U.S. patent application number 12/433262 was filed with the patent office on 2010-06-24 for label that is removable or having a removable section.
This patent application is currently assigned to MULTI-COLOR CORPORATION. Invention is credited to Steve Boucher, Tom Renier, Wally Zychowski.
Application Number | 20100154613 12/433262 |
Document ID | / |
Family ID | 42264175 |
Filed Date | 2010-06-24 |
United States Patent
Application |
20100154613 |
Kind Code |
A1 |
Boucher; Steve ; et
al. |
June 24, 2010 |
Label that is Removable or Having a Removable Section
Abstract
A perforating apparatus for perforating a sheet. The apparatus
includes a plurality of perforating assemblies. Each perforating
assembly includes a perforating wheel, which is operatively coupled
to a pneumatic cylinder, and a plurality of air hoses, wherein each
pneumatic cylinder of each perforating assembly is operatively
coupled to, and in flow communication with one air hose of the
plurality of air hoses. Further each pneumatic cylinder is
associated with an air muffler. And the apparatus includes a
secondary roller that includes a peripheral wrap around the outer
surface thereof.
Inventors: |
Boucher; Steve; (Iron
Mountain, MI) ; Zychowski; Wally; (Norway, MI)
; Renier; Tom; (Vulcan, MI) |
Correspondence
Address: |
WOOD, HERRON & EVANS, LLP
2700 CAREW TOWER, 441 VINE STREET
CINCINNATI
OH
45202
US
|
Assignee: |
MULTI-COLOR CORPORATION
Sharonville
OH
|
Family ID: |
42264175 |
Appl. No.: |
12/433262 |
Filed: |
April 30, 2009 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
61139283 |
Dec 19, 2008 |
|
|
|
Current U.S.
Class: |
83/591 ;
83/648 |
Current CPC
Class: |
Y10T 83/8789 20150401;
B26F 1/20 20130101; Y10T 428/31663 20150401; Y10T 428/31971
20150401; Y10T 428/31801 20150401; Y10T 428/31844 20150401; Y10T
428/14 20150115; Y10T 428/24331 20150115; B26D 5/02 20130101; B26D
5/12 20130101; Y10T 428/1486 20150115; B26D 7/2635 20130101; Y10T
83/889 20150401; Y10T 428/1471 20150115; Y10T 428/31993 20150401;
B26D 1/245 20130101 |
Class at
Publication: |
83/591 ;
83/648 |
International
Class: |
B26D 5/08 20060101
B26D005/08; B26D 7/01 20060101 B26D007/01 |
Claims
1. A perforating apparatus comprising: a plurality of perforating
assemblies, each perforating assembly of the plurality of
perforating assemblies including a perforating wheel operatively
coupled to a pneumatic cylinder; and a plurality of air hoses,
wherein each pneumatic cylinder of each perforating assembly is
operatively coupled to, and in flow communication with one air hose
of said plurality of air hoses.
2. The perforating apparatus of claim 1, further comprising a
frame, and wherein said plurality of perforating assemblies is
supported by said frame.
3. The perforating apparatus of claim 2, further comprising a
plurality of valves, wherein each air hose of said plurality of air
hoses is associated with one valve of said plurality of valves.
4. The perforating apparatus of claim 1, further comprising a
plurality of air mufflers, wherein at least one air muffler of said
plurality of air mufflers is operatively coupled to a perforating
assembly of said plurality of perforating assemblies.
5. The perforating apparatus of claim 4, wherein each air muffler
is in flow communication with one air hose of said plurality of air
hoses and one pneumatic cylinder of said plurality of perforating
assemblies.
6. The perforating apparatus of claim 5, wherein each air muffler
includes a first end and a second end and a flow path between said
first end and said second end, and wherein said first end is
operatively coupled to said air hose and said second end is
operatively coupled to said pneumatic cylinder.
7. The perforating apparatus of claim 6, wherein each air muffler
of said plurality of air mufflers further comprises a breather vent
positioned along said flow path.
8. The perforating apparatus of claim 7, wherein said breather vent
is a porous element.
9. A perforating assembly comprising: a perforating wheel
operatively coupled to a pneumatic cylinder; and an air muffler
operatively coupled to and in flow communication with said
pneumatic cylinder.
10. The perforating assembly of claim 9, wherein said air muffler
is further operative coupled to an air hose.
11. The perforating assembly of claim 10, wherein said air muffler
includes a first end and a second end and a flow path between said
first end and said second end, and wherein said first end is
operatively coupled to said air hose and said second end is
operatively coupled to said pneumatic cylinder.
12. The perforating assembly of claim 11, wherein said air muffler
further comprises a breather vent positioned along said flow
path.
13. The perforating assembly of claim 12, wherein said breather
vent is a porous element.
14. The perforating assembly of claim 13, further comprising a
fibrous element positioned proximal to said porous element and
along said flow path.
15. A perforating apparatus comprising: a perforating wheel having
a plurality of protrusions disposed about the outer circumference
of said perforating wheel; a roller; and a wrap disposed around the
outer circumference of said roller; wherein the perforating wheel
is positioned in relation to said roller such that a sheet is
capable of passing between said perforating wheel and said roller,
and the protrusions of said perforating wheel are adapted to
perforate said sheet, and the path of travel of said protrusions is
not limited by said wrap.
16. The perforating apparatus of claim 15, wherein said wrap
comprises a polymer film.
17. The perforating apparatus of claim 16, wherein said polymer
film is chosen from olefin film, cellophane film, and PET film.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of the filing date of
U.S. Patent Application Ser. No. 61/139,283, entitled "Label that
is Removable or Having a Removable Section," filed on Dec. 19,
2008, the disclosure of which is incorporated by reference herein
in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to labels that are
associated with various articles, and relates more specifically to
a label that is removable from the article with which it is
associated, or has a section that is removable from the article
with which the label is associated.
BACKGROUND
[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] Articles, such as containers, are prevalent in a wide
variety of shapes and sizes for holding many different kinds of
materials such as cosmetics, cleaning supplies, foodstuffs,
beverages, light duty liquids, heavy duty liquids, etc. Such
articles may be fabricated from plastic (e.g., polypropylene,
polyethylene, and polyesters), glass, paperboard, cardboard, or
other materials.
[0005] Regardless of the material, such articles are often provided
with a label thereon, having text, logos, graphics, decorations,
and/or other indicia that provide a consumer with information about
the article and its contents. For example, this label information
may include the trade name of the product, the producer of the
product, ingredients, price, and/or other such information. In some
instances, the label is associated with a surface of the article by
means of an adhesive or the like. For example, one such type of
label is a pressure-sensitive label. As is known to those skilled
in the art, a pressure-sensitive label generally includes a
substrate having indicia providing label information printed on one
side thereof, and a pressure-sensitive adhesive applied on the
opposite side thereof. The pressure-sensitive adhesive forms a bond
between the label and an article when pressure is applied in order
to adhere the label to the article.
[0006] The label information described above is generally situated
on the label such that it is visible to a consumer when the label
is associated with an article. However, in addition to the label
information described above, certain labels may also include other
information (in the form of text, logos, graphics, decorations,
and/or other indicia), which may not be visible to the consumer
when the label, or a section thereof, is associated with the
article. Game-type information is an example of this sort of
information. Game-type information may be included on the back side
of the label (i.e., the nonvisible side). Another exemplary type of
information that may be printed on the back side of a label
includes coupon-type information. In order to be viewed, the label,
or a section thereof, may be removed from the article, thereby
exposing the game-type, coupon-type, or other type of information.
Thus, it is desirable that the label, or a section of the label, be
removable. This allows any game-type information to be revealed and
any winning game piece (i.e., removable section or removable label)
to be redeemed. It also allows for any coupon to be removed and
retained by the retailer, or saved by the consumer for later
use.
[0007] Labels that are removable from an article, or have removable
sections, are known. However, these labels exhibit several
drawbacks. For example, these known labels often include two
substrates (with the first substrate affixed to an article, and a
second substrate--the removable substrate--overlying and affixed to
the first substrate). More specifically, in these labels, the
second substrate may have indicia on its back side, and the back
side is adhered to the first substrate. The back side of the first
substrate is then affixed to an article to be labeled through the
use of adhesives. The first substrate is applied to the article
with greater force of adhesion (i.e., a stronger bond) than the
force of adhesion of the second substrate to the first substrate.
Thus, the second substrate can be removed from the first substrate
while the first substrate remains adhered to the article. However,
the use of two substrates increases the bulk of the label. This
results in increases in materials used, with attendant increases in
cost to prepare and ship the labels. Further, multiple adhesives of
differing strengths must be used, further increasing the materials
and cost, and increasing the time, calculation, and design that
must go into the label. Further, the use of a first adhesive to
bond the second substrate to the first substrate results in a
second substrate that may not be easily removable from the first
substrate, and may tear, thereby damaging the indicia.
[0008] As another drawback, prior labels having indicia printed on
the back side of the second substrate have had difficulty in
retaining the ink of that indicia on the back side of the second
substrate during removal. For example, the adhesive of these labels
can split during removal, leaving adhesive on both surfaces (i.e.,
first and second substrates). Moreover, the bond of the adhesive
may become greater on aging than the strength of the substrate,
resulting in tearing of the substrate on attempting to peel the
label or a section thereof. This results in tearing of one or both
of the substrates, and often results in the transfer of indicia
from one surface to another, which removes indicia from one
substrate and adheres it, in an unwanted fashion, to the other
substrate. This destroys the usefulness of any game piece or coupon
or other information.
[0009] Further, the very use of an adhesive on the removable label
or removable section thereof (whether in a flood application or
patterned application) can increase the difficulty in removing the
label or removable section thereof from a secondary substrate, or
article. This also can result in tearing or destruction of any
coupon or game piece.
[0010] Further, even when a section of a label is designed to be
removable (such as by including a release layer), the adhesives
used for the remainder of a label (such as the standard adhesives
used on labels for beer bottles), create a strong enough bond that
the removable section also becomes bonded, thereby destroying its
function. For example, some labels having a removable section may
include a release coating over at least the removable section.
However, before that label is placed onto an article or other
substrate, the back side of the label is exposed to a roller, which
floodcoats an adhesive onto the back side of the label, and thus
over any release coating. In these labels, it is hoped that the
release coating will continue to allow removal of the section, even
in view of the presence of the adhesive. However, the adhesives are
generally stronger than the release coating and create a bond
between the article and the removable section, even in the presence
of a release coating. This results in a removable section
exhibiting the same drawbacks described above (e.g., a section that
cannot be removed, that tears, that doesn't retain ink, etc.).
[0011] Further still, any label including a removable section may
include perforations to define the removable section, and
facilitate removal of the section from the remainder of the
substrate. In general, perforations are made by methods well known
to those of ordinary skill in the art. For example, in one general
method, an infeed roller directs a web of labels into a perforation
apparatus, and a draw roller, disposed generally "downstream" from
the infeed roller, pulls the web of labels through the perforation
apparatus. Positioned between the infeed and draw rollers are one
or more perforating wheels. The outer circumferential surface of
each perforating wheel is provided with a plurality of "knives."
Proximal to the perforating wheel or wheels is a secondary roller.
A roller gap is thus formed between the perforating wheels and the
secondary roller. The web of labels is stretched taut over the
secondary roller and passes through this roller gap. The "knives"
of the perforating wheels puncture or indent the web of labels as
it passes, and the desired depth of the perforations can be
controlled by controlling the pressure of the perforating wheel
against the web of labels and secondary roller. For example, such
pressure may be set using air pressure provided by a pneumatic
cylinder.
[0012] However, there are drawbacks to these perforating apparatus
that result in inconsistent perforations of poor quality. For
example, the position of the perforating wheels relative to the
secondary roller may be mechanically adjusted, but it is difficult
to ensure that the pressure of the perforating wheels is constant
during operation of the apparatus. Generally, a single air source
provides the air for the pressure that is used for all of the
perforating wheels in a perforating apparatus. Due to blockages
that may arise within the system, the pressure may not be constant
for each perforating wheel. Further, the wheels, pneumatic
cylinders, or attachment of those two components may be different
(due to different age, for example). Thus, the single air source
may result in differing pressures in different perforating wheels.
This leads to inconsistent perforations across a particular web of
labels.
[0013] Further, during operation of a perforating apparatus, the
pressure within the pneumatic cylinder itself may not be held
constant. For example, variances in the operation of the apparatus
may cause the pressure to fluctuate (i.e., increase or decrease)
relative to the desired set pressure. All of the above can cause
inconsistencies in perforations along each single line of
perforations.
[0014] Further, in the perforating apparatus, the outer surface of
the secondary roller is hard, as the rollers are generally made of
a hard substance, such as steel. As described above, during a
perforating operation, the web of labels moves against this hard
surface as the "knives" of the perforating wheels puncture the
labels. However, the hard surface of the secondary roller does not
provide any "give," such that the knives may be stopped by the hard
surface from puncturing the labels to the desired depth.
[0015] Any difference in pressure between the perforating wheels or
within the pneumatic cylinder alters the depth, consistency, and
quality of the perforations formed in the labels. This leads to
labels with areas that are prematurely separated from the remainder
of the label, labels that do not have a removable section at all
(when they should), or labels with poorly functioning perforations
(such that any attempted removal may tear the label where not
intended).
SUMMARY
[0016] 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.
[0017] The various exemplary aspects of the present invention,
described below, overcome the drawbacks in present removable
labels, and labels having a removable section, described in the
Background. For example, one aspect provides a label that includes
a single substrate that is removable from the article with which it
is associated, or includes a removable section thereof, thereby
eliminating excess layers, adhesives, etc., and lowering costs of
the label.
[0018] Another aspect of the present invention provides a removable
label, or a label including a removable section, which does not
result tearing, splitting, or damage to the removed portion or
transfer of any indicia from the back side of the substrate to any
other surface. In one particular embodiment, the label includes a
substrate having a front side and a back side, and an ink disposed
on the back side of the substrate, wherein the formulation of the
ink includes components chosen from nitrocellulose resin, maleic
resin, rosin ester resin, phosphate plasticizer, and mixtures
thereof. The ink also includes various pigments (depending on the
particular colors desired). The ink is thus formulated with an
amount of resin (and thus a ratio of resin to pigment), which
differs from prior inks and is superior in its ability to remain
with the substrate during removal of the substrate, or a section
thereof, from an article.
[0019] A further aspect of the present invention provides a
removable label, or a label including a removable section,
including a substrate having a front side and a back side (wherein
the substrate is adapted to receive ink on the front side and the
back side), with a first abhesive layer disposed proximal to the
back side, and a second abhesive layer disposed adjacent to the
first abhesive layer. By use of the first and/or second abhesive
layers, the label or section thereof can be easily removed from an
article (as opposed to prior labels, which used some adhesives
between substrates, resulting in tearing and unwanted transfer of
ink).
[0020] A further aspect of the present invention provides a label
having at least one set of perforations to provide a removable
section of the label. In this aspect, each perforation of the set
of perforations exhibits substantially consistent features (e.g.,
size, shape, depth, etc.) as compared to the other perforations of
the set of perforations. Further, this aspect of the present
invention provides a label having a plurality of sets of
perforations wherein each perforation of the plurality of sets of
perforations exhibit substantially consistent features (e.g., size,
shape, depth, etc.) as compared to the other perforations of all
the plurality of sets of perforations.
[0021] A further aspect of the present invention provides an
apparatus for providing consistent perforations within a set of
perforations, and consistent sets of perforations, one to another.
The apparatus does so, for example, by providing individualized air
sources for each of a plurality of pneumatic cylinders, by
providing at least one breather vent to reduce and eliminate
fluctuations in pressure within a pneumatic cylinder, and by
providing a secondary roller including a peripheral surface, or
substance thereon that allows for travel of the knives of a
perforating wheel beyond its outer surface.
BRIEF DESCRIPTION OF THE FIGURES
[0022] Various features and advantages of the aspects of the
present invention will become better understood when the following
detailed description is read with reference to the accompanying
figures in which like characters represent like parts throughout
the figures, wherein:
[0023] FIG. 1 is a perspective view of an exemplary embodiment of a
label having a removable section associated with an outer surface
of an article in accordance with aspects of the present
invention.
[0024] FIG. 2 is a top view of the exemplary embodiment of the
label of FIG. 1.
[0025] FIG. 3 is a bottom view of the exemplary embodiment of the
label of FIG. 1.
[0026] FIG. 4 is a cross-sectional view of the exemplary embodiment
of the label of FIG. 1, taken along line 4-4 of FIG. 1.
[0027] FIG. 5 is a perspective view of the exemplary embodiment of
the label of FIG. 1, depicting the removable section of the label
being removed from the article with which it is associated.
[0028] FIG. 6 is a cross-sectional view of the exemplary embodiment
of the label of FIG. 1, taken along line 6-6 of FIG. 5.
[0029] FIG. 7 is a cross-sectional view of an alternate exemplary
embodiment of a label having a removable section associated with an
outer surface of an article, in accordance with aspects of the
present invention.
[0030] FIG. 8 is a schematic depicting an exemplary method of
preparing labels in accordance with aspects of the present
invention.
[0031] FIG. 9 is a schematic of a gravure cylinder used in an
exemplary method of preparing labels in accordance with aspects of
the present invention.
[0032] FIG. 10 is a perspective view of a perforating apparatus
used to perforate labels in accordance with the aspects of the
present invention.
[0033] FIG. 11 is a front view of the perforating apparatus of FIG.
10.
[0034] FIG. 12 is a partial cross-sectional view depicting an
exemplary perforation assembly in conjunction with rollers of the
perforating apparatus, in accordance with aspects of the present
invention.
[0035] FIG. 13 is a partial cutaway view of the perforation
assembly depicted in FIG. 12.
[0036] FIG. 14 is a schematic depicting an exemplary apparatus for
application of labels to articles in accordance with aspects of the
present invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0037] One or more embodiments of the present invention will be
described below. In an effort to provide a concise description of
these embodiments, not all features of an actual implementation may
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.
[0038] The various exemplary aspects of the present invention,
described below, overcome the drawbacks in present removable
labels, and labels having a removable section, described in the
Background. For example, one aspect provides a label that includes
a single substrate that is removable from the article with which it
is associated, or includes a removable section thereof, thereby
eliminating excess layers, adhesives, etc., and lowering costs of
the label.
[0039] Another aspect of the present invention provides a removable
label, or a label including a removable section, which does not
result tearing, splitting, or damage to the removed portion or
transfer of any indicia from the back side of the substrate to any
other surface. In one particular embodiment, the label includes a
substrate having a front side and a back side, and an ink disposed
on the back side of the substrate, wherein the formulation of the
ink includes components chosen from nitrocellulose resin, maleic
resin, rosin ester resin, phosphate plasticizer, and mixtures
thereof. The ink also includes various pigments (depending on the
particular colors desired). The ink is thus formulated with an
amount of resin (and thus a ratio of resin to pigment), which
differs from prior inks and is superior in its ability to remain
with the substrate during removal of the substrate, or a section
thereof, from an article.
[0040] A further aspect of the present invention provides a
removable label, or a label including a removable section,
including a substrate having a front side and a back side (wherein
the substrate is adapted to receive ink on the front side and the
back side), with a first abhesive layer disposed proximal to the
back side, and a second abhesive layer disposed adjacent to the
first abhesive layer. By use of the first and/or second abhesive
layers, the label or section thereof can be easily removed from an
article (as opposed to prior labels, which used some adhesives
between substrates, resulting in tearing and unwanted transfer of
ink).
[0041] A further aspect of the present invention provides a label
having at least one set of perforations to provide a removable
section of the label. In this aspect, each perforation of the set
of perforations exhibits substantially consistent features (e.g.,
size, shape, depth, etc.) as compared to the other perforations of
the set of perforations. Further, this aspect of the present
invention provides a label having a plurality of sets of
perforations wherein each perforation of the plurality of sets of
perforations exhibit substantially consistent features (e.g., size,
shape, depth, etc.) as compared to the other perforations of all
the plurality of sets of perforations.
[0042] A further aspect of the present invention provides a label
including a substrate having a front side and a back side (wherein
the substrate is adapted to receive ink on the front side and the
back side), including a removable section defined by at least one
set of perforations, with at least one abhesive layer disposed
proximal to the back side of the substrate and substantially in
register with the removable section. This aspect may further
provide a second abhesive layer disposed adjacent to the first
abhesive layer and substantially in register with the removable
section.
[0043] A further aspect of the present invention provides an
apparatus for providing consistent perforations within a set of
perforations, and consistent sets of perforations, one to another.
The apparatus does so, for example, by providing individualized air
sources for each of a plurality of pneumatic cylinders, by
providing at least one breather vent to reduce and eliminate
fluctuations in pressure within a pneumatic cylinder, and by
providing a secondary roller including a peripheral surface, or
substance thereon that allows for travel of the knives of a
perforating wheel beyond its outer surface.
[0044] There are several varieties of labels (e.g., pressure
sensitive, shrink sleeve, heat transfer, in-mold, etc.). The
description below and the Figures describe and show a pressure
sensitive label. However, those of ordinary skill in the art will
recognize that the present invention is not necessarily limited to
pressure sensitive labels, but may include other label types.
[0045] As can be seen from the Figures, the label includes a
plurality of layers. And certain of those layers may be common to
the various embodiments described herein. Referring particularly to
FIGS. 1-7, the label 10 includes a substrate 12 having a front side
14 and a back side 16, a first ink layer 18 disposed on or proximal
to the front side 14 of the substrate 12, a second ink layer 20
disposed on or proximal to the back side 16 of the substrate 12,
and a first abhesive layer 22 disposed on or proximal to the second
ink layer 20. Disposed "on," as used herein, means that there is
direct contact between the various layers (such as the substrate 12
and the first ink layer 18 or second ink layer 20). Disposed
"proximal to," as used herein, means that although a particular
layer may be positioned relative to a particular surface (e.g.,
that the first ink layer 18 is positioned near the front side 14 of
the substrate 12), it is not necessary that there be any direct
contact between the layer and the surface (e.g., the first ink
layer 18 and the front side 14 of the substrate 12), although there
may be. For example, another layer, or layers, may be disposed
between the first ink layer 18 and the front side 14 of the
substrate 12 such that the first ink layer 18 would then be
disposed "proximal to" the front side 14 of the substrate 12.
[0046] Further, various embodiments of the label 10 of the present
invention may include additional layers to those referenced above.
These include a protective layer 24 disposed on or proximal to the
first ink layer 18 (on a side of the first ink layer 18 that is
opposite the substrate 12), and a second abhesive layer 26 (see
particularly FIG. 7) disposed on or proximal to the first abhesive
layer 22 (on a side of the first abhesive layer 22 that is opposite
the second ink layer 20).
[0047] The label 10 may be adapted to be removed from an article 28
with which it is associated. As used herein, "associated with"
means that the label 10 is adhered to, affixed to, joined,
connected, merged, fastened, secured, or otherwise cooperative with
the article 28. Alternatively, the label 10 may include a removable
section 30, which is adapted to be removed from the article 28 with
which the label 10 is associated, while leaving a remainder section
or sections 32 of the label 10 with the article 28. Such a
removable section 30 may be defined by, and/or its removal may be
facilitated by, at least one set of perforations 34, as will be
described in greater detail below.
[0048] Turning now to the various layers of the label 10 which may
be present in various embodiments: In general, the label 10
includes a single substrate 12 having a front side 14 and a back
side 16. The front side 14 is the side that is visible when the
label 10 is associated with an article 28, and the back side 16 may
not be visible when the label 10 is associated with an article 28.
The back side 16 of the substrate 12 is generally opposite the
front side 14. As is known to those skilled in the art, a coating
36 suitable for printing high quality graphics may be applied (or
have been applied) to a side of the substrate, such that the front
side 14 exhibits this coating 36. Such substrates are known in the
art as "coated-one-side" or "C1S" substrates. Such coatings 36 are
usually applied in two steps. First, a base coat is applied, and
then a top coat is applied over the base coat. Compositionally,
coatings 36 useful for printing high quality graphics generally
include a fluidized blend of minerals such as coating clay, calcium
carbonate, and/or titanium dioxide with a suitable binder such as
starch, polyvinyl alcohol, polystyrene, or the like.
[0049] Further, the substrate 12 may be chosen from a full wet
strength paper and a full wet strength metalized paper. As is known
to those of ordinary skill in the art, the ability of paper
products to maintain a substantial proportion of their original
strength after being completely saturated with aqueous solution is
known as wet strength. Sometimes the criterion for defining a wet
strength grade of paper is that the ratio of wet to dry tensile or
burst strength is at least 10% or 15%. The primary means of
increasing the wet strength of paper consists of reactive,
polymeric chemicals. Most prominent among wet strength additives is
the family of polyamidoamine-epichlorohydrin resins.
[0050] Thus, the substrate 12 of the label 10 may be a single ply
C1S substrate. In particular embodiments, the single ply C1S
substrate 12 may be coated-one-side paper (such as a clay coated
paper) or a one-side metalized paper. A first indicia 38 may be
printed on the coated (e.g., clay coated or metalized) side of the
C1S substrate 12 (i.e., the front side 14 of the substrate 12), and
a second indicia 40 may be printed on the uncoated side of the C1S
substrate 12 (i.e., the back side 16 of the substrate 12).
[0051] The first indicia 38 may be formed from one or more inks
that make up the first ink layer 18. The first ink layer 18 may be
disposed on or proximal to the front side 14 of the substrate 12.
In one particular embodiment, the first ink layer 18 may be printed
on the front side 14 of the substrate 12. The ink of the first ink
layer 18 may be printed in the form of indicia 38 such as text,
graphics, and/or other decorations, and may be used to provide
label information, for example. As is known to those of ordinary
skill in the art, the ink (or inks) of the first ink layer 18 is a
liquid containing various pigments and/or dyes that is applied to a
surface (such as the front side 14 of the substrate 12) to produce
indicia (i.e., text, images, graphics, designs, etc.). In general,
the ink or inks may include solvents, pigments, dyes, resins,
lubricants, solubilizers, surfactants, particulate matter,
fluorescers, and other materials (though it is not necessary that
all of these materials be present in all inks). Two general types
of inks are pigmented inks and dye-based inks. Certain embodiments
of the label include a pigmented ink or inks. Further, as is known
to those of ordinary skill in the art, pigmented inks contain
further agents that ensure adhesion of the pigment to the surface,
which prevent the ink from being removed by mechanical abrasion.
These agents are typically referred to as resins in solvent-based
inks.
[0052] A second ink layer 20 may be disposed on or proximal to the
back side 16 of the substrate 12. In one particular embodiment, the
second ink layer 20 may be printed on the back side 16 of the
substrate 12. The ink of the second ink layer 20 may be printed in
the form of indicia 40, such as text, graphics, and/or other
decorations, to provide label information, such as for a coupon or
game piece, for example. And so, generally, the second ink layer 20
will be printed on the back side 16 of the substrate 12 at a
location that is designed to be removable from the label 10,
leaving the remainder section or sections 32 (in embodiments that
include a removable section 30 of the label 10). However, those of
ordinary skill in the art will recognize that the second ink layer
20 is not limited to being disposed on or proximal to only the
removable section 30 of the label. Thus, once the label 10, or
removable section 30 thereof, is removed, the second ink layer 20
(and the second indicia 40) can be viewed.
[0053] In one aspect of the present invention, the ink or inks of
the second ink layer 20 are disposed on or proximal to the back
side 16 of the substrate 12 (or a removable section 30 thereof) and
are formulated to transfer along with the removable label, or
removable section 30 of the substrate 12 (e.g., of metalized
paper). Such substrates are commonly used for labels, and are well
known to those of ordinary skill in the art. This eliminates the
above-described problem with prior inks not transferring completely
or effectively with a removable label or removable section thereof,
(such as when a second substrate is separated from a first
substrate).
[0054] To accomplish this complete transfer, the ink or inks
applied to the back side 16 of the substrate 12 as the second ink
layer 20 is of a formulation that provides greater adhesion to the
substrate 12 (e.g., a one-side metalized paper). The formulation of
the ink of the second ink layer 20 includes, in one embodiment, a
nitrocellulose resin, a maleic resin, a rosin ester resin, a
phosphate plasticizer, and pigments. The pigments provide the color
for the ink, and the remaining components (i.e., resins and
plasticizer) provide the vehicle for the pigments. The pigments
that are added to the formulation of the ink of the second ink
layer 20 of the present invention may be chosen based on the
particular color or colors desired. In one particular embodiment,
pigments may include black pigment (commercially available from
Flint Group, of Lebanon, Ohio), rubine red pigment, and HR yellow
pigment (rubine red and HR yellow are commercially available from
INX International of West Chicago, Ill.). For example, a particular
black ink available from Flint Group, of Lebanon Ohio, is TMK40200,
which has a formulation of 1-5% phosphate plasticizer, 4-8% rosin
ester resin, and 15-20% N/C black chip. As will be recognized by
those of ordinary skill in the art, this ink is merely exemplary of
inks that may be used in the various aspects of the present
invention. The ink, as described above, is of a formulation that
provides greater adhesion to the back side 16 of the substrate 12,
thereby preventing removal, transfer, etc. of the second ink layer
20 from the back side 16 of the substrate 12. This is accomplished
by formulating the resin content and amount. One particular
embodiment of an ink may include a formulation of nitrocellulose
resin, maleic resin, rosin ester resin, and a phosphate
plasticizer, to form a vehicle for the pigments of the ink, wherein
this vehicle comprises 73% of the ink composition. The components
of the vehicle are commercially available from Flint Group, of
Lebanon, Ohio. For example, a particular vehicle available from
Flint Group, of Lebanon Ohio, is TMW-96341, which has a formulation
of 10-15% nitrocellulose, 1-5% phosphate plasticizer, and 20-30%
maleic resin. As will be recognized by those of ordinary skill in
the art, this vehicle is merely exemplary of vehicles that may be
used in the various aspects of the present invention. The remaining
portion of the ink may include a pigment or pigments selected for
various desired color or colors. In one particular embodiment, the
ink composition includes 3% rubine red pigment, 22% HR yellow
pigment, and 2% black pigment. While the pigments of this
particular embodiment are described as black, rubine red, and HR
yellow, it will be recognized by those of ordinary skill in the art
that these pigments may be used in any combination, and any other
pigments of any other combination or alone may be used, based on
the desired colors to be used for various indicia (text, graphics,
logos, decorations, etc.). The particular pigments recited above
are not necessary.
[0055] As described above, the ink or inks of the second ink layer
20 are formulated to completely transfer with the label 10, or a
removable section 30 thereof, once the label 10, or removable
section 30, is removed from the article 28. As described in the
Background, many inks cannot completely transfer. Also, as
pigmented inks remain on the surface to which they are applied (as
opposed to dye-based inks), they are more susceptible to mechanical
abrasion due to the removal process (and thus separation from the
back side 16 of the substrate 12). Thus, the vehicle of the ink,
and particularly the resin components thereof, are formulated (and
increased in content) to provide greater adhesion of the ink (and
thus complete transfer) while still allowing for high quality of
indicia.
[0056] The ink that is applied as the second ink layer 20 to the
back side 16 of the substrate 12 may also be applied as the first
ink layer 18 on the front side 14 of the substrate 12.
Alternatively, other inks may be applied as the first ink layer 18
(as the ink of the first ink layer 18 may not be subjected to the
same mechanical abrasion during the removal process). The ink of
the first ink layer 18 thus may include a conventional polyamide
inks, or other standard inks. The first and second ink layers 18,
20 may be disposed on or proximal to the substrate 12 in a
conventional manner by depositing, by gravure printing, or the
like, the ink composition or compositions onto one or more desired
areas. For example, the labels may be printed both offset and
rotogravure on paper, metalized paper, and metalized film.
[0057] Although in this embodiment, the label 10 is described as
having a first ink layer 18, a C1S substrate 12 (e.g., metalized
paper), and a second ink layer 20, those of ordinary skill in the
art will recognize that there does not necessarily need to be a
first ink layer 18 disposed on the coated (e.g., metalized) front
side 14 of the substrate 12. In other words, labels including
indicia only in the form of an ink layer on the back side 16 of the
substrate 12 are also contemplated.
[0058] At least one layer of an abhesive (referred to herein as the
"first abhesive layer" 22) may be disposed on or proximal to the
second ink layer 20 (on the side of the second ink layer 20 that is
opposite the back side 16 of the substrate 12). In one particular
embodiment, the first abhesive layer 22 may be disposed on the
second ink layer 20. As is known to those of ordinary skill in the
art, abhesive compositions are used for coating various materials
in order to decrease the tendency of those materials to adhere to
other surfaces. Abhesive coating compositions are used, for
example, to coat paper, films, or sheets, which are used as backing
for pressure-sensitive labels (i.e., carrier sheets from which
labels are removed prior to application to an article).
[0059] In the present aspect of the invention, the first abhesive
layer 22 is used to prevent the label 10, or removable section 30
thereof, from adhering to the article 28. Thus, in embodiments
including a removable section 30, the first abhesive layer 22 may
be printed generally in substantial registry with the removable
section 30 of the substrate 12. However, in alternate embodiments,
the abhesive may be printed over the entire label 10. Further, the
first abhesive layer 22 may be flood coated or may be applied in a
pattern (i.e., other than a flood coating).
[0060] In one particular embodiment, the abhesive of the first
abhesive layer 22 includes a polyamide resin, polyether modified
dimethylpolysiloxane, polyethylene wax, and paraffin wax. One such
abhesive is Abseal.TM., commercially available from Flint Group, of
Lebanon, Ohio. For example, a particular abhesive formulation
available from Flint Group, of Lebanon Ohio, is TMW95387, which has
a formulation of 30-40% polyamide resin, 0.5-1% PE wax, 1-5%
parrifin wax, and 0.5-1% polyether modified dimethylpolysiloxane.
As will be recognized by those of ordinary skill in the art, this
abhesive is merely exemplary of abhesives that may be used in the
various aspects of the present invention. As described above, many
prior labels having removable sections exhibit difficulty in
removing the removable section from a secondary substrate. Even
prior use of certain abhesives has proven unsuccessful, because, as
described above, certain applications (such as the standard
adhesives used on beer bottles) provide a bond of such strength
that the removable section becomes bonded, even in the presence of
an abhesive. This is because once a label with an abhesive on a
back side of a removable section is prepared, the back side of the
entire label will be flood coated, or pattern coated, with an
adhesive prior to application. Thus, this adhesive, which bonds the
entire label to another surface, also overlies the abhesive coated
removable section of the label. Prior abhesives have not exhibited
the feature of being able to break free from those adhesives to
allow the removable section to be removed. However, the abhesive
includes components (polyamide resin, polyether modified
dimethylpolysiloxane, polyethylene wax, paraffin wax) that allows
the label, or a removable section thereof, to break free from any
bond provided by adhesives (including the very strong adhesives
used, for example, with beer bottles). The abhesive may also be of
an amount that facilitates removal of the label, or a removable
section thereof. The first abhesive layer 22, in one embodiment,
may be present in an amount in a range of 1.25-1.75 lbs./ream.
[0061] As described above, the first abhesive layer 22 may be
printed generally in substantial registry with the removable
section 30 of the substrate 12. Such a removable section 30 may be
defined by at least one set of perforations 34 transecting the
substrate 12. Thus, in one embodiment (for example, as shown in
FIG. 3), the removable section 30 may be defined by first and
second perforation lines 52, 54 transecting the substrate 12.
However, by being in "substantial registry," it is not mandatory
that the abhesive cover only the removable section 30 (i.e.,
defined by the boundary of any at least one set of perforations
34). Rather (and referring particularly to FIG. 3), the first
abhesive layer 22 may be printed in substantial registry by
overlapping any at least one set of perforations 34, such that some
amount of abhesive may be coated onto any remainder section or
sections 32 of the label 10. However, as will be recognized by
those of ordinary skill in the art, an adhesive will also be
applied to the remainder sections 32 of the label 10, and this
adhesive will be in an amount to retain the remainder sections 32
with the article 28 during and after removal of the removable
section 30. One particular embodiment includes a first perforation
line separating the label into removable section that comprises
approximately 65% of the label, and a remainder section that
comprises approximately 35% of the label.
[0062] The label 10 may further include a protective layer 24 (such
as a varnish) disposed on the front side 14 of the substrate 12.
Any such protective layer 24 may operate as a protective surface
and to improve processing. For example, wax can provide optical
clarity. Further, the protective layer can result in better and
more consistent die-cutting of the labels once formed. In one
particular embodiment, the protective layer may be an overprint
varnish including an acrylic emulsion resin, an acrylic solution
resin, polyether modified dimethylpolysiloxane, a surfactant, and
polyethylene wax. Such an overprint varnish is commercially
available from Flint Group, of Lebanon, Ohio. This protective layer
can make the label more slick and lubricious, thereby allowing it
to more through the die-cutting operation better than prior labels,
and labels without such a protective layer. For example, a
particular protective layer available from Flint Group, of Lebanon
Ohio, is TTW-233116, which has a formulation of 40-50% acrylic
polymer, 10-17% PE wax, 8-13% acrylic solution resin, 1-3%
surfactant, and 0.5-1% polyether modified dimethylpolysiloxane. As
will be recognized by those of ordinary skill in the art, this
formulation is merely exemplary of a formulation for protective
layers that may be used in the various aspects of the present
invention.
[0063] As described above, the label 10 may include a first layer
22 of an abhesive disposed on or proximal to the second ink layer
20. Still further, the label 10 may include a second abhesive layer
26 disposed on or proximal to the first layer 22 of abhesive (on
the side of the first abhesive layer 22 that is opposite the second
ink layer 20). The second abhesive layer 26 may be applied in the
same manner, and may include the same composition as the first
abhesive layer 22. Alternatively, the second abhesive layer 26 may
be disposed in a different manner, different location(s), etc. than
the first abhesive layer 22, and may be of a different composition
than the first abhesive layer 22. The second abhesive layer 26 may
be present in an amount in a range of 1.25-1.75 lbs./ream. In
embodiments including more than one abhesive layer, the layers may
or may not be printed over the same amount of the label 10 or with
the same pattern. In one particular embodiment, the abhesive of the
second abhesive layer 26 includes a polyamide resin, polyether
modified dimethylpolysiloxane, polyethylene wax, and paraffin wax.
Such an abhesive is Abseal.TM., commercially available from Flint
Group, of Lebanon, Ohio.
[0064] The printing of various layers onto the substrate 12 (e.g.,
first ink layer 18, protective layer 24, second ink layer 20, first
layer of abhesive 22, and second layer of abhesive 26) may be
accomplished in one pass through a press 56 (as is shown in FIG.
8). Referring now to FIG. 8, a substrate 12, as described above,
can be seen progressing through the press 56 to apply various
layers of the label. In particular, the substrate 12 first passes
through first and second gravure cylinders 42, 44, which apply the
first and second ink layers 18, 20 to the substrate 12. A third
gravure cylinder 46 then applies the protective layer 24 over the
first ink layer 18. Fourth and fifth gravure cylinders 48, 50 apply
the first and second abhesive layers 22, 26 over the second ink
layer 20. While the schematic depicted in FIG. 8 shows the various
layers being applied to the substrate via gravure cylinders, it
will be recognized by those of ordinary skill in the art that this
is merely one exemplary method of applying layers to a substrate to
form a label, and other standard methods known to those skilled in
the art may be used. Further, while the illustrated embodiment
depicts all layers as being applied during one pass through a press
56, this is not necessary. For example, the abhesive (either the
first or second layer 22, 26, or just the second layer 26) can be
printed on a second pass through the press 56. The end result is a
plurality of labels 10 including printed indicia on both sides of
the substrate 12.
[0065] As described above as an example, and referring now to FIG.
9, the various layers can be applied using a gravure cylinder 58.
While, as described above, the particular use of gravure cylinders
is not necessary, and other methods of application may be used, the
following is a description of how a gravure cylinder may be used to
apply the first abhesive layer 22. Gravure printing units are known
to those skilled in the art. Gravure printing units include a
rotary press that includes a tray 62, which is filled with the
abhesive. A gravure cylinder 58 (the outer surface 64 of which has
gravure cells (not shown) for taking up the abhesive), is mounted
so that it can rotate at least partially within the tray 62 in such
a way that, as it is rotating, while the press 56 is running, it
dips into the abhesive so that the gravure cells are filled with
the abhesive. Substantially perpendicularly above the gravure
cylinder 58, an impression roller 68 is mounted rotatably for
rotating opposite to the direction of the rotation of the gravure
cylinder 58. The impression roller 68, together with the gravure
cylinder 58, forms a roller gap 70 therebetween, through which the
substrate 12 and ink layers 18, 20, which are to be printed with
abhesive, is passed during the operation of the press 56 in order
to take up abhesive from the gravure cells on the outer surface 64
of the gravure cylinder 58.
[0066] For carrying out the process, excess abhesive on the gravure
cylinder 58 may be stripped from the outer surface 64 thereof with
the help of a doctor blade (not shown) or other stripping device,
which engages the outer surface 64, thereby leaving abhesive in the
etched gravure cells. Afterwards, in the roller gap 70, the
abhesive is drawn from the gravure cells of the outer surface 64 by
means of the impression roller 68 exerting an elastic
counterpressure and is taken up by the substrate 12.
[0067] Referring back to FIGS. 1-7, the label 10, in one
embodiment, further includes at least one set of perforations 34.
As is known to those of ordinary skill in the art, "perforation"
refers to the puncturing of a material with a harder (usually
sharp) object to create an aperture or indentation. And, in
particular, perforation refers to the practice of creating a long
series of holes or indentations so that paper can be torn more
easily along this "perforation line." As used herein, a
"perforation" will generally refer to a single aperture or
indentation that is created in a label. And, as used herein, a "set
of perforations" will generally refer to a plurality of apertures
or indentations that are grouped together, such as in a perforation
line (although it will be recognized by those of ordinary skill in
the art that such a set of perforations need not be linear, but
rather must merely be grouped to facilitate a tearing along the
perforations of the set of perforations).
[0068] The at least one set of perforations 34 may define, or
partially define, the removable section 30 of the label 10. And,
the at least one set of perforations 34 may facilitate removal of
the removable section 30 from the remainder of the label 10 (i.e.,
from the remainder section or sections 32). The at least one set of
perforations 34 may form a single perforation line transecting the
substrate 12, such that a removable section 30 is defined on one
side of the single perforation line, while the remainder of the
label 10 on the opposite side of the single perforation line 34
remains associated with the article 28 (such as by adhesion
thereto). Alternatively, a plurality of sets of perforations 34 may
transect the substrate 12, for example. Thus, in such an
alternative embodiment, the label 10 may include a first set of
perforations forming a first perforation line 52 transecting the
substrate 12, and a second set of perforations forming a second
perforation line 54 transecting the substrate 12, the first and
second perforation lines 52, 54 not being collinear. In this
alternative embodiment, the removable section 30 may be defined in
the region between the first and second perforation lines 52, 54,
while the portions of the label 10 not between the first and second
perforation lines 52, 54 (i.e., remainder sections 32) remain
associated with the article 28 following removal of the removable
section 30. (Those skilled in the art will recognize that there may
be more than one removable section, such as by having the two
sections of the label not between the first and second perforation
lines 52, 54 being removable, while the portion of the label 10
between the first and second perforation lines remains with the
article 28.) In yet a further alternative embodiment, at least a
third perforation line (not shown) may be made perpendicular to the
first perforation line or first and second perforation lines. And
still further, a fourth perforation line (not shown) may be made
perpendicular to the first perforation line or first and second
perforation lines, and not collinear with the third perforation
line. As a consequence, the label 10, in this alternate embodiment,
is provided with a substantially quadrilateral perforated area that
is removable. Those skilled in the art will recognize that the
above embodiments are merely exemplary, and one of ordinary skill
in the art may configure the number and shape of sets of
perforations in any manner to produce a desired removable section
or sections.
[0069] As described above with reference to FIG. 8, the labels are
printed on a press (possibly in one pass) with the first ink layer
18 and protective layer 24 (e.g., overprint varnish) being disposed
on the front side 14 of the substrate 12 (such as by gravure
cylinders 58--or other methods known to those skilled in the art),
and with the second ink layer 20, first abhesive layer 22, and/or
second abhesive layer 26 being disposed on the back side 16 of the
substrate 12 (again, such as by gravure cylinders 50--or other
methods known to those skilled in the art). After printing of these
layers (e.g., first ink layer 18, protective layer 24, second ink
layer 20, first abhesive layer 22, and/or second abhesive layer
26), and referring now to FIGS. 10-13, the labels 10 may be
perforated on a perforating apparatus 72. This perforating
apparatus 72 may be in-line with the press 56, such that after the
various layers are printed onto the substrate 12 to form the labels
10, the labels 10 are then perforated before they exit the press
56. Alternatively, the perforating apparatus 72 may be associated
with a separate apparatus from the press 56. For example, the
perforating apparatus may be associated with a slitter/rewinder 74
(see particularly FIG. 10). Finally, the perforating apparatus 72
may not be associated with, positioned on, or attached to the press
or any other apparatus, but may be a separate stand-alone
perforating apparatus. In the illustrated embodiment of FIG. 10,
the labels 10 are shown as being perforated on a slitter/rewinder
74. However, this is merely exemplary, and the present invention is
not limited to perforations being formed in a perforating apparatus
72 associated with a slitter/rewinder 74.
[0070] As is known to those of ordinary skill in the art, a
slitter/rewinder 74 includes straight or circular blades (not
shown), to cut material into narrow strips. Thus, in the present
invention, a web of labels 10 (e.g., a sheet 30 inches wide that
will be cut into many narrower strips of labels) is run through the
slitter/rewinder 74. The cutting blades (not shown) of the
slitter/rewinder 74 are set to a width that is desired for the
labels 10. Once the web of labels 10 is fed through the
slitter/rewinder 74 and slit into narrower strips, rollers (not
shown) on the exit side of the slitter/rewinder 74 rewind the cut
material. In the illustrated embodiment, the perforating apparatus
72 is a separate apparatus that can be associated with (e.g.,
positioned relative to, such as by being placed onto, for example)
the slitter/rewinder 74 in order to adapt the slitter/rewinder for
perforating a web of labels 10.
[0071] Perforations, in and of themselves, are known and are made
in ways known to those of ordinary skill in the art. For example,
in one general and exemplary method, an infeed roller directs a web
of labels into a perforation apparatus, and a draw roller disposed
generally "downstream" from the infeed roller pulls the web of
labels through the perforation apparatus. Positioned between the
infeed and draw rollers are one or more perforating wheels 76 (the
number of wheels can be altered depending on the number of
perforation lines desired). The outer circumferential surface 78 of
each perforating wheel 76 is provided with a plurality of "knives"
80, which serve to puncture the web of labels 10 as it passes,
thereby providing the desired perforations. In other words, the
outer circumference 78 of the perforating wheels 76 defines a
series of protrusions 80 that are capable of puncturing or
indenting the web of labels 10. Each of the protrusions are
separated by a portion 82 of the outer circumference 78 of the
wheel 76 that does not include any protrusion, such that any
substrate 12 is not punctured or indented by the non-protrusion
portion 82 of the outer circumference 78 of the perforating wheels
76. Proximal to the perforating wheels 76 is a secondary roller 83.
The web of labels 10 is stretched taut over the secondary roller 83
and passes between the perforating wheels 76 and the secondary
roller 83. The "knives" 80 of the perforating wheels 76 puncture
the labels 10 as the web passes between the perforating wheels 76
and secondary roller 83.
[0072] During the perforation of labels 10, the penetration depth
of the knives 80 may be adjusted, so that it is possible to make
the desired perforation. In particular, when implementing types of
perforation in which the perforating knives 80 are only intended to
partly penetrate (i.e., indent) the labels 10, it is especially
important to adjust the penetration depth of the knives 80 of the
perforating wheels 76 into the labels 10. The very minute
tolerances involved become clear when one considers that the
thickness of the labels 10 may be as little as 0.06 mm and
thinner.
[0073] Referring to FIGS. 10-13, the position of the perforating
wheels 76 relative to the secondary roller 83 may be mechanically
adjusted using set screws 86, and air pressure is used to set the
depth to which the perforating wheel(s) will cut (for example, as
provided by a pneumatic cylinder 88). Prior perforating apparatus
also used perforating assemblies including a perforating wheel or
plurality of perforating wheels that were each associated with a
pneumatic cylinder for controlling the pressure applied to the
perforating wheels when making perforations. However, in those
prior apparatus, and as described in the Background, a single air
hose provided the air for the pressure of all of the pneumatic
cylinders. As described above, this resulted in drawbacks that the
pressure may not be constant for each perforating wheel within the
apparatus, due to differences in age between the various cylinders,
differences in tolerances due to manufacturing, different amount of
build-up or blockages amongst the cylinders, etc. Further, such a
configuration requires that only one pressure can be set for all
perforating assemblies associated with a single perforating
apparatus.
[0074] However, the perforating apparatus 72 of one aspect of the
present invention includes components that allow for the pressure
delivered to each of the pneumatic cylinders 88 of the perforating
assemblies 84 to remain constant at the set desired level. To that
end, and referring now to FIGS. 10-13, there are shown therein
components of a perforating apparatus 72 according to the present
invention. In particular, the perforating apparatus 72 is shown, in
the exemplary illustrated embodiment, as an apparatus that can be
placed onto a standard slitter/rewinder. The perforating apparatus
includes a frame 90 for supporting other components of the
apparatus; a flow valve panel 92 extending between first and second
sides 94, 96 of the frame 90; a plurality of flow control valves 98
positioned on the flow valve panel 92; a plurality of air hoses 100
having first and second ends 102, 104, with each of the first ends
102 associated with one of the plurality of flow control valves 98;
a plurality of air mufflers 106, wherein each one of the plurality
of air mufflers 106 is attached to a second end 104 of one of the
plurality of air hoses 100; a plurality of pneumatic cylinders 88,
wherein each pneumatic cylinder 88 is operatively connected to one
of the plurality of air mufflers 106; a plurality of perforating
wheels 76, wherein each perforating wheel 76 is operatively
connected to one of the plurality of pneumatic cylinders 88; at
least one idler roller 110, and a secondary roller 83.
[0075] The slitter/rewinder 74 includes an infeed roller (not
shown) disposed proximal to a first end thereof, and a draw roller
(not shown) disposed proximal to a second end thereof. The
perforating apparatus 72 of the illustrated embodiment is
positioned relative to the slitter/rewinder 74 such that it is
operatively disposed along the path of travel of any web of labels
10 between the infeed roller and draw roller. As is shown in the
Figures, the web of labels 10 proceeds around a first idler roller
110, around the secondary roller 83, and around a second idler
roller 112. Before the web of labels encounters the first idler
roller 110, it encounters the infeed roller of the
slitter/rewinder. After the web of labels encounters the second
idler roller 112, it encounters the draw roller of the
slitter/rewinder 74. The draw roller of the slitter/rewinder is
connected to a drive motor (not shown) such that the web of labels
is pulled through the slitter/rewinder 74 and perforating apparatus
72.
[0076] As is described above, the apparatus includes a plurality of
perforating wheels. The perforator wheels 74 each are formed with a
plurality of spaced perforating knives 80 around the outer
circumferential surface of each of the perforating wheels. The
knives 80 are provided with relatively sharp cutting edges. The
knives 80 are adapted to be pressed against the label 10. As a
result, each perforating wheel is adapted to form a set of
perforations in the label 10 as it passes between the perforator
wheel 76 and secondary roller 83. As shown in the figures, the
perforating wheels 76 of the illustrated embodiment will form
longitudinal perforation lines. However, those of ordinary skill in
the art will recognize that perforations lines of other directions
(e.g. latitudinal), or sets of perforations of shapes other than
lines, may be formed. In particular, the perforation wheels 76 are
attached to holders 114 that may be adjusted such that the knives
80 of the perforating wheels 76 will perforate to a set depth.
[0077] More specifically, by means of a perforating wheel 76, which
is rotatably mounted on a holder 114, a set of perforations 34 is
made in the web of labels 10 that is moving between the perforating
wheel 76 and the secondary roller 83. Thus, one perforating wheel
will make one set of perforations in a label. As can be seen in the
illustrated embodiment of the figures, the perforating apparatus 72
includes a plurality of perforating wheels 76. Thus, a plurality of
sets of perforations 34 can be made across a web of labels 10. As
is known to those of ordinary skill in the art, a web of labels 10
will include many rows of labels 10 across the web. And since each
of the perforating wheels 76 is individually positionable relative
to the web of labels 10, the number of sets of perforations 34 per
label 10 can be controlled. Thus, each label 10 may have one set of
perforations 34 (such as a perforation line 52) transecting the
label, or each label may have multiple sets of perforations 34
(such as two or more perforation lines 52, 54 transecting each
label.
[0078] As described above, each perforating wheel 76 is associated
with a pneumatic cylinder 88 that allows for a particular pressure
(e.g., air pressure) to be supplied, such that the knives 80 of the
perforating wheel 76 can contact and perforate the web of labels 10
at a particular desired pressure. As is known to those of ordinary
skill in the art, pneumatic cylinders 88 are mechanical devices
which produce force, often in combination with movement, and are
powered by compressed gas (e.g., air). The pneumatic cylinders
impart a force by converting the potential energy of compressed gas
into kinetic energy due to the pressure gradient established by the
compressed gas being at a greater pressure than the atmospheric
pressure. The air in the cylinder 88 thus expands, and this air
expansion forces a piston 116 to move in a desired direction. As is
known to those of ordinary skill in the art, pneumatic cylinders 88
may be adjusted so as to control the amount of extension and/or
retraction of the piston 116 once actuated. The piston 116 is
operatively coupled to the perforating wheel 76 (whether directly,
or indirectly via a holder 114) such that the wheel 76 may be moved
as a result of movement of the piston 116.
[0079] More specifically, and referring now to FIG. 13, a portion
of the perforating apparatus 72 that includes an assembly 84 of
pneumatic cylinder 88 and perforating wheel 76 is shown in
cross-section. The assembly also includes a holder 114, which
serves to hold the perforating wheel 76, and set screws 86, which
are used to mechanically position the perforating wheel 76 at a
desired location relative to any web of labels 10 to be passed
through the perforating apparatus 72. The holder 114 has an axle
118 to which the perforating wheel 76 can be fastened in a
rotatable manner. The holder 114 is operatively connected to a
piston of the pneumatic cylinder, such that it may be cooperatively
moved along with the piston 116 during movement of the piston 116.
For rectilinear guidance of movement, guide bushes (not shown) may
be provided to prevent a rotation of the holder 114 about the axis
of the piston 116. The piston 116 and consequently the perforating
wheel 76 are moved downward by pressure, in particular, air
pressure, being admitted to an air space 122 within the pneumatic
cylinder 88, while the piston 116 is fixed in position. The
resulting pressure is transmitted to the piston 116, and, as a
result, the piston 116 is moved downward, thereby cooperatively
moving the perforating wheel 76 downward.
[0080] As described above, each wheel of the plurality of
perforating wheels 76 is operatively connected to one of the
pneumatic cylinders 88 of the plurality of pneumatic cylinders 88.
And, each of the pneumatic cylinders 88 is, in turn, operatively
connected to one air hose 100 of the plurality of air hoses 100.
Thus, each assembly 84 of pneumatic cylinder 88, holder 114, and
perforating wheel 76, has air individually supplied by its own air
hose 100. As a result, certain of the drawbacks of prior
perforating apparatus, described in the Background, are eliminated.
First, the present perforating apparatus 72 allows for consistent
perforation pressures (and thus consistent perforations) across
each label. For example, if a label is designed to include first
and second perforation lines 52, 54 running parallel and
non-collinear to one another, each of the two perforating
assemblies 84 making those two perforating lines 52, 54 can be
individually set to make sure each is being made with the same
amount of pressure being applied. Second, the prior apparatus only
allowed for one pressure to be set at any one time for all the
perforating assemblies in the apparatus, whereas, due to the
individual air supplies for each perforating assembly 84, each
perforating assembly 84 can be individually adjusted, and so
different pressures may be applied by the multiple perforating
wheels 76, if so desired.
[0081] Further, during operation of a perforating apparatus 72, the
pressure within the pneumatic cylinder 88 itself may not be held
constant. Variances in the operation of the apparatus may cause the
pressure to fluctuate (i.e., increase or decrease relative to the
desired set pressure). This can cause inconsistencies in
perforations along each single line of perforations. However, the
perforating apparatus of the present invention includes a plurality
of air mufflers 106, each air muffler having a first end 124, a
second end 126, and a breather vent member 128. In the illustrated
embodiment, each one of the plurality of air mufflers 106 is
attached at its first end 124 to a second end 104 of one of the
plurality of air hoses 100, and the second end 126 of each of the
plurality of air mufflers 106 is attached to a pneumatic cylinder
88. Thus, as air travels from an air source (not shown), through
the air hose 100, and into the pneumatic cylinder 88, it passes
through the air muffler 106, which is disposed between the air hose
100 and pneumatic cylinder 88.
[0082] In the illustrated embodiment, the air muffler 106 is of a
T-shape. The air muffler includes a first passageway 130 for the
air which is defined by the T-pipe, and proceeds along a
longitudinal axis from the air hose to the pneumatic cylinder. A
branched portion 132 of the T-pipe, that defines a second
passageway 134, lies perpendicular to the first passageway 130 (and
is in fluid communication therewith). An end of the second
passageway 134 opposite from the intersection of the first and
second passageways 132, 134 includes a breather vent 128. In one
embodiment, the breather vent 128 is a porous bronze element having
a filtration rating of 40 microns. Such T-pipes and breather vents
are commercially available from the McMaster-Carr Supply Company,
of Elmhurst, Illinois. The T-pipe can be selected with fittings to
match the size of the pneumatic cylinders and air hoses, and the
breather vents can be selected to match the fittings of the T-pipe,
as known to those of ordinary skill in the art. Additionally, a
separate substance 136 may be placed inside the second passageway
134 and proximal to the porous element. For example, a cotton-type
substance may be present as part of the breather vent. The air
muffler 106 assists in keeping the desired pressure within the
pneumatic cylinder constant. For example, should pressures
fluctuate by rising in the pneumatic cylinder 88 (above the desired
set pressure), the breather vent 128 allows for escape of air to
reduce the pressure and maintain it at its set level.
[0083] Further, in the perforating apparatus, the outer surface of
the secondary roller 83 is hard, as the rollers are generally made
of a hard substance, such as steel. As described above, during a
perforating operation, the web of labels 10 moves against this hard
surface as the "knives" 80 of the perforating wheels 76 puncture
the labels 10. However, the hard surface of the secondary roller 83
does not provide any "give," such that the knives 80 may be stopped
by the hard surface from puncturing the labels 10 to the desired
depth. However, as can be seen in the illustrated embodiment of
FIG. 12, the secondary roller 83 of the perforating apparatus 72 of
this aspect of the present invention includes a peripheral wrap 138
about its outer circumference 140. This wrap 138 is made of a
material that does not have the hardness of steel, and displays
some "give," such that the knives 88 of the perforating wheels 76
are not limited in their degree of travel by the peripheral wrap
138. In other words, the knives 80 of the peripheral wheels 76, in
an exemplary embodiment, puncture through the web of labels 10, and
at least the outer ends of the knives 80 enters into the peripheral
wrap 138. For example, the material may be a polymer film. Further,
this polymer film may, for example, be chosen from olefin film,
cellophane film, and polyethylene terephthalate (PET) film. The
film may have a pressure sensitive adhesive on one side that allows
the film to adhere to the secondary roller 83. Thus, in one
embodiment, the material may be Scotch tape, commercially available
from 3M, of St. Paul, Minn. While the above describes use of
polymer films such as olefin film, cellophane film, and PET film,
it will be recognized by those of ordinary skill in the art that
the material is not limited to these films, but may include any
other materials that would suffice to allow the knives of the
perforating wheels to enter into the peripheral wrap. Further, the
thickness of the peripheral wrap 138 about the secondary roller 83
can be of any thickness that suffices to support the necessary
degree of travel of the knives 80 of the perforating wheels 76.
[0084] Following preparation, the labels 10 may be die-cut for a
particular use, or application to a particular article 28. After
die-cutting, the label 10 is applied to an article 28. This may be
done, for example, on a cold glue, cut-and-stack labeling machine.
Referring to FIG. 14, bundles of labels 10 are put in a magazine
142 with the back side 16 of the label 10 exposed. A wheel 143
turns a number of palettes 144. These palettes 144 are steel or
rubber and are in the shape of the label 10. This palette 144 comes
in contact with a roller 146 containing the glue 148. This glue 148
is sheared onto the palette 144 in a controlled thickness. The
glue-containing palette 144 then comes in contact with the back 16
of the label 10, causing the label 10 to be pulled onto the palette
144. The back side 16 of the label 10 is affixed to the object to
be labeled through the use of an adhesive 148. Die-cut labels can
use conventional wet labeling glue, such as but not limited to,
Henkel BL300 for brewery applications, Aqueous adhesives or Hot
Melt adhesives from Fuller, Findley, or National Starch and
Chemical for wraparound labels, Morton International Aqueous 37P295
or Solvent 33P5 type Gel Lacquer heat activated adhesives or
pressure sensitive adhesives such as Nacor 4990 from National
Starch and Chemical Company. The palette 144 with the
glue-containing label 10 turns toward a "gripper wheel" 150.
Fingers 152 on the gripper wheel 150 pull the glue-containing label
10 from the palette 144 and place it on the article 28. The label
10 is then smoothed onto the article 28 with various brushes and
rollers 154.
[0085] As various changes could be made in the above-described
aspects and exemplary embodiments without departing from the scope
of the invention, it is intended that all matter contained in the
above description shall be interpreted as illustrative and not in a
limiting sense
* * * * *