or
substantially matches) the area of the carrier layer (as in labels of the
prior art). The printable
layer is of a formulation that allows it to receive ink thereon following
cooling, solidifying, UV-
curing, etc. The ability to apply the printable layer in a pattern also
reduces the amount of
material that is needed for the web of labels (thereby reducing cost),
eliminates the need for die
cutting (and the waste of the discarded die cut material), and can be used to
allow the entire
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label to be constructed in one location (as opposed to the need of acquiring a
base pressure
sensitive label stock from a third party supplier).
[0020] In other aspects, the label may include an ink layer positioned such
that the printable
layer is between the carrier layer and the ink layer. And, the label may
include an adhesive
layer positioned such that the ink layer is between the printable layer and
the adhesive layer.
By this configuration, the pressure sensitive labels described herein include
the printable layer
most proximal to the carrier, and the adhesive layer most distal to the
carrier (which is a
somewhat opposite configuration as compared to the pressure sensitive labels
of the prior art).
Due to this configuration, the transfer portion (e.g., printable layer, ink
layer, adhesive layer) of
the pressure sensitive labels described herein do not have to be peeled away
from the carrier to
expose the adhesive for adherence to an article. Rather, the labels are
configured such that the
adhesive is already the outer layer of the label construction prior to
application to an article, and
so the adhesive is pre-exposed and ready to contact an article ¨ thereby
increasing the ease of
application to an article.
[0021] The configuration of the layers in this aspect and embodiment of the
present labels
also results in the ink being beneath the printable layer (and thus protected
by the printable
layer) once the transfer portion is transferred to an article. This results in
the ink layer (the
indicia, graphics, design, text, information, etc.) being protected from
damage once the label is
transferred to an article. This protection is achieved without have to add any
additional
protective lacquer layers (as is done sometimes with prior art pressure
sensitive labels). The
configuration that allows the printable layer to protect the ink layer
following transfer also
increases the number of materials that may be used in the ink layer ¨ such as
being able to use
easily damaged materials, such as metallic inks.
[0022] In another aspect, the pressure sensitive label may further include
a release layer
positioned such that the carrier layer is between the printable layer and the
release layer. In
other words, the release layer is not on the side of the carrier adjacent to
the transfer portion of
the label, but rather is on the underside or backside of the carrier. This
release layer allows the
web of labels to be wound on a roll, for example, while preventing blocking
(i.e., the problem of
the adhesive on the labels adhering to the underside of the carrier as the web
of labels is wound
on the roll).
[0023] Another aspect of the present invention provides a pressure
sensitive label
comprising: (a) a support portion including at least a carrier layer; and (b)
a transfer portion
including at least a printable layer in confronting relationship with the
carrier layer, and an ink
layer may be present between the printable layer and the carrier layer.
Depending on the
nature of the ink layer, at least a portion or portions of the printable layer
may contact the carrier
layer (i.e., in any areas where ink or inks of the ink layer are not present).
In general, the
transfer portion may overlie the support portion for transfer of the transfer
portion from the
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support portion to an article upon application of pressure to the transfer
portion while the
transfer portion is in contact with the article. In one embodiment, the
carrier layer does not
include any release layer on the side of the carrier layer facing the ink
layer. This eliminates a
layer of the labels of the prior art, thus reducing the cost of the label. In
this configuration, the
pressure sensitive labels of this aspect include the ink layer most proximal
to the carrier, and the
adhesive layer most distal to the carrier. Due to this configuration, the
transfer portion (e.g., ink
layer, printable layer, adhesive layer) of the pressure sensitive labels
described in this aspect do
not have to be peeled away from the carrier to expose the adhesive for
adherence to an article.
Rather, the labels are configured such that the adhesive is already the outer
layer of the label
construction prior to application to an article, and so the adhesive is pre-
exposed and ready to
contact an article ¨ thereby increasing the ease of application to an article.
Further, this version
of the label may also include a release layer positioned such that the carrier
layer is between
the ink layer and the release layer (to prevent blocking when the web of
labels is wound on a
roll, for example).
[0024] Another aspect of the present invention may include a method or
methods for
making a pressure sensitive label. And another aspect of the present invention
may include a
method or methods for applying a pressure sensitive label to an article.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The accompanying drawings, which are incorporated in and constitute
a part of this
specification, illustrate embodiments of the invention and, together with the
general description
of the invention given above and the detailed description of the embodiments
given below,
serve to explain the principles of the present invention.
[0026] Fig. 1 is a cross-sectional view of a typical pressure sensitive
label construction of
the prior art.
[0027] Fig. 2 is a cross-sectional view of one embodiment of a pressure
sensitive label
construction in accordance with principles of the present invention.
[0028] Fig. 2A is a cross-sectional view of another embodiment of a
pressure sensitive label
construction in accordance with principles of the present invention.
[0029] Fig. 3 is a cross-sectional view of another embodiment of a pressure
sensitive label
construction in accordance with principles of the present invention.
[0030] Fig. 3A is a cross-sectional view of yet another embodiment of a
pressure sensitive
label construction in accordance with principles of the present invention.
[0031] Fig. 4 is a cross-sectional view of another embodiment of a pressure
sensitive label
construction in accordance with principles of the present invention.
[0032] Fig. 4A is a cross-sectional view of yet another embodiment of a
pressure sensitive
label construction in accordance with principles of the present invention.
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[0033] Fig. 5 is a schematic showing the preparation of a pressure
sensitive label
construction in accordance with principles of the present invention.
[0034] Fig. 6 is a schematic showing a completed pressure sensitive label
in accordance
with principles of the present invention on a roll of labels.
[0035] Fig. 7 is a schematic showing application of a pressure sensitive
label construction in
accordance with principles of the present invention to an article.
[0036] Fig. 8 depicts an article with a pressure sensitive label in
accordance with the
principles of the present invention associated therewith.
[0037] Fig. 9 is a cross-sectional view of another embodiment of a pressure
sensitive label
construction in accordance with principles of the present invention.
[0038] Fig. 10 is a schematic showing another embodiment of the preparation
of a pressure
sensitive label construction in accordance with principles of the present
invention.
[0039] Fig. 11 is a schematic showing another embodiment of the preparation
of a pressure
sensitive label construction in accordance with principles of the present
invention.
[0040] Fig. 12 is a schematic showing another embodiment of the preparation
of a pressure
sensitive label construction in accordance with principles of the present
invention.
DETAILED DESCRIPTION
[0041] One or more specific embodiments of the present invention will be
described below.
In an effort to provide a concise description of these embodiments, all
features of an actual
implementation may not be described in the specification. It should be
appreciated that in the
development of any such actual implementation, as in any engineering or design
project,
numerous implementation-specific decisions must be made to achieve the
developers' specific
goals, such as compliance with system-related and business-related
constraints, which may
vary from one implementation to another. Moreover, it should be appreciated
that such a
development effort might be complex and time consuming, but would nevertheless
be a routine
undertaking of design, fabrication, and manufacture for those of ordinary
skill having the benefit
of this disclosure.
[0042] As described above, various aspects of the present invention address
the drawbacks
described above with pressure sensitive labels of the prior art by providing
pressure sensitive
labels that, among other characteristics, have reduced layers, reduced cost,
increased
recyclability, increased ease of application to an article being labeled, and
reduced incidence or
likelihood of damage to an ink layer (as compared to pressure sensitive labels
of the prior art, as
described in the Background). To accomplish this, one aspect of the present
invention provides
a pressure sensitive label comprising: (a) a support portion including at
least a carrier layer;
and (b) a transfer portion including at least a printable layer in contacting
relationship with the
carrier layer. In general, the transfer portion may overlie the support
portion for transfer of the
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transfer portion from the support portion to an article upon application of
pressure to the transfer
portion while the transfer portion is in contact with the article. In one
aspect of the present
invention, the carrier layer does not include any release layer between the
carrier layer and the
printable layer. This eliminates a layer of the labels of the prior art, thus
reducing the cost of the
label.
[0043] Referring now to Fig. 2, one embodiment of such a pressure sensitive
label 10 is
shown. As can be seen in Fig. 2, the pressure sensitive label 10 of the
illustrated embodiment
is a multilayered construction, with each layer having its own function. Other
embodiments are
also of a multilayered construction. In general, the labels include a "support
portion" 12 (e.g., a
carrier layer 14) and a "transfer portion" 18 (e.g., at least a printable
layer 20¨ although various
embodiments may also include an ink layer 22, and an adhesive layer 24, for
example). When
subjected to pressure, as will be described in greater detail below, the
transfer portion 18 may
be separated from the carrier 14 to adhere to an article. This occurs when the
label 10 is placed
in confronting relationship with an article 26 and pressure is applied, such
that the transfer
portion 18 makes direct contact with an outer surface 28 of the article 26 (an
article 26 can be
seen in Figs. 7 and 8). After contact of the transfer portion 18 to the
article 26, the carrier sheet
14 is removed, leaving the transfer portion 18 affixed to the article 26 via
the adhesive layer 24
of the transfer portion 18.
[0044] There may be several embodiments of the pressure sensitive labels 10
in
accordance with aspects of the present invention. All embodiments include the
general support
portion 12 and transfer portion 18 described above. The support portion 12 of
each
embodiment includes a carrier layer 14, which may have a release coating 16
(e.g., a wax or
silicone coating) on one side thereof (which can be seen in the embodiment
shown in Fig. 2A).
In an alternate embodiment, the carrier 14 may have no release coating, but
may be otherwise
treated, such as by a corona treatment. In still other embodiments, the
carrier 14 may be
untreated and have no release coating. The transfer portion 18 of each of the
embodiments is
positioned adjacent to, and in confronting relationship with, the carrier 14
prior to transfer
therefrom. The transfer portion 18 of the embodiments includes at least (1) a
printable layer 20
in confronting relationship with the carrier 14. Such a confronting
relationship does not require
contact between the two layers (although contact is possible). The layers
merely need be
proximal and adjacent one another, though there may be one layer or coating
between the
carrier 14 and the printable layer 20¨ e.g., as in Fig. 2A. The transfer
portion 18 may also
include an ink layer 22, and an adhesive layer 24. In the embodiments shown in
Figs. 2 and 2A,
the ink layer 22 may be positioned such that the printable layer 20 is between
the carrier layer
14 and the ink layer 22. And, in those embodiments, the adhesive layer 24 may
be positioned
such that the ink layer 22 is between the printable layer 20 and the adhesive
layer 24.
Additional layers may be included within the transfer portion 18.
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[0045] Certain layers of the pressure sensitive label 10 may be made with
UV-curable
materials (and in some embodiments, all the layers may include UV-curable
materials). UV-
curable materials are generally known to those of ordinary skill in the art.
For example, certain
inks, coatings and adhesives are formulated with photoinitiators and resins.
When exposed to
the correct energy and irradiance in a certain band of UV light,
polymerization occurs, and so
the material cures. This reaction may take only a few seconds. The UV sources
used may
include UV lamps and UV LEDs. Fast processes such as flexographic printing
(which may be
used for certain layers on certain embodiments of the pressure sensitive
labels, or on all layers)
may use high intensity light.
[0046] Referring still to Fig. 2, the illustrated embodiment includes a
carrier layer 14, a
printable layer 20, an ink layer 22, a pressure sensitive adhesive layer 24,
and a backside
release layer 27. As can be seen from Fig. 2, the release layer 27 is
positioned such that the
carrier layer 14 is between the printable layer 20 and the release layer 27.
As will be described
in further detail below (in a more detailed discussion of the various layers
of the labels 10), the
backside release layer 27 prevents blocking when the web of labels is wound on
a roll, for
example.
[0047] As described above, the various pressure sensitive label embodiments
in
accordance with principles of the present invention include a carrier layer
14. The carrier layer
14 as used in certain embodiments (and in the illustrated embodiment of Fig.
2) is of a material
that allows the transfer portion 18 of the label 10 to separate from the
carrier layer 14 without
the need for a separate release layer (such as release layers in the prior
art). This allows for
the reduction in materials and cost used in the present pressure sensitive
labels. And so, in
embodiments of the present invention, the carrier layer 14 is of, or includes,
a material having a
surface tension that allows the printable layer 20 to releasably bond thereto.
And, in more
specific embodiments of the present invention, the surface of the carrier
layer 14 that contacts
the printable layer 20 may have a dyne level below about 32.
[0048] Further, as described above, a web of the labels 10 may be wound on
a roll (See, for
example, Fig. 6). In the wound state, the adhesive layer 24 of a label will
contact the carrier
portion 12 of the label web on top of it (and may particularly contact the
backside release layer
27). In such embodiments, the bond of transfer portion 18 to the carrier 12
needs to be stronger
than any bond between the adhesive layer 24 and the release layer 27 (or back
surface of
carrier 14) of an adjacent portion of the wound web. This prevents the
transfer portion 18 from
prematurely separating from the support portion 12 during unwinding of the
roll.
[0049] The carrier layer 14 of various embodiments of the present invention
may include
various materials, so long as those materials allow for a releasable bond of
the printable layer
20 thereto (as described above). For example, the carrier layer 14 may be
chosen from
materials such as plastic film, foil, parchment, lightweight paper, and
heavyweight paper. In one
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specific exemplary embodiment, the carrier layer 14 may include polypropylene.
And, more
specifically, in certain embodiments, the carrier layer may be a biaxially-
oriented co-extruded
polypropylene film having an oriented polypropylene core, a treatable
polyolefin layer on the
underside of the core, and a corona treated polyolefin layer on the topside of
the core (i.e., the
treatable polyolef in layer being the side that would confront and/or contact
the printable layer --
the treatable layer including the surface that receives the printable layer
when the printable layer
contacts the treatable layer). In one specific embodiment, the carrier layer
may include
RayofaceTM C 160 film, commercially available from Innovia Films, Inc. of
Atlanta, Georgia.
[0050] A second film is commercially available under the product name TT ¨
General
Purpose Non Heatsealable BOPPfilm, from AmTopp of Livingston, New Jersey. This
film is also
a coextruded film with an oriented polypropylene core, a treatable
polypropylene layer on the
underside of the laminate, and a high energy treated polypropylene layer on
the top. Like the
embodiment of film described above, the underside is the layer which will be
printed.
[0051] Yet another film, in another embodiment of the present invention, is
commercially
available under the product name Hostaphan 4470RL Clear Non-Silicone Release
Liner, from
Mitsubishi Polyester Film of Greer, South Carolina. This film is chemically
primed on one
surface for adhesive release and a low coefficient of friction, and is
chemically primed on the
opposite surface for adhesion promotion.
[0052] In other embodiments (such as the illustrated embodiment of Fig.
2A), the carrier
layer may have a coating 16 applied to the surface that will confront the
printable layer 20 of the
label 10. Thus, the carrier layer 14 has two surfaces: (1) a top surface 29,
which has a surface
tension low enough to allow the printable layer 20 to releasably bond to it
(which can be
accomplished, as described above, with various treatments of the top surface ¨
such as with
silicones and/or waxes in the embodiment of Fig. 2A); and (2) a bottom surface
31, which is
treated (as will be described in greater detail below) to prevent adhesives 24
from adhering to it
¨ thereby allowing the finished web of labels to be wound into a roll (and
subsequently unwound
during the label application process) without damaging the labels by having
the labels adhere to
one another and to the web (i.e., blocking).
[0053] In the more specific embodiments of the carrier described above, the
surface of the
carrier layer 14 that contacts the printable layer 20 may have a dyne level
below about 32.
[0054] As described above, the pressure sensitive label 10 of the various
embodiments also
includes a printable layer 20 that may be disposed onto and may contact the
carrier layer 14.
This is different from pressure sensitive labels of the prior art (as shown in
FIG. 1), which
included a pressure sensitive adhesive 5 against a release layer 4 on the
carrier layer 3.
Referring again to Figs. 2 and 2A, the printable layer 20 may be a film layer
positioned in
confronting relationship with the carrier layer, or it may be a material, such
as a varnish, which
can be printed onto the carrier layer, to thereafter solidify (or be
solidified) to a state that allows
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the printing of an ink design (text, graphics, and all other indicia) thereon.
By using a printable
layer 20 that may be applied in a softened, molten, thixotropic, liquid, etc.
form, the printable
layer 20 may be applied as a pattern (such as in the shape, size, contour,
etc. of a label that is
to be produced) rather than being provided as a face stock that matches (or
substantially
matches) the area of the carrier layer (as in labels of the prior art). The
printable layer 20 is of a
formulation that allows it to receive ink thereon following cooling,
solidifying, UV-curing, etc.
The ability to apply the printable layer 20 in a pattern also reduces the
amount of material that is
needed for the web of labels (thereby reducing cost), eliminates the need for
die cutting (and the
waste of the discarded die cut material), and can be used to allow the entire
label to be
constructed in one location (as opposed to the need of acquiring a base
pressure sensitive label
stock from a third party supplier).
[0055] In certain embodiments, the printable layer 20 may include a
material formulated
from a base resin. This base resin may, in various embodiments, be chosen from
vinyls,
acrylics, urethanes, epoxys, polyesters, and alkyds. Further, the printable
layer 20 is solvent-
based, water-based, or ultraviolet curable-based. The printable layer 20,
including these
solvent-based, water-based, and/or UV curable-based chemistries, (which are
formulated from
the base resins), may be formulated into a printable liquid at the viscosity
and rheology
applicable to various printing processes (such as screen printing, ink-jet
printing, flexographic
printing, rotogravure printing, and lithographic printing for example). In one
specific
embodiment, the printable layer may include an imprintable varnish including a
triacrylate ester
monomer, a diacrylate ester monomer, an aromatic urethane acrylate, a
difunctional acrylate,
an acrylate oligomer, triethanolamine, and 4-phenylbenzophenone. In a more
specific
embodiment, the printable layer may include an imprintable varnish including
about 30% to
about 50% of a triacrylate ester monomer, about 10% to about 12.5% of a
diacrylate ester
monomer, about 10% to about 12.5% of an aromatic urethane acrylate, about 10%
to about
12.5% of a difunctional acrylate, about 5% to about 7% of an acrylate
oligomer, about 3% to
about 5% of triethanolamine, and about 1% to about 2% of 4-phenylbenzophenone
Such an
imprintable varnish may be supplied in liquid form, have a density of about
1.07g/cm3 (about
8.921b/gal or about 1070 g/I), have a flash point of greater than about 93 C,
and a boiling point
of about 106 C. One example of such an imprintable varnish is commercially
available from
INX International Ink Co. of Schaumburg, Illinois, under the product name
ProcureTM KCC5185
(and product code 1487893). Another such print-receptive coating is JRX-1253,
commercially
available from Dyna-Tech Adhesives and Coatings, Inc., of Grafton, West
Virginia. JRX-1253 is
a UV radiation cured printable and metallizable coating for plastics such as
PET, PE, etc. It is
printable with UV and classical solvent and water based inks. At 100% solids,
it is clear after
curing. Those of ordinary skill in the art will recognize that other materials
of the same or similar
characteristics may be used in embodiments of the present invention.
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[0056] In other aspects, the label 10 may include an ink layer 22
positioned such that the
printable layer 20 is between the carrier layer 14 and the ink layer 22. And,
the label 10 may
include an adhesive layer 24 positioned such that the ink layer 22 is between
the printable layer
20 and the adhesive layer 24. By this configuration, the pressure sensitive
labels 10 described
herein include the printable layer 20 most proximal to the carrier 14, and the
adhesive layer 24
most distal to the carrier 14 (which is a somewhat opposite configuration as
compared to the
pressure sensitive labels of the prior art). Due to this configuration, the
transfer portion 18 (e.g.,
printable layer 20, ink layer 22, adhesive layer 24) of the pressure sensitive
labels described
herein do not have to be peeled away from the carrier to expose the adhesive
for adherence to
an article. Rather, the labels 10 are configured such that the adhesive 24 is
already the outer
layer of the label construction prior to application to an article 26, and so
the adhesive 24 is pre-
exposed and ready to contact an article 26 ¨ thereby increasing the ease of
application to an
article 26.
[0057] The configuration of the layers in these embodiments of the present
labels (e.g.,
those shown in Figs. 2 and 2A) also results in the ink being beneath the
printable layer 20 (and
thus protected by the printable layer 20) once the transfer portion 18 is
transferred to an article
26. This results in the ink layer 22 (the indicia, graphics, design, text,
information, etc.) being
protected from damage once the label 10 is transferred to an article 26. This
protection is
achieved without having to add any additional protective lacquer layers (as is
done sometimes
with prior art pressure sensitive labels). The configuration that allows the
printable layer 20 to
protect the ink layer 22 following transfer also increases the number of
materials that may be
used in the ink layer 22 ¨ such as being able to use easily damaged materials,
such as metallic
inks.
[0058] The inks used in the ink layer 22 are used to create the various
indicia (e.g., text,
graphics, etc.) of the label. The indicia may be printed using any printing
process including, but
not limited to, offset printing, flexographic printing, rotogravure printing,
letterpress printing,
digital printing, ink jet printing, and screen printing. Further, the
incorporation of standard
printing effects such as combination printing (the use of gravure printing in
combination with
flexographic printing in a single press), the use of cold-foil and hot-foil
decoration, and pattern
embossing, for example, are contemplated by the invention described herein.
[0059] In one embodiment, the ink layer 22 may include UV-curable inks. In
one particular
embodiment, the UV-curable ink may include a blend of at least polyfunctional
components and
photoinitiators. In particular, the polyfunctional components may be
polyfunctional acrylates. In
one embodiment, the UV-curable ink may include polyfunctional acrylates in an
amount of
greater than 30% based on the total resin weight. More specifically, one
embodiment of a UV-
curable ink may include polyfunctional acrylates in an amount of 65-95%, and a
photoinitiator
blend in an amount of 1-20%. An example of such an ink is FP-500 UV process
red ink,
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commercially available from Gotham Ink Corporation of Marlboro, Massachusetts.
Another
such ink is commercially available from INX International Ink Co., of
Schaumberg, Illinois, which
uses only polyfunctional components in its ink formulations (and thus does not
include any
monofunctional components) and is offered under the trade name INXFIex2000 UV
HTL.
Another ink that can be used is an "ITX-Free" ink commercially available from
INX International
Ink Co., of Schaumberg, Illinois.
[0060] Yet another embodiment of an ink that may be used is one including
polyester
acrylate, glycerol propoxy triacrylate [e.g., poly(oxy(methy1-1,2,-
ethanediy1)), alpha, alpha',
alpha"-1,2,3-propanetriyltris(omega-((1-oxo-2-propenyl)oxy)-; such as that
under CAS number
52408-84-1], hydroxycyclohexyl phenyl ketone (CAS number 947-19-3) and acrylic
acid ¨
monoester with propane-1,2-diol (CAS number 25584-83-2). In one specific
embodiment of this
ink, the polyester acrylate may be present in an amount of about 1% to about
5%, the glycerol
propoxy triacrylate may be present in an amount of about 1% to about 5%, the
hydroxycyclohexyl phenyl ketone may be present in an amount of about 0.5% to
about 1.5%,
and the acrylic acid, monoester with propane-1,2-diol may be present in an
amount of about
0.1% to about 1%. The ink may have a flashpoint higher than about 93.3 C, a
boiling/condensation point of about 100 C, a density of about 1049g/l(about
8.7539 lbs/gal),
and a viscosity [kinematic (room temperature)] of greater than about 2.2 cm2/s
(greater than
about 220 cSt). The VOC content of such an ink may be about 0.5% by weight.
One such ink
is a UV LED curing flexo ink commercially available from Flint Group Narrow
Web of Plymouth,
Minnesota, under the trade name Ekocure FTM.
[0061] In another embodiment, the ink may be a solvent based ink, and may
include
ethanol, propylene glycol methyl ether, propyl acetate, isopropanol, and
aluminum flake. In one
specific embodiment, the solvent based ink may include about 25% to about 35%
ethanol, about
20% to about 25% propylene glycol methyl ether, about 15% to about 20% propyl
acetate,
about 15% to about 20% isopropanol, and about 3% to about 5% aluminum flake.
Such an ink
may have a density of about 0.888 g/cm3, a flashpoint estimated to be greater
than about 23 C,
and a boiling point of about 78.5 C to about 119.9 C. One such ink is
commercially available
from INX International Ink Co., of Schaumberg, Illinois, under the name
"Platinum Plus F124
Metallic," and product code 1489010.
[0062] Other inks that may be used include digital inks, such as those
commercially
available from Indigo Ink of Columbia, Maryland. However, one of ordinary
skill in the art will
recognize that the above-described inks are not the only inks that can be
used.
[0063] The various embodiments of the pressure sensitive label 10 (such as
those
illustrated in Figs. 2 and 2A) also include a pressure sensitive adhesive 24.
In various
embodiments of the present invention, the adhesive chemistry used for the
pressure sensitive
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adhesive 24 can include any formulation capable of being applied in a pattern
duplicating or
similar to the contour, size, and shape of the printable layer 20 as applied
to the carrier 14.
[0064] As is generally known, pressure sensitive adhesives are adhesives
which form a
bond when pressure is applied to marry the adhesive with the adherend. No
solvent, water, or
heat is needed to activate the adhesive in such instances. As the name
indicates, the degree of
bond is influenced by the amount of pressure which is used to apply the
adhesive to the
surface. Further, pressure-sensitive adhesives are manufactured with either a
liquid carrier or in
100% solid form. Articles such as labels are made from liquid pressure
sensitive adhesives by
coating the adhesive on a support and evaporating the organic solvent or water
carrier, usually
in a hot air dryer. The dry adhesive may be further heated to initiate a cross-
linking reaction and
increase molecular weight. 100% solid pressure sensitive adhesives may be low
viscosity
polymers that are coated and then reacted with radiation to increase molecular
weight and form
the adhesive (a radiation cured pressure sensitive adhesive); or they may be
high-viscosity
materials that are heated to reduce viscosity enough to allow coating, and
then cooled to their
final form (a hot melt pressure sensitive adhesive).
[0065] The pressure sensitive adhesive used may be consistent with typical
gravure
printing, but modified to allow printing with flexographic techniques. A
formulation for such a
solvent adhesive may be UV curable. One particular adhesive in one specific
embodiment of
the present invention may be a high tack pressure sensitive adhesive adaptable
for flexographic
printing and having a viscosity of 1500-2000 cPs. Such an adhesive may include
about 37.5%
to about 80% acrylate, and about 2.5% to about 10% of a photoinitiator (along
with additional
materials making the remainder of the formulation). The adhesive provided
under this
formulation may have a flash point of about 94 C, and a specific gravity at 20
C of about
1.06g/cm3 (about 8.85Ib5/gal). One such adhesive is commercially available
from Craig
Adhesives & Coatings of Newark, New Jersey under the product name Craigbond
1029BTJ UV
High Tack PSA.
[0066] Another such adhesive in one specific embodiment of the present
invention may
have a formula including at least nonylphenol ethoxylated acrylate (CAS number
50974-47-5),
and ethoxyethoxy ethyl acrylate (CAS number 7328-17-8), among other materials.
The
adhesive may also include 2-hydroxy-2-methyl-1-phenyl-1-propanone. One such
adhesive is
commercially available from Craig Adhesives & Coatings of Newark, New Jersey
under the
product name Craigcote 1029J.
[0067] Another adhesive that may be used in various embodiments of the
present invention
includes a self-crosslinking acrylic polymer that cures upon solvent removal.
Such an adhesive
may be about 53% to about 56% non-volatiles with a Brookfield viscosity at 77
F of about 3500
to about 6000. The solvent of the adhesive may be ethyl acetate/heptanes with
a solvent ratio
of 83/17. The adhesive may have a density of about 7.7 to about 8.1 lbs/gal
(about 0.92 to
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about 0.98 gm/cm3), and a flash point of less than about 20 F. An example of
such an adhesive
is commercially available from Ashland Performance Materials of Dublin, Ohio
under the
tradename AROSETTm PS-6416.
[0068] Yet another adhesive that may be used in various embodiments of the
present
invention includes a hot melt pressure sensitive adhesive. Such an adhesive is
100% solids
with a viscosity of about 66,500 at 300 F, a Mettler softening point of about
250 F, and a density
of about 7.8Ibs/gal. Such an adhesive may also include a piperylene copolymer
and a modified
terpene resin. In one specific embodiment, this adhesives may include about
10% to about
30% piperylene copolymer and about 10% to about 30% modified terpene resin.
The adhesive
may have a boiling point of greater than about 260 C, a melting point of about
110 C, a specific
gravity of about 0.98, and a flash point of greater than about 260 C (by the
Cleveland open cup
method). An example of such an adhesive is commercially available from Henkel
Corporation
of Rocky Hill, Connecticut under the trade name Technomelt and product number
Technomelt
PS 9197.
[0069] However, one of ordinary skill in the art will recognize that these
are not the only
adhesives that can be used. For example, other UV-curable adhesives may be
used.
Ultraviolet (UV) light curing adhesives, also known as light curing materials
(LCM), have
become popular within the manufacturing sector due to their rapid curing time
and strong bond
strength. Light curing adhesives can cure in as little as a second and many
formulations can
bond dissimilar substrates (materials) and withstand harsh temperatures.
Unlike traditional
adhesives, UV light curing adhesives not only bond materials together but they
can also be
used to seal and coat products.
[0070] In this embodiment of the pressure sensitive labels 10, the adhesive
layer 24 is UV
cured following the printing step. As such, the label 10 can be wound in roll
form without
blocking (due to tackiness). During the decoration step, heat (or heat and
pressure) is applied
and the adhesive becomes soft, fluid, and tacky just prior to application at
which point the label
bonds to the substrate.
[0071] One such UV-curable heat activated adhesive is H530 and is
commercially available
from Actega Radcure Inc. of Wayne, New Jersey. Per the MSDS, H530 is used as a
UV/EB
curable adhesive, primer, coating. Another such heat activated UV cured
adhesive is FP-500
NUV85 from Gotham Ink Corporation of Marlboro, Massachusetts. FP-500 NUV85 is
a
proprietary mixture of materials. However, those of ordinary skill in the art
will recognize that
these are not the only UV-curable adhesives that can be used, and that other
UV-curable
adhesives providing similar characteristics can be used.
[0072] In another aspect, the pressure sensitive label 10 as shown in the
embodiments of
Figs. 2 and 2A may further include a release layer 27 positioned such that the
carrier layer 14 is
between the printable layer 20 and the release layer 27. In other words, the
release layer 27 is
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not on the side of the carrier 14 adjacent to the transfer portion 18 of the
label 10, but rather is
on the underside of the carrier 14. This release layer 27 allows the web of
labels 10 to be
wound on a roll, for example, while preventing blocking (i.e., the problem of
the adhesive on the
labels adhering to the underside of the carrier as the web of labels is wound
on the roll). Thus,
the presence and positioning of this release layer 27 allows the web of labels
to be wound into a
roll after printing of the labels 10. In particular, the bond of the pattern
applied printable layer 20
is greater to the top surface of the continuous web of the carrier layer 14
than it is to the release
layer 27 on the bottom side of the carrier layer 14. Thus, when the roll is
unwound, the label 10
is positioned adhesive side up to allow ease of application to articles 26
being labeled.
[0073] One particular release formulation for a release layer in one
specific embodiment of
the present invention may include a UV curable release material, and such a
material may ¨ in
one embodiment ¨ be a cationic release coating. Such a release formulation may
include
dimethyl siloxanes and silicones (CAS number 67762-95-2). An example of such a
material is
commercially available from Craig Adhesives and Coatings, of Newark, New
Jersey, under the
trade name Craigcoat UV9300 and product code uv9300. In an embodiment of the
present
invention, the release material described above may include a photocatalyst
material used in
conjunction therewith. Such a photocatalyst material may include ¨ in one
embodiment ¨ 2-
isopropylthioxathone, C12 and C14 alkylglycidyl ethers, bis(4-
dodecylphenyl)iodonium
hexafluoroantimonate, and linear alkylate dodecylbenzene. More specifically, a
certain
embodiment may include about 1% to about 5% 2-isopropylthioxathone, about 30%
to about
60% C12 and C14 alkylglycidyl ethers, about 30% to about 60% bis(4-
dodecylphenyl)iodonium
hexafluoroantimonate, and about 5% to about 10% linear alkylate
dodecylbenzene. An
example of such a photocatalyst material is commercially available from Craig
Adhesives and
Coatings, of Newark, New Jersey, under the trade name UV9390C.
[0074] As described above, and referring now to Figs. 3 and 3A, another
aspect of the
present invention provides a pressure sensitive label comprising: (a) a
support portion including
at least a carrier layer; and (b) a transfer portion including at least a
printable layer in
confronting relationship with the carrier layer. In a label of this aspect, an
ink layer may be
present between the printable layer and the carrier layer. Depending on the
nature of the ink
layer, at least a portion or portions of the printable layer may contact the
carrier layer (i.e., in any
areas where ink or inks of the ink layer are not present). In general, the
transfer portion may
overlie the support portion for transfer of the transfer portion from the
support portion to an
article upon application of pressure to the transfer portion while the
transfer portion is in contact
with the article. In one embodiment, the carrier layer does not include any
release layer on the
side of the carrier layer facing the printable layer. This eliminates a layer
of the labels of the
prior art, thus reducing the cost of the label. In this configuration, the
pressure sensitive labels
of this aspect include the ink layer most proximal to the carrier, and the
adhesive layer most
distal to the carrier. Due to this configuration, the transfer portion (e.g.,
ink layer, printable layer,
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adhesive layer) of the pressure sensitive labels described in this aspect do
not have to be
peeled away from the carrier to expose the adhesive for adherence to an
article. Rather, the
labels are configured such that the adhesive is already the outer layer of the
label construction
prior to application to an article, and so the adhesive is pre-exposed and
ready to contact an
article ¨ thereby increasing the ease of application to an article.
[0075] Referring now to Fig. 3, a particular embodiment of such a pressure
sensitive label
is shown. As can be seen in Fig. 3, the pressure sensitive label 10 of the
illustrated
embodiment is a multilayered construction, with each layer having its own
function. Other
embodiments are also of a multilayered construction. The embodiment of label
shown in Fig. 3
does include the general support portion 12 and transfer portion 18 described
above. The
support portion 12 of each embodiment includes a carrier layer 14, which may
have a release
coating 16 (e.g., a wax or silicone coating) on one side thereof (which can be
seen in the
embodiment shown in Fig. 3A). In an alternate embodiment, the carrier 14 may
have no release
coating (on the carrier facing the ink layer ¨ see the embodiment of Fig. 3),
but may be
otherwise treated, such as by a corona treatment. In still other embodiments,
the carrier 14 may
be untreated and have no release coating. The transfer portion 18 of each of
the embodiments
is positioned adjacent to, and in confronting relationship with, the carrier
14 prior to transfer
therefrom. The transfer portion 18 of the embodiments includes at least (1) a
printable layer 20
in confronting relationship with the carrier 14. Such a confronting
relationship does not require
contact between the two layers (although contact is possible). The layers
merely need be
proximal and adjacent one another. The transfer portion 18 may also include an
ink layer 22,
and an adhesive layer 24. The ink layer 22 may be positioned such that it is
between the carrier
layer 14 and the printable layer 20. And, the adhesive layer 24 may be
positioned such that the
printable layer 22 is between the ink layer 22 and the adhesive layer 24.
Additional layers may
be included within the transfer portion 18.
[0076] Referring still to Fig. 3, the illustrated embodiment includes a
carrier layer 14, an ink
layer 22, a printable layer 20, a pressure sensitive adhesive layer 24, and a
backside release
layer 27. As can be seen from Fig. 3, the release layer 27 is positioned such
that the carrier
layer 14 is between the ink layer 22 and the release layer 27. As will be
described in further
detail below (in a more detailed discussion of the various layers of the
labels 10), the backside
release layer 27 prevents blocking when the web of labels is wound on a roll,
for example.
[0077] As described above, the various pressure sensitive label embodiments
in
accordance with principles of the present invention include a carrier layer
14. The carrier layer
14 as used in certain embodiments (and in the illustrated embodiment of Fig.
3) is of a material
that allows the transfer portion 18 of the label 10 to separate from the
carrier layer 14 without
the need for a separate release layer (such as release layers in the prior
art). This allows for
the reduction in materials and cost used in the present pressure sensitive
labels. And so, in
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embodiments of the present invention, the carrier layer 14 is of, or includes,
a material having a
surface tension that allows the printable layer 20 to releasably bond thereto.
And, in more
specific embodiments of the present invention, the surface of the carrier
layer 14 that contacts
the printable layer 20 may have a dyne level below about 32.
[0078] In other embodiments (such as the illustrated embodiment of Fig.
3A), the carrier
layer may have a coating 16 applied to the surface that will confront the ink
layer 22 of the label
10. Thus, the carrier layer 14 has two surfaces: (1) a top surface 29, which
has a surface
tension low enough to allow the ink layer 22 to releasably bond to it (which
can be
accomplished, as described above, with various treatments of the top surface ¨
such as with
silicones and/or waxes in the embodiment of Fig. 3A); and (2) a bottom surface
31, which is
treated (as will be described in greater detail below) to prevent adhesives 24
from adhering to it
¨ thereby allowing the finished web of labels to be wound into a roll (and
subsequently unwound
during the label application process) without damaging the labels by having
the labels adhere to
one another and to the web (i.e., blocking).
[0079] The printable layer 20 (in the embodiments of Figs. 3 and 3A) will
be positioned
behind the ink or inks of the ink layer 22 once the label is applied to an
article. The printable
layer 20 is the filmic layer that provides some mass and bulk to the label.
Further, the printable
label may include pigments in its formulation in or to provide a degree of
opaqueness (i.e., a
background) to any label information, text, graphics, etc provided by the ink
layer. This
opaqueness may be provided in any color desired. Alternatively, the printable
layer may be
clear. The use of pigments to provide a degree of background coloration is
well known to those
of ordinary skill in the art.
[0080] The layers (carrier 14, ink layer 22, printable layer 20, adhesive
layer 24, backside
release layer 27, etc.) of the embodiments of Figs. 3 and 3A of the present
invention may
include various materials, including those described above with respect to the
embodiments of
Figs. 2 and 2A.
[0081] As described above, various embodiments of the label may include
other layers.
One such layer may be a protective layer, which may be used to protect the ink
layer from
abrasion following transfer of a label to an article (such as the version
shown in Figs. 3 and 3A,
where the ink layer would be the outer exposed layer of the label following
transfer. Such an
embodiment including a protective layer 33 is shown in Figs. 4 and 4A. The
transfer portion 18
of this embodiment includes at least (1) a printable layer 20 in confronting
relationship with the
carrier 14. Such a confronting relationship does not require contact between
the two layers
(although contact is possible). The layers merely need be proximal and
adjacent one another.
The transfer portion 18 may also include an ink layer 22, and an adhesive
layer 24. The ink
layer 22 may be positioned such that it is between the protective layer 33 and
the printable layer
20. And, the adhesive layer 24 may be positioned such that the printable layer
22 is between
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the ink layer 22 and the adhesive layer 24. And, the protective layer 33 may
be positioned such
that it is between the carrier 14 and the ink layer 22. (The embodiment shown
in Fig. 4A is of
similar construction, though it includes a separate release layer 16 on one
side of the carrier
14.)
[0082] Referring still to Fig. 4, the illustrated embodiment includes a
carrier layer 14, a
protective layer 33, an ink layer 22, a printable layer 20, a pressure
sensitive adhesive layer 24,
and a backside release layer 27. As can be seen from Fig. 3, the release layer
27 is positioned
such that the carrier layer 14 is between the protective layer 33 and the
release layer 27. The
backside release layer 27 prevents blocking when the web of labels is wound on
a roll, for
example (as has been described above with respect to the embodiments of Figs.
2 and 3).
[0083] The protective layer 33 may be of various kinds including, but not
limited to UV-cured
or UV-curable overprint varnishes. However, the protective layer may be of
other types (for
example solvent gravure HTL protective layers).
[0084] In one example, then, the protective layer 33 may be a coating of a
UV-curable
chemistry in which the formula has been modified with additives that will
increase the scuff
resistance and or chemical resistance. Such a coating may have the properties
of high gloss,
chemical resistance, good UV reactivity, free of benzophenone and bisphenol A,
and non-
yellowing. One particular coating for a protective layer may have a film
weight of 0.40 ¨ 0.70
lbs/1000 sqft, using a 180-250 !pi, 6-9 billion cubic microns (bcm) per square
inch anilox roll; a
viscosity of 160 centipoise (cps) using a Brookfield RV, #3 spindle, 100
revolutions per minute
(rpm) @ 77 F (25 C); may cure at 150-250 feet per minute (fpm) per 400 watts
per inch (wpi)
lamp; may appear as a translucent liquid; may have a gloss of >90 @60 angle
(over black
portion of Leneta N2A-3); may have a measured static CoF <0.30 and a kinetic
CoF between
0.15-0.21, using a 200 gram sled; and may have a solvent resistance of >50
methylethyl ketone
(MEK) double rubs (those of ordinary skill in the art will recognize that
properties such as gloss
CoF, and solvent resistance will depend on coating film thickness, degree of
cure and substrate
type). One specific example of such a coating to be used for a protective
layer would be
SunCure HG (High Gloss) TL 4098 coating (commercially available under product
number
RCYFV0484098 from Sun Chemical, of Parsippany, NJ). Such a coating may be
applied with
flexo, tower coater, or roller coater.
[0085] While the above embodiments (of Figs. 4 and 4A) describe a
protective layer 33 that
is separate from the ink layer, alternate embodiments may include a protective
layer that is
combined with providing the graphics of the ink layer. This may be achieved by
pigmenting the
protective layer to be the color or colors of ink that is desired (and
configured into the various
desired graphics, text, etc. of the label.
[0086] As described above, another aspect of the present invention may
include a method
or methods for making a pressure sensitive label. And still another aspect of
the present
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invention may include a method or methods for applying a pressure sensitive
label to an article.
Referring now to Fig. 5, the pressure sensitive label 10 of embodiments such
as that shown in
Fig. 2 may be prepared as follows: The printable layer 20 may be laid down on
a carrier layer
14 by a first roller/cylinder 34 (for example), followed by the ink layer 22
being laid down on the
printable layer 20 by a second roller/cylinder 36, and then the adhesive layer
24 being laid down
on the ink layer 22 by a third roller/cylinder 38, thereby forming a label 10
with these separate
and distinct layers. During the process of laying down the printable layer 20,
ink layer 22, and
adhesive layer 24, a release layer 27 may also be applied to the opposite side
of the carrier
layer from the transfer portion of the label by a fourth roller/cylinder 40.
In the embodiments
where one or more of these layers (printable, ink, adhesive, release) is UV-
curable, they may be
exposed to UV radiation provided by ultraviolet light, which cures the various
UV-curable layers.
This UV-curing may be done as each separate UV-curable layer is laid down, or
it may occur
after all UV-curable layers have been laid down. (Further, although Fig. 5
shows, and is
described as, putting down a printable layer followed by an ink layer, those
skilled in the art will
recognize that for embodiments of the label having a different ordering of
layers ¨ such as that
shown in Figs. 3 and 3A ¨ the layers may be put down in a different order than
shown in Fig. 5,
e.g., ink layer put down followed by printable layer.)
[0087] Further, any UV-curable components may be applied using flexographic
printing
techniques. UV components do not present the problem of "swelling" when used
in flexographic
printing (unlike certain typical rotogravure solvent components). Flexographic
printing is a
process that is well known to those of ordinary skill in the art. In general,
in the flexographic
process (used for the UV cured ink), a flexible relief plate (not shown)
includes image areas
raised above the non-image areas. A component, such as ink, is transferred
from an ink roll
(not shown), which is partially submerged in an ink tank to a second roll (not
shown) whose
texture holds a specific amount of ink. A doctor blade (not shown) then
removes excess ink
from the second roll before inking the flexible relief plate. The substrate is
then positioned
between the plate and an impression cylinder (not shown) to transfer the
image. While the plate
is described as having "image areas," the "image" of those areas may be
designed as to
provide a floodcoating of the protective lacquer layer onto the substrate.
[0088] By using flexographic printing techniques for various layers of the
label 10, this
aspect of the present invention results in cost savings over that of
previously manufactured
pressure sensitive labels 10, (or labels 10 including a UV-curable layer),
using rotogravure
printing techniques. This is because rotogravure printing techniques are
expensive, especially
as compared to printing techniques such as flexographic printing. By
eliminating gravure
printing for the layers of the pressure sensitive label 10 (especially those
that include the most
complicated design -- i.e., the ink layer 22), great cost savings may be
realized due to the need
not to have to provide multiple and different etched gravure cylinders for
different production
runs.
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[0089] However, the layers of the labels 10 are not limited to flexographic
techniques, and
may be applied using other techniques, including gravure printing techniques.
In rotogravure
techniques (which are also well known to those of ordinary skill in the art),
the printing plate (not
shown) is in cylinder form, and includes wells that are etched or engraved to
differing depths
and/or sizes to provide the image or images. The component such as the
protective lacquer or
adhesive is applied directly to the cylinder by rotating in a bath (not shown)
where each cell of
the image is flooded with the lacquer or adhesive. A doctor blade (not shown)
wipes away the
excess lacquer or adhesive, and capillary action of the substrate and pressure
from impression
rollers (not shown) draw the lacquer or adhesive out of the wells and transfer
it to the substrate.
[0090] Thus, the apparatus (not shown) for a gravure printed layer includes
a gravure
printing unit (not shown) for a rotary press, with a gravure sleeve (not
shown) supplied with
lacquer or adhesive from a gravure tray (not shown) and an impression roller
(not shown), which
lies in confronting relationship to the gravure sleeve, to form a roller gap
(not shown)
therebetween. When the rotary press is running, a carrier, such as a sheet
material, that is to
be printed is passed through the roller gap, taking up lacquer or adhesive
from the peripheral
surface of the gravure sleeve. At the same time, the gravure sleeve rotates in
a specified
direction opposite to that of the impression roller and its rotational
movement is composed of a
leading, rotating sector from the printing unit to the roller gap and a
trailing rotating sector from
the roller gap to the printing unit. Apparatus and techniques for both
rotogravure and
flexographic printing are common and are very well known to those of ordinary
skill in the art.
[0091] Further, as has been mentioned above, certain layers of the label
(e.g., printable
layer 20, ink layer 22, and adhesive layer 24), may be laid down, or printed,
in a particular
pattern corresponding to the size, shape, and/or contour of the desired end
label image. This
also results in solving a problem of the prior art (which led to too much
material being used, and
thus, increased cost to labels). Because the ink design is printed only on a
portion of the base
construction that (in prior art) is purchased from a third party, this
requires that the face stock
onto which the ink is printed be a film that spans the entirety of the carrier
(to be die cut later
on). It also requires that the adhesive (which is part of the base
construction in the prior art) be
flood coated onto the carrier (since this is done before sale of the base
construction). In other
words, since the carrier suppliers do not know in advance what ink designs
will be applied by
the label-maker, they flood-coat the entire carrier with adhesive, and cover
the entirety of the
carrier with face stock, to allow for any size, shape, configuration, and
registration of ink design.
The use of such a large amount of face stock and flood-coated adhesive results
in a large
amount of unused, and thus excess, adhesive, as well as an excess amount of
face stock that
must be die cut and discarded. The use of this excessive amount of adhesive
and face stock
results in increased costs to the prior art labels, because the excess amount
of face stock and
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adhesive results in increased cost of the carrier, and thus increased cost of
label preparation
and of the labels themselves.
[0092] However, the design of the present pressure sensitive label 10
allows for printing of
a printable layer 20 to be laid down in a pattern, as well as a patterned ink
layer 22 and an
adhesive 24. This is due in part to the construction of the label in somewhat
reverse order to
previous pressure sensitive labels. In other words, the prior art labels had
an adhesive
disposed on the release of a carrier, with the face stock on top of the
adhesive, and the ink on
top of the face stock. In the label of the present application, the printable
layer may be applied
at the site of labeling with the ink on top of the printable layer and the
adhesive on top of that.
Since this occurs at the site of labeling, the entity providing and creating
the label will know at
the time of printing what the design of the label will be. And so, rather than
providing a face
stock of the same area as the carrier, the present invention does not use a
face stock. Rather,
the typical face stock of pressure sensitive labels of the prior art is
eliminated, and instead a
printable layer (such as an imprintable varnish) may be placed down on the
carrier. This allows
one to print the printable layer in the shape of the final label design ¨
which allows one to create
a label without the need for die cutting any extra face stock. In one
embodiment, the printable
layer may be applied using a 30 bcm anilox roller.
[0093] In the same manner, this allows one to also print the adhesive onto
the ink design in
the shape of the ink design (i.e., having a same or similar outer contour to
the ink design) in
order to avoid the waste of excess adhesive that occurs via floodcoating in
the prior art. In one
embodiment, the ink layer may be applied using an 8 bcm anilox roller. In one
embodiment, the
adhesive layer may be applied using a 4.5 bcm anilox roller. In another
embodiment, the
adhesive layer may be applied using an 8 bcm anilox roller.
[0094] For example, then, another aspect of the present invention provides
a process for
applying a printable layer 20, ink layer 22, and/or an adhesive layer 24 onto
a carrier, wherein
the printable layer 20, ink layer 22,and/or adhesive layer 24 covers less than
substantially the
entire surface of a first side of the carrier. Thus, the printable layer 20,
ink layer 22, and/or
adhesive layer 24 can be applied in a patterned form and/or can be applied to
match any size,
shape, configuration, or registration desired for a label. More specifically,
this process may
include contacting the materials for the printable layer 20, ink layer 22,
and/or adhesive layer 24
with a surface having at least one etched region thereon, and confronting the
carrier 14 (for
example) with the surface such that at least a portion of the printable layer
20 transfers from the
surface to the carrier 14. The printable layer that transfers may particularly
be received by and
transferred from the etched region of the surface. Thus, the process may
include (a) softening a
material for the printable layer 20 (such as by melting the formulation), (b)
contacting the
softened printable layer and/or adhesive formulation with a gravure sleeve
having at least one
etched portion wherein the formulation is adsorbed onto the surface of the
gravure sleeve, (c)
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removing excess printable layer from the surface of the gravure sleeve so the
printable layer
formulation is adsorbed only to the etched portion of the gravure sleeve, and
(d) contacting the
gravure sleeve with the carrier to deposit the printable layer and/or adhesive
formulation onto
the carrier, thereby forming a printable layer 20 upon a portion of the
carrier 14. An ink layer 22
can then be printed onto the printable layer, and an adhesive layer can then
be printed onto the
ink layer to form a label having a support portion and a transfer portion. The
transfer portion of
the label may be subsequently transferred onto an article.
[0095] In use, and referring now to Figs. 7 and 8, the label 10 in
accordance with principles
of the present invention is applied to an article 26 as follows. In the
illustrated embodiment, the
labels 10 are carried on a web that has been wound into a roll 42. The
transfer portion 18 of the
labels 10 are releasable from the support portion 12 (e.g., carrier 14) and
the web progresses
from a feed reel 44 to a take-up roll 46. After being unwound from the
rotating feed reel 44, the
web of labels generally will pass proximal to the articles 26 being labeled.
It will be recognized
by those of skill in the art that the various rolls listed above are merely
exemplary, and are not
necessary to the principles of the present invention. Upon reaching proximity
to the article 26
(see 48 of Fig. 7), contact occurs between the adhesive layer 24 of the
transfer portion 18 of the
label 10 and a surface of the article 26. At this point, pressure may be
applied to adhere the
adhesive layer 24 of the label 10 to the surface of the article (by methods
and apparatus
generally known to those of ordinary skill in the art). This pressure
facilitates adherence of the
transfer portion of the label 10 to the article 26. After the transfer portion
18 has been applied to
an article 26, the bond between the adhesive layer 24 and article is stronger
that the releasable
bond between the printable layer 20 and carrier 14 (or printable layer 20 and
release
composition 16 ¨ or ink layer 22 and carrier 14). This causes the transfer
portion 18 to peel
away from the support portion 12 as the web of labels and articles continue to
move. The now
empty carrier web (i.e., support portion 12) may progress to a take-up reel
46, where it may be
recycled (or discarded). It will be recognized by those skilled in the art
that the particular
number, type, and configuration of components described above are merely
illustrative. And
after the web has moved past the labeling point, the article 26 (as seen in
Fig. 8) now includes
the transfer portion 18 of the label adhered thereto.
[0096] The application of the label described in this application may occur
with the label
being rolled onto the article in the same or similar way a heat transfer label
would be, which
eliminates the opportunity for wrinkles and blisters to occur, thereby
reducing and/or eliminating
one of the problems with pressure sensitive labels of the prior art.
[0097] As described above, in various embodiments of the present invention,
one or more
of the layers of the label 10 may be applied as a pattern (such as in the
shape, size, contour,
etc. of a label that is to be produced) rather than being provided as a face
stock with layers that
match the carrier layer (as in the prior art). And so, and referring now to
Fig. 9, an alternate
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embodiment is shown that includes an adhesive layer 24 applied in a pattern.
In such an
embodiment, the adhesive chemistry used for the pressure sensitive adhesive 24
can include
any formulation capable of being applied in a desired pattern. While certain
embodiments
above are described as having the adhesive layer 24 as the outer layer of a
label (i.e., distal
from the carrier 14), the embodiment of Fig. 9 shows the adhesive layer 24
proximal to the
carrier 14. Although this differs from previous embodiments, it also resolves
certain issues seen
in the prior art (which have heretofore been unsolved), such as the need in
prior art labels to
fold coat adhesive when providing a separate label facestock (as described in
the Background
of the Invention). The present embodiment eliminates such excess adhesive.
[0098] And so, referring to Fig. 9, one aspect of the present invention
provides a label 10,
and a process for applying a layer, such as an adhesive layer 24 onto a
carrier 14, wherein the
adhesive layer 24 covers less than substantially the entire surface of one
side of the carrier 14.
A carrier 14, as previously described, typically may be a sheet of paper,
film, or other material
having a first side 29 to which further label components may be applied, and a
second side 31
opposite the first side 29. Thus, the adhesive layer 24 can be applied to the
first side 29 of the
carrier 14 as a patterned form and/or can be applied to match any size, shape,
configuration, or
registration of an ink design, or other layer of the label, relative to the
carrier 14. As the
adhesive layer contacts the carrier 14 in this illustrated embodiment, the
carrier may be
designed to facilitate release of the adhesive layer therefrom. And so, in
such an embodiment,
the carrier 14 may be a silicone release liner [i.e., the top surface of the
carrier 14 (the
continuous web of substrate) may have a silicone release coating, which
creates a releasable
bond]. The adhesive layer 14 may be applied thereto using any conventional
printing process
including rotary screen, flexographic, ink jet, etc.
[0099] Still referring to Fig. 9, additional layer(s) may be added adjacent
to the adhesive
layer. As shown in the illustrated embodiment, an ink layer 22 is applied to
the adhesive layer
24, such that the adhesive layer 24 is positioned between the ink layer 22 and
carrier 14. As
shown in Fig. 9, the ink layer 22 may be patterned to match that of the
adhesive layer 24. The
ink layer 22 (like the adhesive layer 24) may be applied using any
conventional printing
processes including rotary screen, flexographic, ink jet, etc. Although not
shown in Fig. 9, those
of ordinary skill in the art will recognize that the label may include other
layers than, or in
addition to, the adhesive layer 24 and ink layer 22 (as described previously),
and such other
layers may also be patterned.
[00100] The carrier 14 may be formed from various materials, and the following
is a non-
limiting list of materials for various embodiments of the carrier 14: virgin
polypropylene film
(such as PSPL10264), silicone coated paper liner, silicone coated polyester
film (such as
2SLKN 1.2 mil silicone coated polyester film commercially available from
Mitsubishi), polyester
film (such as 4470RL series 92 gauge polyester film, commercially available
from Mitsubishi, or
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39RL series 200 gauge polyester film commercially available from Mitsubishi),
and biaxially
oriented polypropylene film (such as BRT35T BOPP film commercially available
from Inteplast).
For a construction where the adhesive layer 24 is positioned adjacent the
carrier 14 (such as in
Fig. 9), a silicone coated film may be used as the carrier, to facilitate
separation of the adhesive
layer 24 from the carrier 14. For a construction having the adhesive layer 24
distal from the
carrier 14 (such as in Figs. 2, 2A, 3, 3A, 4, and 4A), films of polypropylene
or polyester film may
be used (such polypropylene and polyester films ¨ as well as other possible
films -- have been
described above with respect to other embodiments of the label 10).
[00101] Various adhesive materials and various ink materials may be used for
the adhesive
layer 24 and ink layer 22, and the following is a non-limiting list of
adhesive and ink materials:
Siegwerk SF RS Opaque White MP A08 (commercially available from Siegwerk USA,
Inc.),
Siegwerk EXP Linerless OPV (commercially available from Siegwerk USA, Inc.),
Siegwerk RS
DC SF Extender A02 (commercially available from Siegwerk USA, Inc.), 1249385
INXFIex UV
Ink Warm Red (commercially available from INX International), Novamet Gravure
Silver Ink
2155 (commercially available from Novamet) and 1029 FST UV High Tack PSA
5G401R
(commercially available from Craig Adhesives & Coatings).
[00102] One particular embodiment includes the Siegwerk white ink with the 22
wire rod and
the adhesive (1029 FST UV High Tack PSA 5G401 R) with the 2.5 wire rod.
Another
embodiment includes the Siegwerk EXP Linerless OPV and the Mitsubishi 2SLKN
1.2 mil
silicone coated polyester film. Another embodiment includes the Siegwerk EXP
Linerless OPV
and the virgin polypropylene film PSPL20164. Different wire rods and hand
proofers may be
used for application for the various printable materials. Wire rods include
#2.5, 3, 5, 6, 7, 8, 12,
16, 22, as known to those of ordinary skill in the art. One hand proofer may
be used with a
500/3.32 anilox roll. One particular embodiment includes the Siegwerk white
ink applied with the
22 wire rod and the adhesive (1029 FST UV High Tack PSA 5G401 R) applied with
the 2.5 wire
rod. The Siegwerk EXP Linerless OPV may be applied with the 2.5 wire rod in
embodiments
including the Siegwerk EXP Linerless OPV.
[00103] Referring now to Figs. 10-12, methods for providing a label having
patterned layers
(such as that shown in Fig. 9) are shown.
[00104] Fig. 10 shows a first exemplary embodiment of a method for providing a
label 10
having a patterned adhesive layer 24 and a patterned ink layer 22. In this
embodiment, the
label 10 or labels 10 is/are constructed without a conventional facestock, but
instead by
depositing a pattern of adhesive 24 (e.g., a pressure sensitive adhesive) onto
a top surface 29
of a continuous web of substrate (the carrier 14), which is subsequently
printed with indicia in
register with the pattern of adhesive, by depositing an ink layer 22 adjacent
the adhesive layer
24 and in register with the pattern of adhesive.
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[00105] Referring to Fig. 10, the pressure sensitive label 10 of embodiments
such as that
shown in Fig. 9 may be prepared as follows: The adhesive layer 24 may be laid
down on a
carrier layer 14 by a first roller/cylinder 34 (for example), followed by the
ink layer 22 being laid
down on the adhesive layer 24 by a second roller/cylinder 36, thereby forming
a label 10 with
these separate and distinct layers. In embodiments where one or more of these
layers (ink,
adhesive) is UV-curable, they may be exposed to UV radiation provided by
ultraviolet light,
which cures the various UV-curable layers. This UV-curing may be done as each
separate UV-
curable layer is laid down, or it may occur after all UV-curable layers have
been laid down.
(Further, although Fig. 10 shows, and is described as, putting down a adhesive
layer followed
by an ink layer, those skilled in the art will recognize that for embodiments
of the label having a
different ordering of layers ¨ such as that shown in Figs. 3 and 3A ¨ the
layers may be put down
in a different order than shown in Fig. 10).
[00106] As has been mentioned above, certain layers of the label 10 of the
embodiment of
Fig. 9 (e.g., ink layer 22 and adhesive layer 24), may be laid down, or
printed, in a particular
pattern corresponding to the size, shape, and/or contour of the desired end
label image. This
also results in solving a problem of the prior art (which led to too much
material being used, and
thus, increased cost to labels). Because the ink design is printed only on a
portion of the base
construction that (in prior art) is purchased from a third party, this
requires that the adhesive
(which is part of the base construction in the prior art) be flood coated onto
the carrier (since this
is done before sale of the base construction). In other words, since the
carrier suppliers do not
know in advance what ink designs will be applied by the label-maker, they
flood-coat the entire
carrier with adhesive to allow for any size, shape, configuration, and
registration of ink design.
The use of such a large amount of flood-coated adhesive results in a large
amount of unused,
and thus excess, adhesive. The use of this excessive amount of adhesive
results in increased
costs to the prior art labels, because the excess amount of adhesive results
in increased cost of
the base construction purchased, and thus increased cost of label preparation
and of the labels
themselves.
[00107] However, the design of the present pressure sensitive label 10 (as
shown in Figs. 9
and 10) allows for printing of an adhesive layer 24 to be laid down in a
pattern, as well as a
patterned ink layer 22. Since this occurs at the site of labeling, the entity
providing and creating
the label will know at the time of printing what the design of the label will
be. And so, rather than
providing a face stock of the same area as the carrier, the present invention
does not use a face
stock. Rather, the typical face stock of pressure sensitive labels of the
prior art is eliminated,
and instead a printable layer (such as a printable adhesive) may be placed
down on the carrier.
This allows one to print the adhesive and ink in the shape of the final label
design - which allows
one to create a label without the need for removing any extra material from
layers of a third
party face stock base construction.
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[00108] Fig. 11 shows another exemplary embodiment of a method for providing a
label 10
having a patterned adhesive layer 24 and a patterned ink layer 22. In this
embodiment, the
label 10 or labels 10 is/are constructed without a conventional facestock, but
instead by
depositing a pattern of adhesive 24 (e.g., a pressure sensitive adhesive) onto
a top surface 29
of a continuous web of substrate (the carrier 14), followed by lamination of a
cold foil film to the
adhesive, curing the adhesive, removing the cold foil film, and subsequently
printing with indicia
in register with the pattern of adhesive and cold foil images, by depositing
an ink layer 22
adjacent the adhesive layer 24 and in register with the pattern of adhesive
and cold foil images.
[00109] Referring to the embodiment of Fig. 11, a pressure sensitive label 10
may be
prepared as follows: The adhesive layer 24 may be laid down on a carrier layer
14 by a first
roller/cylinder 34 (for example). Subsequently, a cold foil film 50 is then
laminated onto the
adhesive layer 24. The cold foil is pulled from a cold foil unwind roller 52
and laminated to
adhesive layer 24 at roller 54. Next, the adhesive is cured (e.g., UV cured)
at 56, followed by
removal of excess cold foil film to a cold foil rewind roller 58, leaving
remaining cold foil film 50'
laminated to adhesive as desired. Thereafter, the ink layer 22 is laid down by
a second
roller/cylinder 36, thereby forming a label 10 with separate and distinct
layers as shown.
(Further, although Fig. 11 shows, and is described as, putting down an
adhesive layer followed
by cold foil processing, and an ink layer, those skilled in the art will
recognize that for
embodiments of the label having a different ordering of layers ¨ such as that
shown in Figs. 3
and 3A ¨ the layers may be put down in a different order than shown in Fig.
11).
[00110] One particular embodiment of a method in accordance with Fig. 11 may
use an iFlex
press to print on top of cold foil. In this embodiment, adhesive is run at 3-8
BCM with white cold
foil (or holographic foil) at 33-100 fpm on untreated polypropylene film. In
one specific
embodiment, adhesive is run at 3 BCM and the speed of the press is 100 fpm.
[00111] Fig. 12 shows another exemplary embodiment of a method for providing a
label 10
having a patterned adhesive layer 24 and a patterned ink layer 22. In this
embodiment, the
label 10 or labels 10 is/are constructed without a conventional facestock, but
instead by
depositing a pattern of adhesive 24 (e.g., a pressure sensitive adhesive) onto
a top surface 29
of a continuous web of substrate (the carrier 14), followed by application of
a matching pattern
of UV-curable ink 60 to the adhesive layer 24, and subsequently printing with
indicia in register
with the pattern of adhesive 24 and UV-curable ink 60, by depositing an ink
layer 22 in register
with the pattern of adhesive and UV-curable ink.
[00112] Referring to the embodiment of Fig. 12, a pressure sensitive label 10
may be
prepared as follows: The adhesive layer 24 may be laid down on a carrier layer
14 by a first
roller/cylinder 34 (for example). Subsequently, a UV-curable ink 60 (e.g., in
a pattern matching
the pattern of the adhesive) is then deposited onto the adhesive layer 24 via
a second roller 62.
The cold foil is pulled from a cold foil unwind roller 52 and laminated to
adhesive layer 24 at
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CA 03183144 2022-11-10
WO 2021/231414 PCT/US2021/031762
roller 54. Thereafter, the ink layer 22 is laid down by a third
roller/cylinder 64, thereby forming a
label 10 with separate and distinct layers as shown. (Further, although Fig.
11 shows, and is
described as, putting down an adhesive layer followed by UV-curable ink and a
seaprate ink
layer, those skilled in the art will recognize that for embodiments of the
label having a different
ordering of layers ¨ such as that shown in Figs. 3 and 3A ¨ the layers may be
put down in a
different order than shown in Fig. 11).
[00113] The embodiments of the present invention recited herein are intended
to be
merely exemplary and those skilled in the art will be able to make numerous
variations
and modifications to it without departing from the spirit of the present
invention. For
example, the particular types of materials used in the adhesive, ink, and
protective
lacquer layers may be selected to optimize performance of the label,
interlayer
adhesion, article adhesion, and/or mechanical and chemical resistance suitable
for the
intended use of the article. Further, the above description may include
disclosures of
specific materials to use in each individual layers of a label (i.e., a
specific ink may be
described and so the specification discloses the use of that specific ink,
with any carrier,
printable layer, and adhesive). However, those descriptions will also be
understood by
those of skill in the art to include embodiments including the specific
material described
in each layer of the label (i.e. a specific ink, specific, carrier, specific,
printable layer,
and specific adhesive described at various locations of the specification will
be
understood to include a specific embodiment including each of those specific
materials).
Notwithstanding the above, certain variations and modifications, while
producing less
than optimal results, may still produce satisfactory results. All such
variations and
modifications are intended to be within the scope of the present invention as
defined by
the claims appended hereto.
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SUBSTITUTE SHEET (RULE 26)
