U.S. patent application number 14/570278 was filed with the patent office on 2015-07-02 for label application system.
The applicant listed for this patent is Avery Dennison Corporation. Invention is credited to John MOFFATT, Radha SEN, Mark J. WYATT, Yuan Yuan ZHANG.
Application Number | 20150183544 14/570278 |
Document ID | / |
Family ID | 52302358 |
Filed Date | 2015-07-02 |
United States Patent
Application |
20150183544 |
Kind Code |
A1 |
MOFFATT; John ; et
al. |
July 2, 2015 |
Label Application System
Abstract
According to an aspect, the present invention is directed to a
method for applying a label to a substrate. The method includes
applying an ink layer to a transfer mechanism; applying a binding
layer to the ink layer; and contacting the binding layer to the
substrate such that the binding layer and the ink layer are
substantially removed from the transfer mechanism.
Inventors: |
MOFFATT; John;
(Schererville, IN) ; WYATT; Mark J.; (Chino Hills,
CA) ; SEN; Radha; (Glendale, CA) ; ZHANG; Yuan
Yuan; (San Dimas, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Avery Dennison Corporation |
Glendale |
CA |
US |
|
|
Family ID: |
52302358 |
Appl. No.: |
14/570278 |
Filed: |
December 15, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61921600 |
Dec 30, 2013 |
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Current U.S.
Class: |
156/240 |
Current CPC
Class: |
B29K 2105/24 20130101;
Y10T 428/24802 20150115; B41M 5/0064 20130101; B65C 9/00 20130101;
B65C 9/0015 20130101; B41M 5/0256 20130101; B29C 39/003 20130101;
B29L 2007/008 20130101; B05D 3/007 20130101; C08J 2375/04 20130101;
B41M 3/12 20130101; B41M 5/0047 20130101; B44C 1/1733 20130101;
C09J 7/29 20180101; B29K 2075/00 20130101; B29L 2009/00 20130101;
C08J 5/18 20130101; C08J 2475/04 20130101; B29K 2105/0005 20130101;
B44C 1/1758 20130101; C09J 2475/006 20130101; B41M 5/03 20130101;
Y10T 428/1476 20150115; Y10T 428/28 20150115 |
International
Class: |
B65C 3/08 20060101
B65C003/08; B65C 9/22 20060101 B65C009/22; B65C 9/26 20060101
B65C009/26; B65C 9/00 20060101 B65C009/00 |
Claims
1. A method for applying a label to a substrate, the method
comprising: a. applying an ink layer to a transfer mechanism; b.
applying a binding layer to the ink layer; and c. contacting the
binding layer to the substrate such that the binding layer and the
ink layer are substantially removed from the transfer
mechanism.
2. The method of claim 1, wherein the transfer mechanism comprises
a moving conveyer belt or sheet feed.
3. The method of claim 1, wherein the method further comprises
repeating steps a, b, and c with the same transfer mechanism.
4. The method of claim 1, wherein the transfer mechanism is
continuously moving, batch moving, or semi-batch moving.
5. The method of claim 1, wherein the transfer mechanism stops
between steps a and b.
6. The method of claim 1, wherein the transfer mechanism comprises
a textured or matte surface.
7. The method of claim 1, wherein the transfer mechanism comprises
a low surface energy material and/or a releasable substrate.
8. The method of claim 1, wherein the transfer mechanism comprises
a low surface energy coating.
9. The method of claim 1, wherein the transfer mechanism is
flexible to contour to the dimensions of the substrate.
10. The method of claim 1, wherein the transfer mechanism comprises
a surface energy between about 20 mN/m and about 40 mN/m.
11. The method of claim 1, wherein the ink layer is applied to the
transfer mechanism by raster graphics or bitmap imaging.
12. The method of claim 1, wherein the ink layer is applied to the
transfer mechanism by an inkjet printer, a thermal inkjet printer
or piezo ink jet printer.
13. The method of claim 1, wherein the ink layer comprises ink
selected from the group consisting of UV-curable, latex,
water-based, nonpolar, solvent-based, pigments, dyes, solvent-based
with polar functionality, Eco-solvent, hot-solvent, solventless,
100% solid and combinations thereof.
14. The method of claim 1, wherein the binding layer comprises a
pressure sensitive adhesive.
15. The method of claim 1, wherein the method further comprises the
step of curing the ink layer, the binding layer, or both the ink
layer and the binding layer between steps b and c.
16. The method of claim 1, wherein the method further comprises the
step of curing and/or drying through heating the ink layer, the
binding layer, or both the ink layer and the binding layer between
steps b and c, and wherein drying through heating is commenced
before curing if both curing and drying through heating are
performed.
17. A method for applying a label to a substrate, the method
comprising: a. applying a printable release layer to a transfer
mechanism; b. applying an ink layer to the printable release layer;
c. applying a binding layer to the ink layer; and d. contacting the
binding layer to the substrate such that the binding layer and the
ink layer are substantially removed from the transfer
mechanism.
18. The method of claim 17, wherein the transfer mechanism
comprises a moving conveyer belt or sheet feed.
19. The method of claim 17, wherein the method further comprises
repeating steps a, b, c and d with the same transfer mechanism.
20. The method of claim 17, wherein the transfer mechanism is
continuously moving, batch moving, or semi-batch moving.
21. The method of claim 17, wherein the transfer mechanism stops
between steps a and b.
22. The method of claim 17, wherein the transfer mechanism
comprises a textured or matte surface.
23. The method of claim 17, wherein the transfer mechanism
comprises a low surface energy material and/or a releasable
substrate.
24. The method of claim 17, wherein the transfer mechanism
comprises a low surface energy coating.
25. The method of claim 17, wherein the transfer mechanism is
flexible to contour to the dimensions of the substrate.
26. The method of claim 17, wherein the transfer mechanism
comprises a surface energy between about 20 mN/m and about 40
mN/m.
27. The method of claim 17, wherein the ink layer is applied to the
transfer mechanism by raster graphics or bitmap imaging.
28. The method of claim 17, wherein the ink layer is applied to the
transfer mechanism by an inkjet printer, a thermal inkjet printer
or piezo ink jet printer.
29. The method of claim 17, wherein the ink layer comprises ink
selected from the group consisting of UV-curable, latex,
water-based, nonpolar, solvent-based, pigments, dyes, solvent-based
with polar functionality, Eco-solvent, hot-solvent, solventless,
100% solid and combinations thereof.
30. The method of claim 17, wherein the binding layer comprises a
pressure sensitive adhesive.
31. The method of claim 17, wherein the method further includes the
step of curing the ink layer, the binding layer, or both the ink
layer and the binding layer between steps c and d.
32. The method of claim 17, wherein the method further comprises
the step of curing and/or drying through heating the ink layer, the
binding layer, or both the ink layer and the binding layer between
steps c and d, and wherein drying through heating is commenced
before curing if both curing and drying through heating are
performed.
33. The method of claim 17, wherein the printable release layer
comprises a low surface energy material.
34. The method of claim 17, wherein the method further comprises
cleaning the transfer mechanism between steps d and e.
35. A method for applying a label to a substrate, the method
comprising: a. applying a printable release layer to a transfer
mechanism; b. applying an ink layer to the printable release layer;
c. applying a binding layer to the ink layer; and d. contacting the
binding layer to the substrate such that the binding layer, the ink
layer, and the printable release layer are substantially removed
from the transfer mechanism.
36. The method of claim 35, wherein the transfer mechanism
comprises a moving conveyer belt or sheet feed.
37. The method of claim 35, wherein the method further comprises
repeating steps a, b, c and d with the same transfer mechanism.
38. The method of claim 35, wherein the transfer mechanism is
continuously moving, batch moving, or semi-batch moving.
39. The method of claim 35, wherein the transfer mechanism stops
between steps a and b.
40. The method of claim 35, wherein the transfer mechanism
comprises a textured or matte surface.
41. The method of claim 35, wherein the transfer mechanism
comprises a low surface energy material and/or a releasable
substrate.
42. The method of claim 35, wherein the transfer mechanism
comprises a coating on the transfer mechanism.
43. The method of claim 35, wherein the transfer mechanism is
flexible to contour to the dimensions of the substrate.
44. The method of claim 35, wherein the transfer mechanism
comprises a surface energy between about 20 mN/m and about 40
mN/m.
45. The method of claim 35, wherein the ink layer is applied to the
transfer mechanism by raster graphics or bitmap imaging.
46. The method of claim 35, wherein the ink layer is applied to the
transfer mechanism by an inkjet printer, a thermal inkjet printer
or piezo ink jet printer.
47. The method of claim 35, wherein the ink layer comprises ink
selected from the group consisting of UV-curable, latex,
water-based, nonpolar, solvent-based, pigments, dyes, solvent-based
with polar functionality, Eco-solvent, hot-solvent, solventless,
100% solid and combinations thereof.
48. The method of claim 35, wherein the binding layer comprises a
pressure sensitive adhesive.
49. The method of claim 35, wherein the method further includes the
step of curing the ink layer, the binding layer, or both the ink
layer and the binding layer between steps c and d.
50. The method of claim 35, wherein the method further comprises
the step of curing and/or drying through heating the ink layer, the
binding layer, or both the ink layer and the binding layer between
steps c and d, and wherein drying through heating is commenced
before curing if both curing and drying through heating are
performed.
51. The method of claim 35, wherein the printable release layer
comprises polyolefins, thermoplastic polymers of ethylene and
propylene, polyesters, polyurethanes, polyacryls, polymethacryls,
epoxy, vinyl acetate homopolymers, co- or terpolymers, ionomers,
antioxidants, inorganic colloidal silica or alumina binder, or
mixtures thereof.
52. The method of claim 35, wherein the printable release layer
further comprises an UV light absorber and an antioxidant.
53. A method for applying a label to a substrate, the method
comprising: a. applying a printable release layer to a
substantially all of a surface of a transfer mechanism; b. applying
an ink layer to at least a portion of the printable release layer;
c. applying a binding layer to the ink layer; and d. contacting the
binding layer to the substrate such that the binding layer, the ink
layer, and at least a portion of printable release layer are
substantially removed from the transfer mechanism.
54. The method of claim 53, wherein the transfer mechanism
comprises a moving conveyer belt or sheet feed.
55. The method of claim 53, wherein the method further comprises
repeating steps a, b, c and d with the same transfer mechanism.
56. The method of claim 53, wherein the transfer mechanism is
continuously moving, batch moving, or semi-batch moving.
57. The method of claim 53, wherein the transfer mechanism stops
between steps a and b.
58. The method of claim 53, wherein the transfer mechanism
comprises a textured or matte surface.
59. The method of claim 53, wherein the transfer mechanism
comprises a low surface energy material and/or a releasable
substrate.
60. The method of claim 53, wherein the transfer mechanism
comprises a low surface energy coating.
61. The method of claim 53, wherein the transfer mechanism is
flexible to contour to the dimensions of the substrate.
62. The method of claim 53, wherein the transfer mechanism
comprises a surface energy between about 20 mN/m and about 40
mN/m.
63. The method of claim 53, wherein the ink layer is applied to the
transfer mechanism by raster graphics or bitmap imaging.
64. The method of claim 53, wherein the ink layer is applied to the
transfer mechanism by an inkjet printer, a thermal inkjet printer
or piezo ink jet printer.
65. The method of claim 53, wherein the ink layer comprises ink
selected from the group consisting of UV-curable, latex,
water-based, nonpolar, solvent-based, pigments, dyes, solvent-based
with polar functionality, Eco-solvent, hot-solvent, solventless,
100% solid and combinations thereof.
66. The method of claim 53, wherein the binding layer comprises a
pressure sensitive adhesive.
67. The method of claim 53, wherein the method further includes the
step of curing the ink layer, the binding layer, or both the ink
layer and the binding layer between steps c and d.
68. The method of claim 53, wherein the method further comprises
the step of curing and/or drying through heating the ink layer, the
binding layer, or both the ink layer and the binding layer between
steps c and d, and wherein drying through heating is commenced
before curing if both curing and drying through heating are
performed.
69. The method of claim 53, wherein the printable release layer
comprises polyolefins, thermoplastic polymers of ethylene and
propylene, polyesters, polyurethanes, polyacryls, polymethacryls,
epoxy, vinyl acetate homopolymers, co- or terpolymers, ionomers,
antioxidants, inorganic colloidal silica or alumina binder, or
mixtures thereof.
70. The method of claim 53, wherein the method further comprises
cleaning the transfer mechanism between steps d and e.
71. A method for applying a label to a substrate, the method
comprising: a. providing a transfer mechanism including a liquid
soluble transfer sheet; b. applying an ink layer to the transfer
mechanism; c. applying a binding layer to the ink layer; d. wetting
the transfer sheet and applying it to the substrate to
substantially conform to at least a portion of an outside surface
of the substrate; e. contacting an adhesive layer to the substrate;
f. cleaning the liquid soluble transfer sheet.
72. The method of claim 71, wherein the film comprises polyvinyl
alcohol (PVOH), rice paper, cellulose, gelatin, polyamide, or
combinations thereof.
73. The method of claim 71, wherein the ink layer is applied to the
transfer mechanism by raster graphics or bitmap imaging.
74. A method for applying a label to a substrate, the method
comprising: a. applying a combination of printable release
materials, ink, and binding materials to a transfer mechanism; b.
contacting the combination to the substrate such that the
combination is substantially removed from the transfer mechanism.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims the benefit of U.S.
Provisional Application No. 61/924,891 filed Jan. 8, 2014, which is
incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to labels, methods
of making labels, and methods of applying labels to substrates.
More specifically, in some embodiments, the present invention
relates to faceless labels and method of making a faceless label
and the application methods of a faceless label to substrates of
various shapes and sizes without the use of a paper or other
material backing.
BACKGROUND OF THE INVENTION
[0003] Currently, labels are applied to containers or bottles to
provide information such as the supplied or the contents of the
container. Such containers and bottles are available in a wide
variety of shapes and sizes for holding many different types of
materials, including detergents, chemicals, personal care products,
motor oils, beverages, and others.
SUMMARY OF THE INVENTION
[0004] According to an aspect, the present invention is directed to
a method for applying a label to a substrate. The method includes
applying an ink layer to a transfer mechanism; applying a binding
layer to the ink layer; and contacting the binding layer to the
substrate such that the binding layer and the ink layer are
substantially removed from the transfer mechanism.
[0005] According to another aspect, the present invention is
directed to a method for applying a label to a substrate. The
method includes applying a printable release layer to a transfer
mechanism; applying an ink layer to the printable release layer;
applying a binding layer to the ink layer; and contacting the
binding layer to the substrate such that the binding layer and the
ink layer are substantially removed from the transfer
mechanism.
[0006] The accompanying drawing, which is incorporated in and
constitute a part of this specification, illustrates one or more
embodiments of the invention and, together with the description,
serves to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] A full and enabling disclosure of the present invention,
including the best mode thereof directed to one of ordinary skill
in the art, is set forth in the specification, which makes
reference to the appended drawing, in which:
[0008] FIG. 1 is a pictorial representation of a method in
accordance with a first embodiment of the present invention;
[0009] FIG. 2 is a graphical representation of the method of FIG.
1;
[0010] FIG. 3 is a pictorial representation of a method in
accordance with a second embodiment of the present invention;
[0011] FIG. 4 is a graphical representation of the method of FIG.
3;
[0012] FIG. 5 is a pictorial representation of a method in
accordance with a third embodiment of the present invention;
[0013] FIG. 6 is a graphical representation of the method of FIG.
5;
[0014] FIG. 7 is a pictorial representation of a method in
accordance with a fourth embodiment of the present invention;
[0015] FIG. 8 is a graphical representation of the method of FIG.
7;
[0016] Repeat use of reference characters in the present
specification and drawings is intended to represent same or
analogous features or elements of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0017] Reference will now be made in detail to presently preferred
embodiments of the invention, one or more examples of which are
illustrated in the accompanying drawings. Each example is provided
by way of explanation of the invention, not limitation of the
invention. In fact, it will be apparent to those skilled in the art
that modifications and variations can be made in the present
invention without departing from the scope or spirit thereof. For
instance, features illustrated or described as part of one
embodiment may be used on another embodiment to yield a still
further embodiment. Thus, it is intended that the present invention
covers such modifications and variations as come within the scope
of the appended claims and their equivalents.
[0018] Embodiments of the present invention include methods for the
application of labels onto substrates of various shapes and sizes.
Common to the embodiments of the invention is the absence of a
paper or other material backing associated with the label and its
application to the substrates. In the embodiments of the present
invention, due to the absence of such non-transferable component
normally associated with a label, there is a reduction in the
amount of waste associated with the application processes. In
addition, utilizing the methods of the present invention, the
application of labels to substrates of various sizes and shapes,
including three-dimensional substrates, may be completed more
effectively as the components of the present invention may contour
to the dimensions of substrate, as more fully discussed below.
[0019] FIGS. 1 and 2 illustrate a first embodiment of the present
invention, as a label may be applied to a desired substrate without
the use of a backing material. As common with the first through
fourth embodiments described, the present invention utilizes a
transfer mechanism that the components of the label are first
applied to and then is used to transfer those components onto the
desired substrate. As shown in FIGS. 1 and 2, a transfer mechanism
101 is deposited (Step 111) with an ink layer 102 and then a
binding layer 103 is deposited (Step 112) on top of ink layer 102.
Ink layer 102 and/or binding layer 103 are then dried and/or cured
(Step 113) while attached to transfer mechanism 101, and ink layer
102 and binding layer 103 are then applied (Step 114) to a
substrate 104 as the adhesive of binding layer 103 makes contact
with substrate 104. Transfer mechanism 101 is then returned to its
starting position such that the process may be repeated (Step
115).
[0020] As indicated above, transfer mechanism 101 of the present
invention is utilized to house the components of the label (i.e.,
the ink layer and binding layer and possible other components, as
discussed further below) prior to the components' application to
the particular substrate. Advantageously, the transfer mechanism
may be utilized again and again thereby reducing the amount of
waste typically associated with such methods.
[0021] To meet the requirements of such methods, transfer mechanism
101 may be a diaphragm constructed on a moving conveyer belt or in
a sheet feed system to aid in the process of the application of the
necessary label components onto the substrate and then to repeat to
process. In some embodiments, the conveyer belt may be continuously
moving or may utilize a batch-movement process, or a semi-batch
movement process, depending on the specifications of the user.
[0022] Transfer mechanism 101 may be constructed of any material or
materials that allow for the various label components to be
transferred on and off transfer mechanism 101 and allow for
transfer mechanism 101 to maintain its shape during the application
of the label components but further allow flexibility to conform to
the shape of the substrate. For example, if a diaphragm is used for
the construction of transfer mechanism 101, it may include a
textured or matte surface to increase the ease of releasability of
the label components to the substrate. In addition, in embodiments
where a diaphragm is utilized, suitable materials for the
construction of the belt that provide enhanced release qualities as
well as the desired flexibility may include silicone, fluorinated
polymers, or low surface energy polymers including polyamide,
Teflon.RTM., polyolefin, and others. Such materials may be utilized
to construct the entirety of the diaphragm or may serve as coatings
on the diaphragm depending on the user's specifications. Examples
of suitable silicone coated release materials include, D2 CL PET
7300A/7350A, Grade 27320 and 2SLKN and 5.0 MT PET 4400/4400 Grade
26967 from Loparex LLC in Iowa City, Iowa. In addition, suitable
polymer examples include, acrylic-based coatings, such as R130W
from Mayzo, Inc. in Suwanee, Ga. and polypropylene based coatings,
such as HFM sheets from Avery Dennison NTP in Pasadena, Calif.
[0023] To ensure the proper releasability of the label components
from transfer mechanism 101, the surface energy of transfer
mechanism 101 on the side that makes contact with the label
components may be between about 20 mN/m and about 40 mN/m. In some
embodiments, including those where silicone is utilized in the
construction of transfer mechanism 101, additional items, including
corona treatment or flame treatment, may be added to transfer
mechanism 101 to ensure the proper surface energy.
[0024] Ink layer 102 utilized in the methods of the present
invention may include ink or graphics, and may be a mono-colored or
multi-colored ink layer depending on the printed message and/or the
intended pictorial design. Such designs for use in connection with
the present methods include serial numbers, bar codes, trademarks,
etc.
[0025] The present methods may utilize a variety of commercially
available inks for use in ink layer 102 including UV-curable,
latex, water-based, nonpolar, solvent-based, pigments, dyes,
solvent-based with polar functionality, Eco-solvent, hot-solvent,
solventless, 100% solid and others. Examples of these inks include
Sun Sheen (a product of Sun Chemical, Inc. of Santa Fe Springs,
Calif. identified as an alcohol dilutable polyamide ink), Suntex MP
(a product of Sun Chemical, Inc. identified as a solvent-based ink
formulated for surface printing acrylic coated substrates, PVDC
coated substrates and polyolefin films), X-Cel (a product of Water
Ink Technologies, Inc. of Lincolnton, N.C. identified as a
water-based film ink for printing film substrates), Uvilith AR-109
Rubine Red (a product of Daw Ink, Inc. of Commerce, Calif.
identified as a UV ink) and CLA91598F (a product of Sun Chemical,
Inc. identified as a multibond black solvent-based ink).
[0026] Ink layer 102 may range, in some embodiments, from about 0.5
to about 10 microns. In further embodiments, the thickness of ink
layer 102 may range from about 1 to about 5 microns, and in other
embodiments, the thickness of ink layer 102 may be about 3
microns.
[0027] The application of ink layer 102 to transfer mechanism 101
may be accomplished by various methods known in the art, including
inkjet printing, screen printing, or coating. In one embodiment of
the invention, the ink layer may be deposited through raster
graphics or bitmap imaging, which is sometimes referred to in the
printing and prepress industries as contone or contone printing. In
some embodiments where inkjet printing is used, a thermal inkjet
printer or piezo inkjet printer may be utilized to apply ink layer
102 to transfer mechanism 101. In such embodiments, the ink of ink
layer 102 utilized in the method should be of a suitable viscosity
when passing through the printhead of such printers to ensure an
accurate and durable image. For example, in such embodiments,
thermal inks may include a viscosity of between about 3 and about 5
mPa/s at 25.degree. C., while piezo ink jet fluids may include a
viscosity in the range of about 1 to about 30 mPa/s at 25.degree.
C.
[0028] Binding layer 103 may be constructed of inkjettable
adhesives to meet the demands of the method utilized. For example,
binding layer 103 may be constructed of monomers, including those
of acrylic, epoxy, silicone, vinyl, and olefinic based chemistries.
In some embodiments, oligomers or short chain polymers may be
utilized in connection with binding layer 103. Short chain polymers
that may be beneficial in connection with binding layer 103 refers
to polymers where number average molecular weight (Mn) is less than
the entanglement molecular weight (Me) for the respective monomeric
systems. In addition, to allow such materials to consistently jet
through an inkjet nozzle, the materials utilized as binding layer
103 may include a viscosity range between about 5 to about 50
cps.
[0029] In embodiments of the invention where inkjettable adhesives
are utilized in connection with binding layer 103, such adhesives
may be prepared using any known methods in the art including,
emulsion, solvent or solvent-less polymerization techniques, where
such inkjettable adhesives may be processed using a solvent, water
or a heated nozzle. The user's specifications may dictate the
necessary methods utilized for such preparation and processing.
[0030] In some embodiments, the inkjettable adhesives utilized in
connection with binding layer 103 may be based on a two-component
adhesive system where a first component is jetted through a first
nozzle and a crosslinking or curing agent (second component) is
jetted through a second nozzle onto the first component. In such
embodiments, the viscosity of both components may be maintained at
a level to ensure adequate room temperature mixing through
diffusion. Suitable first and second component pairs include epoxy
oligomers & resins and amine oligomers; epoxy oligomers &
resins and acid catalysts; epoxy oligomers and basic catalysts; and
oligomers with isocyante functional groups and alchohols,
catalysts, or moisture.
[0031] In additional embodiments of the present invention utilizing
the two component adhesive, one component of the two components may
be coated/printed/fabricated onto the desired surface/media using
additional non-jettable technique, including gravure printing,
screen printing, casting, spin coating, die-coating etc. In further
embodiments of the invention that utilize the two component
adhesive, one of the two components may be situated in ink layer
102 to provide the same effect.
[0032] In addition to those adhesives mentioned above, pressure
sensitive adhesives (PSA) may be utilized in connection with
binding layer 103. PSAs are a class of adhesives characterized by
low Tg and may be applied to a given surface at room temperature
with the application of a small amount of pressure. Pressure
sensitive adhesives are tacky at room temperature and are known to
adhere to a wide variety of high and low energy surfaces.
[0033] Suitable PSAs that may be used in connection with binding
layer 103 include monomers, for example, 2-Ethylhexyl acrylate,
Butyl acrylate that are copolymerized with certain polar monomers
including acrylic acid, N-vinyl pyrrolidone or 2-Hydroxy ethyl
acrylate. The polymer may then be further crosslinked using known
crosslinkers and an energy source to yield a desired balance of
tack and shear properties.
[0034] In some embodiments, the molecular weight of the polymer
utilized may be in excess of ten times the entanglement molecular
weight to allow sufficient chain interactions that allow for proper
viscoelastic properties of such polymers. In some embodiments,
oligomers or short chain polymers that may be used in connection
with a PSA of the present invention may be assembled into a polymer
of sufficiently high molecular weight using a self assembly
process. Such process may be completed by attaching hydrogen
bonding moieties to the oligomeric chains. Suitable hydrogen
bonding moieties include vinyl pyrrolidone and acrylic acid, amine
functionalized chains and acrylic acid, and other hydrogen bond
donors and hydrogen bond acceptors. In further embodiments,
hydrogen bonding solvents such as methanol, ethanol or
tetrahydrofuran may be utilized. In addition, the combination when
processed at a temperature above 75.degree. C., such hydrogen bonds
will cease to exist leading to a lower viscosity and once jetted,
the chains will assemble into a higher molecular weight polymer,
suitable for use in the present invention, due to the aid of
hydrogen bonding.
[0035] As described in prior embodiments a desired two or more
component adhesive could also be realized by incorporating one of
the components onto the surface or media to be printed (jetted) on.
As an example, an acid activated system can be achieved either by
incorporating the acid sensitive polymer in the media and catalyst
in the jettable pack or vice-a-versa to have the same end-effect.
Examples of media and surfaces may include glass, paper, PET, PE,
Aluminum etc. Additionally, one component of the two component
system may be coated/printed/fabricated onto the desired
surface/media using additional non-jettable technique. Examples of
such techniques would include gravure printing, screen printing,
casting, spin coating, die-coating etc.
[0036] In some embodiments, the adhesives utilized in binding layer
103 may include additives to provide enhanced properties. For
example, in some embodiments, additives comprising wetting agents,
surfactants, inorganic fillers, colorants, viscosity modifiers,
optical brighteners and/or others may be added. The user's
specifications will dictate the necessary components utilized.
[0037] As discussed above, the present method may further utilize a
drying and/or curing step for any or all of the label component
layers. Any such methods known in the art may be utilized to
complete the drying and/or curing step depending on the particular
materials utilized for ink layer 102 and binding layer 103. For
example, if the ink utilized for ink layer 102 is UV-curable, then
a UV curing process would be utilized in the curing step. In some
embodiments, if both drying and curing is utilized, drying through
heating may be completed first and then curing may be completed
through any known curing process, including heating or radiation
(IR/UV), where such radiation curing may involve using a free
radical photoinitiator, photo-acid based photocatalytic or a
combination curing pack.
[0038] FIGS. 3 and 4 illustrate a second embodiment of the present
invention, where a printable release layer is utilized. The
printable release layer, depending on the embodiment, may act as a
release or a protective layer as more fully explained below. In the
second embodiment of the present invention, transfer mechanism 501
is deposited (Step 511) with a printable release layer 502, which
acts to aid in the release of the other label components from
transfer mechanism 501. Following the addition of printable release
layer 502, an ink layer 503 is deposited (Step 512) onto printable
release layer 502. A binding layer 504 is then applied (Step 513)
to ink layer 503. The layers 502, 503, and 504 may then be dried
and/or cured (Step 514) as necessary. Following curing, ink layer
503 and binding layer 504 are then transferred (Step 515) to
substrate 505, while printable release layer 502 remains on
transfer mechanism 501 as it provides qualities to release layers
503 and 504. In such embodiments, prior to the repeat of the
process, transfer mechanism 501 may be cleaned (Step 516) with a
suitable material as discussed below. Following the cleaning of
transfer mechanism 501, the process may be repeated (Step 517). In
such embodiments of the present invention, depending on the
particular item utilized as printable release layer 502, an initial
deposit of printable release layer 502 may only be necessary at the
outset, whereas in other embodiments, printable release layer 502
may be applied each time.
[0039] Transfer mechanism 501, ink layer 503, and binding layer
504, of the second embodiment may be the same as those described
above with respect to the first embodiment.
[0040] As indicated above, printable release layer 502 of the
second embodiment acts as a release material to aid in the transfer
of ink layer 503 and binding layer 504 from transfer mechanism 501
to substrate 505. Accordingly, printable release layer 502 may be
constructed of materials that provide such releasability, similar
to those described with respect to transfer mechanism 101 in the
first embodiment.
[0041] When a printable release layer is present, it may have a
single layer or a multilayered structure. The thickness of the
printable release layer may be in the range of about 12.5 to about
125 microns, and in one embodiment from about 25 to about 75
microns. Examples of printable release layers that may be used in
connection with the present invention are described in U.S. Pat.
No. 6,106,982, the entirety of which is incorporated by
reference.
[0042] Printable release layer 502 may comprise polyolefins,
thermoplastic polymers of ethylene and propylene, polyesters,
polyurethanes, polyacryls, polymethacryls, epoxy, vinyl acetate
homopolymers, co- or terpolymers, ionomers, antioxidants, inorganic
colloidal silica or alumina binder, and mixtures thereof. To ensure
the proper releasability of ink layer 503 and binding layer 504
from printable release layer 502, the surface energy of printable
release layer that makes contact with ink layer 503 may be between
about 20 mN/m and about 35 mN/m. In some embodiments, including
those where silicone is utilized in the construction of printable
release layer 502, additional items, including corona treatment or
flame treatment, may be added to printable release layer 502 to
ensure the proper surface energy.
[0043] As indicated above, following the transfer of ink layer 503
and binding layer 504 onto substrate 505, transfer mechanism 501 is
cleaned. Such cleaning process may remove excess ink and/or
adhesive that remains on transfer mechanism 501 following the
transfer to the substrate. The cleaning process may be necessary to
ensure that a new print layer that is deposited during the present
method is not affected by components that may still be on transfer
mechanism 501, thereby altering the aesthetic or functional
qualities of ink layer 503. Any known method for cleaning transfer
mechanism 501 may be utilized, for example, an adhesive plate may
be used to make contact with transfer mechanism 501 and remove any
undesired remaining components.
[0044] FIGS. 5 and 6 illustrate a third embodiment of the present
invention. In the third embodiment, printable release layer 702 may
be released from transfer mechanism 701 and onto the desired
substrate 705 to provide a protective barrier to the ink and
adhesive. During the application process, transfer mechanism is
deposited (Step 711) with printable release layer 702. Following
the application of printable release layer 702, ink layer 703 is
deposited (Step 712) onto printable release layer 702. Then,
binding layer 704 is deposited (Step 713) onto ink layer 703, where
the layers 702, 703, and 704 may be dried and/or cured (Step 714)
depending on the particular items utilized. After curing, layers
702, 703, and 704 may be applied (Step 715) to the substrate 705,
and then the process may be repeated (Step 716). The third
embodiment allows for the cleaning step of the above-described
embodiment to be omitted. Such reduction in method steps likely
reduces the costs of production of labels for application to
substrates.
[0045] As indicated above, printable release layer 702 may provide
desirable properties to the other label components before and after
the label components are affixed to a substrate. The presence of a
transparent printable release layer over the ink layer 703 may, in
some embodiments provide additional properties such as antistatic
properties stiffness and/or weatherability, and printable release
layer 702 may protect ink layer 703 from, e.g., weather, sun,
abrasion, moisture, water, etc. Printable release layer 702 may
enhance the properties of the underlying ink layer 703 to provide a
glossier and richer image. Printable release layer 702 may also be
designed to be abrasion resistant, radiation resistant (e.g, UV),
chemically resistant and/or thermally resistant thereby protecting
the label components and, particularly ink layer 703 from
degradation from such causes. Printable release layer 702 may also
contain antistatic agents, or anti-block agents to provide for
easier handling when the labels are being applied to containers at
high speeds.
[0046] Printable release layer 702 may further contain UV light
absorbers and/or other light stabilizers. Among the UV light
absorbers that may be useful are the hindered amine absorbers
available from Ciba Specialty Chemical Co. of Basel, Switzerland
under the trade designations Tinuvin 111, Tinuvin 123,
(bis-(1-octyloxy-2,2,6,6-tetramethyl-4-piperidinyl) sebacate;
Tinuvin 622, (a dimethyl succinate polymer with
4-hydroxy-2,2,6,6-tetramethyl-1-piperidniethanol); Tinuvin 770
(bis-(2,2,6,6-tetramethyl-4-piperidinyl)-sebacate); and Tinuvin
783. Additional light stabilizers include the hindered amine light
stabilizers available from Ciba Specialty Chemical Co. under the
trade designation "Chemassorb", especially Chemassorb 119 and
Chemassorb 944. The concentration of the UV light absorber and/or
light stabilizer is in the range of up to about 2.5% by weight, and
in one embodiment about 0.05% to about 1% by weight.
[0047] In some embodiments, printable release layer 702 may also
contain an antioxidant. Any antioxidant useful in making
thermoplastic films may be used. These include the hindered phenols
and the organo phosphites. Examples include those available from
Ciba Specialty Chemical Co. under the trade designations Irganox
1010, Irganox 1076 or Irgafos 168. The concentration of the
antioxidant in the thermoplastic film composition may be in the
range of up to about 2.5% by weight, and in one embodiment about
0.05% to about 1% by weight.
[0048] In the embodiment illustrated in FIGS. 7 and 8, the
invention utilizes a flood technique that allows for the addition
of an excess of a printable release layer 902 onto a transfer
mechanism 901. In the embodiment, transfer mechanism 901 is
deposited (Step 911) with a printable release layer 902. As
indicated above, printable release layer 902 provides an amount of
printable release layer material to sufficiently cover transfer
mechanism. Following the addition of printable release layer 902,
ink layer 903 is deposited (Step 912) onto printable release layer
902. In addition, binding layer 904 is deposited (Step 913) onto
ink layer 903. In some embodiments, an ink layer and a binding
layer may not completely cover a printable release layer. As
indicated above, this may be done to ensure that an ink layer and a
binding layer are sufficiently covered when the label is
transferred to a substrate. In instances when a printable release
layer is only applied to a portion of transfer mechanism, it may
not sufficiently transfer to a substrate, thereby leaving the label
with less than ideal protective qualities as desired.
[0049] Following the addition of layers 902, 903, and 904, the
layers may be dried and/or cured (Step 914) as necessary. The
layers 902, 903, and 904 may then be transferred (Step 915) to
substrate 905. In addition, due to the remaining printable release
layer following Step 915, transfer mechanism 901 may be cleaned
(Step 916) prior to the repeat of the process (Step 917).
[0050] By way of further example, unlike the earlier described
embodiments, a fifth embodiment may utilize a transfer sheet that
may be dissolved by water or a solvent. For each transfer, a
transfer sheet, which may be picked up from a stack of such sheets,
ink layer and binding layer may be deposited onto the surface of
the transfer sheet, ink layer and binding layer may be optionally
cured, and ink layer and binding layer may be transferred to the
substrates. In one embodiment of the invention, the transfer sheet
may be made of water soluble or solvent soluble materials. Upon
finishing of the transfer process, the transfer sheet may be washed
away by the dissolving solvent or water. The transfer sheet may be
transferred with the ink layer and binding layer onto the substrate
before being washed away, or the transfer sheet may stay behind on
a transport mechanism, such as a belt or diaphragm. Water soluble
materials suitable for use as the transfer sheet include rice
paper, polyvinyl alcohol (PVAc), ethylene vinyl alcohol (EVOH),
starch and its derivatives, cellulose and its derivatives such as
cellulose ethers, ethylcellulose polymers and other soluble
materials.
[0051] In this exemplary fifth embodiment, a transfer sheet may be
transferred to meet with a substrate on a moving belt. Due to the
washing process, the moving belt may be constructed of a diaphragm
with a plurality of orifices where heat may exit to aid in the
washing process. In other embodiments, the moving belt may be
constructed of a diaphragm without orifices, but that can be heated
and wetted by known methods to also aid in the washing process.
[0052] In some embodiments, the ink layer and the binding layer may
be formulated into one single layer. This formulation may contain
colorants and also adhesive components. The ink and binding layer
may be first deposited onto the transfer mechanism, optionally
dried and or cured, and then applied to a substrate to be
labeled.
[0053] In some embodiments of the invention, the components of the
various ink layers, binding layers and printable release layers
described above may be combined into a single layer. In such
embodiments, the combination of all materials together may limit
the amount of stages necessary for the creation of the labels.
[0054] These and other modifications and variations to the present
invention may be practiced by those of ordinary skill in the art,
without departing from the spirit and scope of the present
invention, which is more particularly set forth in the appended
claims. In addition, it should be understood that aspects of the
various embodiments may be interchanged in whole or in part.
Furthermore, those of ordinary skill in the art will appreciate
that the foregoing description is by way of example only, and is
not intended to limit the invention so further described in such
appended claims. Therefore, the spirit and scope of the appended
claims should not be limited to the description of the versions
contained therein.
* * * * *