U.S. patent application number 10/839542 was filed with the patent office on 2004-10-21 for adhesive constructions; and, methods.
This patent application is currently assigned to The Tapemark Company. Invention is credited to Maloney, James M..
Application Number | 20040209075 10/839542 |
Document ID | / |
Family ID | 25236533 |
Filed Date | 2004-10-21 |
United States Patent
Application |
20040209075 |
Kind Code |
A1 |
Maloney, James M. |
October 21, 2004 |
Adhesive constructions; and, methods
Abstract
Adhesive constructions are provided. In general, the adhesive
constructions include first and second fields pressure sensitive
adhesive. The amount of adhesive or coverage of adhesive in the two
fields differs to advantage. A particular preferred adhesive
construction is provided which includes a flexible substrate
defining an outer perimeter edge and having on a side thereof an
adhesive pattern which includes at least two adhesive fields,
preferably arranged as: an outer perimeter adhesive field adjacent
to the outer perimeter edge; and an inner adhesive field spaced
from the outer perimeter edge and completely surrounded by the
outer perimeter adhesive field. The preferred outer perimeter
adhesive field is a discontinuous pattern of adhesive with adhesive
covering no more than 80% of an area of a portion of the side of
the flexible substrate defined by the outer perimeter adhesive
field; and, the preferred inner adhesive field has adhesive
covering at least 90% of an area of a portion of the side of the
flexible substrate defined by the inner adhesive field, preferably
in a continuous pattern. In typical preferred adhesive
constructions, the inner adhesive field surrounds an adhesive-free
region. Also provided are a preferred roll stock with such an
adhesive construction secured to it, and preferred methods for
constructing such arrangements.
Inventors: |
Maloney, James M.;
(Roseville, MN) |
Correspondence
Address: |
MERCHANT & GOULD PC
P.O. BOX 2903
MINNEAPOLIS
MN
55402-0903
US
|
Assignee: |
The Tapemark Company
West St. Paul
MN
|
Family ID: |
25236533 |
Appl. No.: |
10/839542 |
Filed: |
May 4, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10839542 |
May 4, 2004 |
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09822623 |
Mar 30, 2001 |
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6730396 |
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Current U.S.
Class: |
428/343 ;
428/354 |
Current CPC
Class: |
Y10T 428/28 20150115;
Y10T 428/15 20150115; C09J 2203/334 20130101; Y10T 428/1476
20150115; C09J 2301/204 20200801; Y10T 428/2848 20150115; C09J 7/20
20180101; Y10T 428/14 20150115; Y10T 428/162 20150115 |
Class at
Publication: |
428/343 ;
428/354 |
International
Class: |
B65D 027/00; B32B
007/12; B32B 015/04 |
Claims
What is claimed is:
1. An adhesive construction comprising: (a) a flexible substrate
defining a having a first side; (b) a first adhesive field
comprising pressure sensitive adhesive; (i) the first adhesive
field being a discontinuous pattern of adhesive with adhesive
covering no more than 80% of an area of a portion of the first side
of the flexible substrate defined by the first adhesive field; the
area of a portion of the first side of the flexible substrate
defined by the first adhesive field being at least 10 sq. mm. and,
(c) a second adhesive field comprising pressure sensitive adhesive;
(ii) the second adhesive field covering at least 90% of an area of
a portion of the first side of the flexible substrate defined by
the second adhesive field; the area of a portion of the first side
of the flexible substrate defined by the second adhesive field
being at least 10 sq. mm.
2. An adhesive construction according to claim 1 wherein: (a) the
flexible substrate defines an outer perimeter edge; (b) the first
adhesive field comprises an outer perimeter adhesive field
positioned on the flexible substrate first side and adjacent the
outer perimeter edge; (i) the outer perimeter adhesive field having
a width, in direction inwardly from the perimeter edge, of at least
0.8 mm.; and, (c) the second adhesive field comprises an inner
adhesive field spaced from the outer perimeter edge and completely
surrounded by the outer perimeter adhesive field; (i) the inner
adhesive field comprising adhesive covering at least 95% of an area
of the portion of the first side of the flexible substrate defined
by the inner adhesive field.
3. An adhesive construction according to claim 2 wherein: (a) the
inner adhesive field comprises a continuous adhesive field over the
area of the portion of the first side of the flexible substrate
defined by the inner adhesive field.
4. An adhesive construction according to claim 3 including: (a) an
adhesive-free region on the first side of the flexible substrate;
(i) the adhesive-free region being completely surrounded by the
inner adhesive field.
5. An adhesive construction according to claim 4 wherein: (a) the
adhesive-free region comprises at least 40% of a perimeter area
defined by the flexible substrate outer perimeter edge.
6. An adhesive construction according to claim 5 wherein: (a) the
outer perimeter edge defines a rectangular pattern.
7. An adhesive construction according to claim 6 wherein: (a) the
adhesive-free region of the flexible substrate is transparent.
8. An adhesive construction according to claim 7 wherein: (a) the
outer perimeter adhesive field defines a rectangular frame.
9. An adhesive construction according to claim 8 wherein: (a) the
inner adhesive field defines a rectangular frame.
10. An adhesive construction according to claim 2 wherein: (a) the
outer perimeter edge has no segment of extension of greater than 8
mm., at which there is not adhesive on the substrate first side and
immediately adjacent the outer perimeter edge.
11. An adhesive construction according to claim 11 wherein: (a) the
outer perimeter edge has no segment of extension of greater than 5
mm., at which there is not adhesive on the substrate first side and
immediately adjacent the outer perimeter edge.
12. An adhesive construction according to claim 1 including: (a) a
release liner to which the flexible substrate is secured by the
first adhesive field and the second adhesive field.
13. A roll of adhesive constructions; the roll comprising: (a) an
extension of release liner; (b) at least 10 spaced adhesive
constructions secured to the extension of release liner; each
adhesive construction comprising: (i) a flexible substrate having a
first side; (ii) a first adhesive field comprising pressure
sensitive adhesive; (A) the first adhesive field being a
discontinuous pattern of adhesive with adhesive covering no more
than 80% of an area of a portion of the first site of the flexible
substrate defined by the first adhesive field; the area of a
portion of the first side of the flexible substrate defined by the
first adhesive field being at least 10 sq. mm.; and, (iii) a second
adhesive field comprising pressure sensitive adhesive; (A) the
second adhesive field covering at least 90% of an area of a portion
of the first side of the flexible substrate defined by the second
adhesive field; the area of a portion of the first side of the
flexible substrate defined by the second adhesive field being at
least 10 sq. mm.
14. A roll of adhesive constructions according to claim 13 wherein:
(a) the flexible substrate of each adhesive construction defines an
outer perimeter edge; (b) the first adhesive field of each adhesive
construction comprises an outer perimeter adhesive field positioned
on the associated flexible substrate first side and adjacent the
outer perimeter edge; (i) each outer perimeter adhesive field
having a width, in direction inwardly from an associated perimeter
edge, of at least 0.8 mm.; and, (c) the second adhesive field of
each adhesive construction comprises an inner adhesive field spaced
from an associated outer perimeter edge and completely surrounded
by an associated outer perimeter adhesive field; (i) each inner
adhesive field comprising adhesive covering at least 95% of an area
of the portion of the first side of an associated flexible
substrate defined by the inner adhesive field.
15. A roll of adhesive constructions according to claim 14 wherein:
(a) each inner adhesive field comprises a continuous adhesive
covering over the area of an associated portion of the first side
of the flexible substrate defined by that inner adhesive field.
16. A method of preparing an adhesive construction; said method
including the steps of: (a) preparing a laminate stock comprising a
release liner layer secured to a flexible substrate layer, with an
adhesive pattern of pressure sensitive adhesive therebetween; (i)
the adhesive pattern defining: (A) a first adhesive field
comprising a discontinuous pattern of adhesive with the adhesive
covering no more than 80% of an area of a portion of a side of the
flexible substrate layer defined by the first adhesive field; and,
(B) a second adhesive field comprising adhesive covering at least
90% of an area of a portion of a side of the flexible substrate
layer defined by the second adhesive field; (b) die cutting the
laminate stock by cutting a die cut perimeter pattern completely
through the flexible substrate layer but not completely through the
release liner layer; (i) the perimeter pattern being die cut
through a region in overlap with adhesive in the first adhesive
field and surrounding adhesive in the second adhesive field, (ii)
the step of die cutting defining: (A) waste flexible substrate
layer outside of the die cut perimeter pattern; and, (B) a die cut
adhesive construction within the die cut perimeter pattern; and,
(c) stripping the waste flexible substrate from the laminate stock,
while leaving at least one die cut adhesive construction on the
release liner layer.
17. A method according to claim 16 wherein: (a) the second adhesive
field is an inner adhesive field comprising adhesive covering at
least 95% of the area of the portion of the flexible substrate
layer defined by the second adhesive field; and, (b) the first
adhesive field is an outer perimeter adhesive field completely
surrounding the first inner adhesive field.
18. A method according to claim 17 wherein: (a) the adhesive
pattern defines a first adhesive-free region completely surrounded
by the second adhesive field.
19. A method according to claim 18 wherein: (a) said step of die
cutting comprises cutting to form a die cut perimeter pattern
spaced at least 0.8 mm. from the inner adhesive field completely
around the first inner adhesive field.
20. A method according to claim 19 wherein: (a) said method
comprises a process of generating a series of spaced adhesive
constructions adhered to the release liner; (i) each one of the
series of spaced adhesive constructions comprising: (A) a flexible
substrate defining an outer perimeter edge; the flexible substrate
having a first side; (B) an outer perimeter adhesive field adjacent
the outer perimeter edge; (I) the outer perimeter adhesive field
having a width, in direction inwardly from the perimeter edge, of
at least 0.8 mm.; (II) the outer perimeter adhesive field being a
discontinuous pattern of adhesive with adhesive covering no more
than 80% of an area of a portion of the first side of the flexible
substrate defined by the outer perimeter adhesive field; and, (C)
an inner adhesive field spaced from the outer perimeter edge and
completely surrounded by the outer perimeter adhesive field; (I)
the inner adhesive field comprising adhesive covering at least 95%
of an area of a portion of the first side of the flexible substrate
defined by the inner adhesive field; and, (ii) each one of the
series of spaced adhesive constructions being formed in a die
cutting operation which involves cutting die cut perimeter patterns
each of which is: (A) completely through the flexible substrate
layer but not completely through the release lines layer; and, (B)
cut through a region in overlap with adhesive in an outer perimeter
adhesive field and surrounding and not in overlap with adhesive in
an inner adhesive field.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 09/822,623, filed Mar. 30, 2001, issued as
U.S. Pat. No. 6,730,396 on May 4, 2004, which application is
incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to adhesive constructions and
methods for manufacturing and using such constructions. In
preferred applications, the invention particularly concerns
adhesive constructions from which a label, cover or other adhesive
component, can be applied from a release liner, in an effective and
convenient manner.
BACKGROUND OF THE INVENTION
[0003] In general, in many industries adhesive constructions are
applied using high speed dispensing equipment, from a roll of
individual constructions. The roll generally comprises individual
elements in a line or column, adhered to a release liner. During an
application process, the adhesive constructions or elements are
sequentially stripped from the release liner and are applied to a
package or other substrate on which such a construction is desired.
Arrangements of this type are described, for example, in U.S. Pat.
Nos. 5,351,426 and 4,661,189, the complete disclosures of which are
incorporated herein by reference.
[0004] Adhesive constructions can be used in a variety of
applications. For example, they may be used as labels or as covers.
In other instances they may be used as components in larger
systems, for example as a layer in a laminate.
SUMMARY OF THE INVENTION
[0005] An adhesive construction is provided. The adhesive
construction involves a flexible substrate having a selected
adhesive pattern, of pressure sensitive adhesive, on at least one
side thereof. The selected adhesive pattern of pressure sensitive
adhesive preferably includes at least a first adhesive field and a
second adhesive field. In preferred constructions: the first
adhesive field is a discontinuous pattern of adhesive with adhesive
covering no more than 80% of an area of the portion of the first
side of the flexible substrate defined by the first adhesive field,
the area of that portion of the first side of the flexible
substrate defined by the 80% adhesive field preferably being at
least 10 square millimeters (sq. mm.), typically at least 30 sq.
mm.; and, the second adhesive field preferably covers at least 80%
(typically at least 90%) of an area of a portion of the first side
of the flexible substrate defined by the second adhesive field; the
area of the portion of the first side of the flexible substrate
defined by the second adhesive field being at least 10 sq. mm.,
typically at least 30 sq. mm. Preferably there is more adhesive and
more surface coverage, per unit area, in the second adhesive field
than in the first adhesive field.
[0006] Adhesive constructions as defined herein may have still
further adhesive fields thereon, as long as (preferably) the first
and second adhesive fields are present.
[0007] In preferred adhesive constructions according to the present
invention, the first and second portions of the selected adhesive
pattern are preferably defined (respectively) by an outer perimeter
adhesive field; and, an inner adhesive field. The preferred outer
perimeter adhesive field is arranged along (or to border) a
perimeter edge or edge portion of the flexible substrate. In such
preferred embodiments, the inner adhesive field is completely
surrounded or circumscribed by the outer perimeter adhesive field.
In general, as described above, there is a higher amount of
adhesive or higher coverage of flexible substrate surface by
adhesive, in the region of the inner adhesive field, than in the
region of the outer perimeter adhesive field. Preferred
arrangements and amounts of coverage, are described.
[0008] In certain preferred arrangements, there is also provided an
adhesive-free region on the flexible substrate. Preferably the
adhesive-free region comprises an inner adhesive-free region
completely surrounded or circumscribed by an inner (or second)
adhesive field. In selected embodiments, the adhesive-free region
is substantially transparent.
[0009] The adhesive construction will typically include, during a
portion of its life prior to application to a package or other
substrate, a release liner secured to the flexible substrate with
the defined adhesive fields therebetween. The release liner
generally would comprise a silicone release layer, to facilitate
the separation of the release liner from the flexible substrate,
during a labeling or covering operation, i.e., an application
process, so that the flexible substrate could then be adhered to an
appropriate package or other substrate.
[0010] Methods of preparing preferred adhesive constructions
according to the present invention are provided. In general, the
methods include: applying adhesive to create the different pressure
sensitive adhesive fields defined; and, conducting appropriate die
cutting and waste material stripping operations to achieve the
generation of the individual adhesive constructions secured to a
common release liner. In general, preferred die cutting operations
will be conducted such that die cutting: is through a layer of
laminate which will eventually become the flexible substrate of the
adhesive construction; and, is in overlap only with adhesive in the
first type of adhesive field, and thus in a pattern surrounding or
circumscribing adhesive in the second type of adhesive field.
[0011] Preferred methods include applying adhesive to create a
first, (for example outer perimeter) adhesive field and a second
(for example inner) adhesive field by utilizing a printing
approach, typically a dot screen printing approach, in which more
adhesive is applied to the region that will become the second
(inner) adhesive field than is applied to the region which will
become the first (outer) perimeter adhesive field. This can be
accomplished for example, by varying the number of dots or weight
(wt.) of adhesive per unit area.
[0012] In typical manufacturing operations, a two layer laminate is
prepared comprising two flexible webs secured to one another by
adhesive. One of the flexible webs would comprise a release liner
layer, and the other would comprise a flexible substrate web or
layer that, when die cut, would form the flexible substrates of
individual adhesive constructions for generation of the preferred
constructions as characterized. The adhesive pattern between the
two webs would typically have two regions: a region of adhesive in
a concentration that, after a die cutting operation, would form the
first (outer) perimeter adhesive field; and, a region of higher
adhesive concentration which, after the die cutting operation,
would form the second (inner) adhesive field. In preferred
constructions, the adhesive fields of the laminate are organized
such that during a die cutting operation, die cutting of the
flexible substrate web only occurs in overlap with regions of lower
adhesive concentration.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a schematic plan view of an adhesive construction
according to the present invention; the view of FIG. 1 being toward
a side having adhesive thereon.
[0014] FIG. 2 is a schematic, fragmentary, plan view of a
continuous roll of adhesive constructions in accord with FIG. 1
secured to release liner; the roll of FIG. 2 being useable in a
process to apply adhesive constructions according to FIG. 1 to
various substrates.
[0015] FIG. 3 is a schematic, fragmentary, plan view of a laminate
roll stock from which a continuous roll in accord with FIG. 2 can
be prepared; FIG. 3 being taken of a side having thereon a
transparent flexible web from which individual adhesive
constructions will be die cut.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] Referring to FIG. 1, reference no. 1 depicts an adhesive
construction according to the present invention. In general,
adhesive constructions 1 according to the present invention may be
applied to packages or other substrates, for example as labels,
covers or other components, depending upon the particular
application. When utilized as a label, typically printed matter or
graphic matter will have been applied to the adhesive construction
1. The adhesive construction 1 would then be applied to a container
or other substrate as a means of adhering the printed matter in
place, as a label. When used as a cover, the adhesive construction
1 may or may not contain printing or graphics, but in general would
be applied over a portion of a substrate for which coverage is
desired. Such a portion of substrate may be, for example, an
aperture or hole, i.e., window; or, it may be printing material or
other material which is desired to have covered and protected. It
is foreseen that in many preferred applications, adhesive
constructions 1 according to the present invention will be applied
as substantially transparent windows over an aperture or substrate,
for example, over a hole in a package box. By "substantially
transparent" in this context, it is meant that adequate light
passes through the flexible substrate under normal viewing
conditions, so that items can be readily viewed through the
adhesive-free region of the flexible substrate. Of course, there is
no requirement that the flexible substrate be substantially
transparent, for many of the benefits of the present invention to
be obtained.
[0017] As indicated above, the adhesive constructions may be used
as other components and systems. For example, medical systems may
involve use of such arrangements to adhere a component of a medical
system in place. In addition, the arrangements may be utilized in
shields or as components in laminates, or in other manners as
components in mechanical or electrical systems.
[0018] Still referring to FIG. 1, the preferred adhesive
construction 1 depicted comprises a transparent flexible substrate
5 having a first side 6 (facing the viewer) and an opposite second
side 6 (directed away from the viewer). For the particular
arrangement shown, the first side 6 has adhesive 8 applied thereto,
as described below, for securing the adhesive construction 1 in
place, during use. The opposite side 7 is typically adhesive-free,
although such is not required for all applications. Side 6 will
sometimes be referred to as the adhesive side of the substrate 5,
or of the adhesive construction 1.
[0019] As indicated above, in general adhesive constructions
according to the present invention are utilized by removal from a
release liner and application to a package or other substrate. The
adhesive construction 1, FIG. 1, is depicted after removal of the
release liner.
[0020] In general, the materials selected will involve use of an
adhesive 8 which is, typically, a pressure sensitive adhesive,
i.e., secures upon contact and pressure. The material chosen for
the flexible substrate 5 will generally be one which is adequately
strong or tough to allow for the manipulations required during an
application process, and to remain in place for the intended use.
Some usable materials are characterized below.
[0021] Referring still to FIG. 1, the flexible substrate 5 of
adhesive construction 1 generally defines an outer perimeter edge
10. For the particular adhesive construction 1 depicted, the outer
perimeter edge 10 defines a quadrilateral shape, in particular a
parallelogram. The particular adhesive construction 1 depicted is
rectangular. It is noted, however, that principles according to the
present invention can be utilized in accord with adhesive
constructions having a variety of outer perimeter configurations,
including for example those having irregular shapes, circular
shapes, square shapes, triangular shapes, etc.
[0022] Still referring to FIG. 1, the adhesive construction 1
includes at least two different adhesive fields (or regions of
adhesive) on the adhesive or first side 6. The two different
adhesive fields 11, 12 comprise: a first adhesive field 11 and, a
second adhesive field 12. It is noted that other adhesive fields
different from adhesive fields 11 or 12 could also be provided in
the arrangement 1, provided at least the first and second adhesive
fields 11, 12, preferably as defined, are provided. In general, the
first adhesive field 11 comprises an adhesive field defining an
area of the substrate 5 on which there is no more than 80% coverage
by the adhesive, preferably in a discontinuous pattern. Preferably
the second adhesive field 12 is an adhesive field position to cover
a selected area of the substrate, wherein there is at least 80%
adhesive coverage, typically at least 90%, preferably at least 95%,
and most preferably at least 99.5%. Most preferably the adhesive in
the second adhesive field 12 is applied in a continuous pattern.
Preferably the amount of adhesive coverage in the first field 11 is
less than in the second field, in terms of wt. per unit area; and,
preferably each of the first and second fields 11, 12 is in a
pattern having a perimeter covering at least 10 sq. mm., typically
at least 30 sq. mm., of the substrate 5.
[0023] While the characterizations in the previous paragraph are
general, for adhesive fields according to the present invention,
for the particular preferred arrangements depicted the first
adhesive field 11 and the second adhesive field 12 are provided in
preferred configurations, to achieve selected advantages. In
particular, for the arrangement depicted in FIG. 1, the first
adhesive field 11 comprises a perimeter adhesive field 13 and, the
second adhesive field 12 comprises an internal adhesive field 14.
In general, the preferred perimeter adhesive field 13 is configured
with the following characteristics: it borders the outer perimeter
10 along at least one side and preferably entirely around the
adhesive construction 1; and, it preferably completely surrounds or
circumscribes the internal adhesive field 14. The particular
preferred adhesive field 13 depicted, has the configuration of a
rectangular frame 15 having a constant width and having, as its
outside edge 13a, the outer perimeter 10, and having as its inside
edge 13b, an interface or border with the internal adhesive field
14.
[0024] The particular, preferred, internal adhesive field 14
depicted, circumscribes or surrounds central region 17, in which
there is no adhesive. That is, region 17 is, in preferred
embodiments, adhesive-free. The particular preferred internal
adhesive field 14 depicted is in the form of a rectangular frame 16
of constant width, having as its outer border 16a an interface or
border with inner border 13b of adhesive field 13; and, having as
its inner border 16b, a border surrounding an adhesive-free region
described below. It is foreseen that internal fields 14 having a
frame configuration 16 will be used in preferred embodiments,
however, alternatives are applicable with principles according to
the present invention.
[0025] Still referring to FIG. 1, a characteristic of the preferred
perimeter adhesive field 13 is that within the field 13, adhesive
coverage on the flexible substrate ranges between about 30% and 80%
of the surface (or area) of the flexible substrate 5 covered or
defined by the perimeter adhesive field 13. That is, at least 30%
of the surface of the first side 6 of the flexible substrate 5, (in
the region defined by borders 13a, 13b of the perimeter field 13)
is covered by adhesive, and preferably not more than about 80% is
so covered. Most preferably the coverage is no greater than 70%.
Another characteristic of the preferred perimeter field is that it
has a width, i.e., dimension of extension inwardly from the outer
perimeter edge 10, indicated by dimension A, of at least 0.8
millimeters (mm.), and typically at least 1 mm. and up to 5 mm.
[0026] In preferred embodiments, the adhesive pattern in the
perimeter adhesive field 13 is discontinuous. By "discontinuous" in
this context, it is meant that the pattern comprises a plurality of
spaced adhesive spots, islands or regions 13c, each of which is
surrounded by adhesive-free region, as opposed to a continuous
pattern in which there are no readily identifiable spaced spots,
regions or islands of adhesive.
[0027] Another preferred characteristic of the perimeter field 13,
is that immediately along the adhesive construction outer perimeter
edge 10, the perimeter field 13 does not include an extension of
more than 15 mm., preferably not more than 8mm., and most
preferably not more than 5 mm. without the edge 10 having
intersected a region, spot or island of adhesive. That is, there is
no substantial extension of edge 10, on surface 6, which is
completely adhesive-free. Alternately stated, adhesive in the
region of perimeter adhesive field 13 is applied in a discontinuous
dot, spot or island pattern, with the dots (spots or islands)
having been deformed or squished as a result of a laminate
construction method used to prepare construction 1. Preferably, the
dot pattern is such that the edge 10 encounters the adhesive dots
or deformed dots (spots or islands) often enough so that along the
edge there is no extension greater than about 15 mm., preferably
not more than 8 mm., (most preferably not more than 5 mm. and
typically less) over which an adhesive dot (spot or island) is not
encountered or intersected.
[0028] In general, the typical arrangement of adhesive application
will be applying the adhesive dots from a screen printing process.
A typical such process would use about a 50 line screen (i.e. a
screen of 50 lines per inch in each direction). Different adhesive
patterns or amounts can be applied in different areas, by using an
appropriate lacquer mask, in accord with typical screen printing
techniques. A useable approach would be to provide a full tone
print, where the second type of adhesive pattern is to be applied,
and a half tone print (half as many dots per unit area) in a region
to provide the first type of adhesive pattern. It is noted that
alternate screens from 50 lines per inch can be adapted and
used.
[0029] Still referring to FIG. 1, for the particular embodiment
depicted, the internal field 14 is generally characterized by
having a width inwardly from internal edge 13b of perimeter
adhesive field 13, of at least 0.8 mm., typically at least 3 mm.
and typically not more than 10 mm. Also, preferably, the internal
adhesive field 14 is characterized by having a greater percentage
of surface area having adhesive coverage, in the region defined by
the second (internal) adhesive field 14, than is covered by
adhesive in the region defined by the first (perimeter) adhesive
field 13. Most preferably, the amount of adhesive coverage in the
internal adhesive field 14 is at least 80%, preferably at least
90%, typically at least 95%. In typical preferred embodiments, the
adhesive coverage in the internal adhesive field 14 is continuous.
By the term "continuous" in this context, it is not meant that
coverage is necessarily 100%, indeed the adhesive arrangement may
have various fine pin holes in it. However, when the pattern is
continuous the adhesive is not in isolated spots, islands or
regions, and it typically covers greater than 99.5% of the surface
area of the substrate 5 defined by the outer borders 16a, 16b of
the internal adhesive field 14.
[0030] It is noted that a continuous adhesive pattern 14 can be
formed by applying the adhesive in a discontinuous dot or printed
pattern, by a process as characterized and then squeezing down the
laminate to spread the dots into abutment with adjacent dots, thus
forming a continuous pattern. This will be a typical preferred
approach, as characterized below.
[0031] Another preferred characteristic of adhesive constructions
according to the present invention, is that during manufacture, the
total amount of adhesive applied in the region that will define the
internal adhesive field 14 is at least 30% greater, per unit area,
than is the total amount of adhesive applied to define the
perimeter adhesive field, per unit area. Most preferably, the
amount of adhesive application in the internal adhesive field on a
per unit area basis is about 1.5 to 5 times the amount of adhesive
applied in the region that will become the outer perimeter adhesive
field to the perimeter adhesive field, on a per unit area basis;
typically 1.5-2.5 times. (The ratio for full tone versus half tone,
of course, would be 2:1).
[0032] Thus far the term "adhesive construction" has been used to
characterize a construction comprising a flexible substrate as
characterized, with adhesive fields characterized thereon. It is
noted that in some instances herein, the term "adhesive
construction" will be utilized to refer to such an arrangement with
attached thereto a release liner, which can be stripped from the
remainder of the adhesive construction, so that a resulting
adhesive construction comprising a flexible substrate and adhesive,
without a release liner can be applied for use.
[0033] Attention is now directed to FIG. 2. In FIG. 2, there is
depicted an adhesive construction 30, according to the present
invention in the form of a roll for delivery of individual adhesive
constructions 1. Machine direction for application is shown by
arrow 32. The roll construction 30 comprises a continuous strip 31
having secured thereto, in a line, a plurality of spaced covers 33.
The covers 33 may be generally in accord with adhesive
constructions 1, and are positioned on the continuous strip 31 with
the adhesive side 6 (FIG. 1) of each construction 1 directed
against strip 31 and the non-adhesive side 7 facing the viewer.
[0034] For the particular preferred arrangement 30 depicted in FIG.
2, the individual adhesive constructions 1 each comprise a
transparent substrate 5, so that adhesive fields 13 and 14 are
viewable.
[0035] The continuous strip 31 preferably comprises a release liner
34, for example a silicone coated paper, from which the individual
adhesive constructions 1 can be readily removed in a commercial
labeling or application process; the silicone coating being at
least on the side facing the covers 33. Since each of the
constructions 1 has a first (perimeter) adhesive field 13 in accord
with the preferred description for adhesive construction 1,
stripping of the individual constructions 1 from roll construction
30 in a high speed application process is facilitated. This is in
part because the low coverage of adhesive in first (perimeter)
field 13 helps the lead edge 10d of each adhesive construction 1 to
be started to separate from the continuous strip 31 of release
liner. Unlike the arrangements of U.S. Pat. Nos. 5,351,426 and
4,661,189, in which there is no adhesive along the outer perimeter
edge, the presence of at least 30% adhesive coverage in the
perimeter field 13 facilitates operation by allowing for greater
control and label application; and, after the construction 1 is
applied to a package or other substrate, perimeter field 13
facilitates the label being retained in place and not inadvertently
lifted and separated from the substrate to which the construction 1
has been applied. This latter advantage, inhibition of unintended
or undesired separation from the substrate, is an important
advantage of arrangements according to the present invention which
utilize a perimeter field 13 as the first adhesive field.
[0036] Still referring to FIG. 2, it is noted that regions 35 on
the release liner 34, between and around individual adhesive
constructions 1, are generally adhesive-free. This results from a
manufacturing operation in which any adhesive in these regions is
stripped from the arrangement, as the roll construction 30 is
formed.
[0037] Herein, the term "continuous" when used in reference to
label roll construction 30 is generally meant to a strip 31 which
is sufficiently long to include at least ten individual adhesive
constructions 1 thereon, typically oriented in a single column or
row. It is noted that typically a roll construction 30 will
comprise at least 100 to 500 meters of continuous strip 31, with at
least 1,000 to 5,000 individual constructions 1 in a row thereon.
In some instances the roll construction 30 will include more than
one row or line of constructions 1 thereon.
[0038] Attention is now directed to FIG. 3. In FIG. 3, a roll stock
70 is shown, from which roll constructions 30, FIG. 2, in accord
with the present invention can be made, the machine direction for
manufacture being shown by arrow 71. In general, the roll stock 70
comprises a laminate of two flexible webs 73 and 74 with adhesive
75 positioned therebetween. The adhesive 75 is provided in a
preferred pattern as characterized herein, to eventually form the
preferred fields 13, 14 described above, for individual adhesive
constructions 1. In general, web 73 comprises a web of release
liner material which, after appropriate cutting application, will
form continuous strip 31, FIG. 2. Web 74, on the other hand,
comprises a web of material which, after die cutting, will form the
flexible substrates 5 of the various individual adhesive
constructions 1.
[0039] For the particular embodiment depicted in FIG. 3, flexible
web 74 of the roll stock 70 is depicted as a transparent material,
allowing viewing of adhesive field 75 and the surface of web 73
thereunder. To facilitate understanding, web 74 is fragmented for
viewing web 73, at region 76.
[0040] In FIG. 3, the particular roll stock 70 depicted comprises
two rows 77 and 78 of spaced adhesive free areas 79, over which two
rows of individual adhesive construction 1 will eventually be
formed. The phantom line indicated at 80 depicts a cut line which
will eventually be made through the release liner stock 73, to
separate the rows 77, 78 of roll stock 70 into strips of labels
having a single line of labels. Phantom lines 81 indicate where die
cutting through the web 74, but not through the release liner stock
73, will take place, in order to generate the individual substrates
5, FIG. 1. The die cutting operation will be described in greater
detail, below. The particular roll stock 70 depicted includes
narrow adhesive-free strips 82 along each side edge 83, to
facilitate handling.
[0041] Still referring to FIG. 3, roll stock 70 includes two types
of adhesive fields thereon. The first type of adhesive field is
indicated generally at 85. A portion of field 85 comprises an
adhesive field which, in a final label product, will generate first
(perimeter) fields 13, FIG. 1. Thus, the first type of adhesive
field 85 preferably comprises adhesive coverage of between 30% and
80% coverage of the surface area defined by its borders 85a and
85b, most preferably coverage as defined for FIG. 1.
[0042] The second type of adhesive field is indicated at 86 and, in
the final adhesive constructions 1, will form second (internal)
fields 14, FIG. 1. Thus, preferably the second type of adhesive
field 86 comprises at least 80%, and most preferably continuous
adhesive coverage in the regions defined by borders 86a and
86b.
[0043] Still referring to FIG. 3, it is again noted that the roll
stock 70 includes a plurality of spaced adhesive-free regions 79 in
which there is no adhesive between the two webs 73, 74. Regions 79,
in the final label roll construction 30, FIG. 2, form unsealed
regions 17.
[0044] Still referring to FIG. 3, it is noted that all die cut
lines 81 are positioned in overlap with adhesive fields 85 of the
first type. That is, during the die cutting operation to form the
individual constructions, covers, components for labels, the die
cutting is preferably through web 74 in overlap with regions where,
between the web 74 and the web 73, there is positioned adhesive
field 85 of the first type. As a result, the die cutting operation
avoids die cuts in regions in which there is a higher percentage of
adhesive such as is found in adhesive fields of the second
type.
[0045] By the term "overlap" in this context, it is meant that the
strike of the die cut from the viewpoint of FIG. 3 through web 74
in a portion directly above region 85.
[0046] After the die cutting operation, once waste material from
web 74 is stripped away, the resulting adhesive constructions 1 or
covers 33, FIG. 2, will have a perimeter edge along which there is
a perimeter adhesive field of the type indicated at 13, FIG. 1. It
is noted that in general, the material selected for the adhesive,
the release liner 73 and the substrate web 74 will be such that
adherence of the adhesive to the substrate 74 material is greater
than the adherence of the adhesive to the release liner 73. One
result of this is that when waste or scrap material from web 74 is
stripped away after die cutting, the regions of release liner 73
which remain and which are not covered by the individual die cut
adhesive constructions 1, are adhesive-free.
[0047] In a typical cutting operation, then, die cutting to form
individual adhesive construction, occurs in the regions indicated
at lines 81 to define a die cut pattern or perimeter pattern
circumscribing individual labels or covers. The resulting waste
material between adhesive construction or covers is stripped from
the roll stock 70, leaving continuous web 73 intact with a
plurality of spaced adhesive constructions 1 is secured thereto.
Web 73 can be cut, into strips, by cutting along line 80 between
the rows of adhesive constructions, to result in two one lane roll
constructions 30 each of which is as shown in FIG. 2. This final
cutting operation, to form the individual rolls 30, would be
through adhesive-free regions as a result of the stripping of waste
material of layer 74 from layer 73, after die cutting.
[0048] In general, roll stock 70 in accord with FIG. 3, is readily
manufactured by a process of applying an appropriate adhesive
pattern to one of the two webs 73, 74, and then bringing the two
webs together in a continuous operation. Various methods can be
utilized to apply the adhesive, typically dot or spot printing
being preferred. With dot or spot printing, variations in the
amount of adhesive applied in various locations, to generate the
two types of adhesive fields 85, 86 characterized, can be readily
conducted. In a typical operation, the adhesive is applied in a dot
or spot pattern on one or the other of the two webs 73, 74, prior
to the webs being brought together to form the laminate 70. A
transfer printing process can be utilized.
[0049] When the webs are brought together, typically they are
squeezed together in a nip or bite between rollers. In a typical
printing operation, a higher concentration of dots or spots is
placed in a region which will become the inner portion 14, with a
continuous adhesive pattern. Even though the spots in this region
may be created in an isolated continuous pattern, as a result of
the squeezing process the spots in this region will spread and join
with one another, to form the continuous pattern. In the region
which will become the first (outer perimeter) adhesive pattern 13,
however, typically the spot pattern is sufficiently low in
population, so that even after the squeezing operation a
discontinuous pattern of adhesive still results. This can be
readily accomplished by using 30%-60% (by wt.) of adhesive, per
unit area, of adhesive for the region to become the discontinuous
pattern, than is used in the region to become the continuous
pattern. Typically, dots applied at 20-100 dots/inch, will be
convenient to generate such patterns. A usable printing process is
screen printing using a screen at 50 lines/inch, with half tone
printing for pattern 13, and full tone for pattern 14.
[0050] In general, for the preferred arrangements of FIGS. 1-3, the
adhesive patterns are defined with respect to perimeter patterns
and inner patterns. It is noted that in general the principles
relate to application of at least two different patterns of
adhesives on a substrate, generally referenced as a first pattern
and as a second pattern. The first pattern would in general define
at least 10 sq. mm. (typically at least 30 sq. mm.) of area with a
discontinuous adhesive pattern covering no more than 80% of the
defined area, preferably of no more than 70%; and, the second
adhesive area would define at least 10 sq. mm. (typically at least
30 sq. mm.) with adhesive covering at least 80%, preferably at
least 90%, typically at least 95% with adhesive, most preferably in
a continuous pattern covering at least 99.5% of the area. For such
arrangements, preferably the second area of adhesive comprises at
least 30%, per unit area, more adhesive than is found in the first
adhesive region. Of course, in preferred constructions such as
those described, the first adhesive region is a perimeter adhesive
region and the second adhesive region is an inner adhesive region.
However, from the example provided, it will be understood that
alternate arrangements of the two adhesive patterns are available,
and, indeed, there may be still further adhesive regions provided
on the substrate. In addition, the first adhesive region could be
broken into more than one separate area, each of which has a
minimum area of at least 10 sq. mm.; and/or the second region could
be broken into more than one region, each of which has a minimum
area of at least 10 sq. mm.
[0051] Preferred Materials
[0052] A variety of materials can be utilized in arrangements
according to the present invention. Typical preferred materials
would be as follows:
[0053] (1) for the label substrate, a usable material is, for
example, clear 2 mm. biaxially oriented polypropylene (BOPP), for
example, as available from a variety of films companies such as
Armstrong Specialty Films, Inc., Mukwongo, Wis., 53149;
[0054] (2) for the release liner, a utilizable material is 43 pound
diversified Kraft paper with a silicone release coating, such as is
available from the Siltech Division of Technicote, Co., Miamisburg,
Ohio 45342.
[0055] (3) for the pressure sensitive adhesive a variety of
commercially available pressure sensitive adhesives can be used,
with the specific choice generally being dependent upon the desired
conditions of application. Usable pressure sensitive adhesives are
available, for example, from H. B. Fuller, St. Paul, Minn.; Ashland
Petroleum, Columbus, Ohio 43216; and, Hartland Adhesives of New
Berlin, Wis.
[0056] Typically, the amount of adhesive applied during the
printing operation in the regions that will form the first
(perimeter) fields 13, FIG. 1, is about 35-65% (usually 40-60%) of
the amount of adhesive applied in the regions which will provide
the internal adhesive field 14, FIG. 1. The wt. % given is meant to
refer to the weight of adhesive applied per unit area.
[0057] Preferred Configurations and Dimensions
[0058] While a wide variety of configurations and dimensions may be
utilized in arrangements according to the present invention, it is
foreseen that in typical applications, the adhesive constructions
will be parallelograms, typically rectangles or squares. In
general, it is anticipated that in typical preferred constructions
the perimeter adhesive fields will be of even width around the
perimeter, typically about 1 to 10 mm. wide; and, the internal
adhesive field 14 will be a framed construction having an even
width around the frame, typically about 10 to 40 mm. wide. It is
foreseen that in general, the central region of the label will be a
region that has no adhesive thereon, and will typically comprise at
least about 30% and generally about 40% to 80% of the total
perimeter area of the label or cover; the term "perimeter area" in
this context, refers to label area as defined by the outer
perimeter of the label or cover.
[0059] The above specification, examples and data provide a general
description of the manufacture and use of the composition of the
invention. Many embodiments of the invention can be made without
departing from the spirit and scope of the invention.
* * * * *