CN118354898A

CN118354898A - Pressure sensitive label

Info

Publication number: CN118354898A
Application number: CN202280055009.5A
Authority: CN
Inventors: B·G·麦基里普; S·L·凯尼克; P·J·卡萨尼
Original assignee: Colorful Co
Current assignee: Colorful Co
Priority date: 2021-06-17
Filing date: 2022-06-14
Publication date: 2024-07-16

Abstract

A pressure sensitive label and method of making the same, the pressure sensitive label comprising: (a) A support portion comprising at least a carrier layer; and (b) a transfer portion over the support portion for transferring the transfer portion from the support portion to the article upon application of pressure to the transfer portion while the transfer portion is in contact with the article, the transfer portion comprising at least (1) a first printable layer in facing relationship with the carrier layer, (2) an ink layer, and (3) a second printable layer, wherein the ink layer is disposed between the first and second printable layers.

Description

Pressure sensitive label

Cross Reference to Related Applications

The present application is PCT of U.S. patent application Ser. No. 17/350,370, entitled "Pressure-SENSITIVE LABEL", filed on month 17 of 2021 (and published as U.S. patent application publication No. 2021/0312838, month 10 of 2021), and U.S. patent application Ser. No. 17/490,110, filed on month 9 of 2021 (and published as U.S. patent application publication No. 2022/0020297, month 1 and 20 of 2022), which are incorporated herein by reference in their entireties, and claims continued priority in part.

Technical Field

The present invention relates generally to labels for various articles, and more particularly to pressure sensitive labels for articles (e.g., containers).

Background

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 the 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.

Pressure sensitive labels are multi-layer structures that include a pressure sensitive adhesive that when in contact with an article, labels the article by applying pressure to the label to adhere the label to the article via the pressure sensitive adhesive. Such pressure sensitive labels are popular because, among other characteristics, they are versatile and allow for a high level of printability of bright colors printed on a surface. In addition, they can be printed on a wide range of materials, such as paper, foil, metal, plastic and other synthetic materials. They are also suitable for use in a variety of finishing processes including, but not limited to, perforation, embossing, and hot stamping.

Referring to fig. 1, a typical prior art pressure sensitive label 1 is shown. When labeling an article with a pressure sensitive label, the basic pressure sensitive label stock 2 is typically obtained from a separate supplier. The basic pressure sensitive label stock 2 typically comprises at least four laminate layers: (1) a carrier 3 (sometimes referred to as a "liner"), (2) a release layer 4 disposed on one surface of the carrier, (3) an adhesive layer 5 (including a pressure sensitive adhesive) disposed on the release layer, and (4) a facestock 6 disposed on the adhesive layer.

Thus, a typical basic pressure sensitive label stock 2 may be considered to have a support portion 7 (carrier 3 and release layer 4) and a transfer portion 8 (adhesive layer 5 and facestock 6). The release layer 4 is used to allow the portion to be transferred to the article to be peeled off and released from the carrier 3 during label application.

Facestock 6 is typically made from a paper web or sheet, film or foil and is applied or laminated to adhesive layer 5 sequentially at some time after adhesive layer 5 has been laid. Once the basic pressure sensitive label stock 2 is obtained from the supplier, the facestock 6 may be printed on with one or more layers of ink 9 (text, graphics, indicia, etc.) to create label decorations and information. The conventional pressure sensitive label construction is then applied to the surface of the article by removing the carrier 3 and release layer 4 to expose the adhesive layer 5 and placing the adhesive layer 5 in contact with the desired surface and applying pressure to transfer the adhesive layer 5, facestock 6 and ink layer 9 to the article (the "ink layer" as described herein may include more than one ink to create the appearance of the label decor and information).

Although such pressure sensitive labels are well known, there are a number of disadvantages to using such pressure sensitive labels. As described above, the initial basic pressure sensitive label stock (carrier, release layer, adhesive layer, and facestock) is typically provided by a third party, followed by the addition of the label design (i.e., ink graphics, text, indicia, etc.). This does not allow the entire label (e.g., carrier, release layer, adhesive layer, facestock, and ink layer) to be constructed in one location and/or time. Thus, current pressure sensitive labels require a multi-location, multi-step process for their production, thereby extending the time required to manufacture a complete pressure sensitive label. (when reference is made herein to "construction of a label" or the like, it is intended to refer to construction of a single label and/or construction of a web of multiple single labels.

Furthermore, the size, shape, profile, etc. of the ink layer indicia to be printed on the base stock in advance are not known to the supplier of the base pressure sensitive label stock, which is used to form the final label web ("label web" is a length of base pressure sensitive label stock along which a plurality of individual labels are printed via ink/indicia). Thus, the basic pressure sensitive label stock is formed from a flood coat of adhesive and a facestock that matches or substantially closely matches the area of the carrier (to accommodate any size, shape, contour, etc. of the printable ink layer(s), and any size, shape, and/or contour of the label (s)). Thus, after the printing ink design, the label web must be die cut to produce the final web (carrier/release with individual cut labels thereon). This process requires that the carrier be made of a solid material, such as polyester, so that it can withstand the die cutting process without itself being cut (since only the ink layer, facestock, adhesive and release agent will be cut). The cut matrix, which does not include labels, is then removed and discarded. The use of a solid material for the carrier (e.g., polyester) presents a problem in that the carrier cannot be recycled because the material cannot be placed into the recycling stream of the label web. Although the carrier is typically polyester, this does not prevent the carrier from using other materials (e.g., paper liners, cellophane, polypropylene, or a mixture of these materials).

Furthermore, since the basic pressure sensitive label stock needs to be provided by a third party, followed by printing of the ink layer, it is desirable that the layers of the final label be arranged with the adhesive adjacent the carrier (e.g., adjacent the release layer) and the ink disposed away from the carrier. This construction results in a further disadvantage of the prior art pressure sensitive labels. First, the fact that the adhesive is adjacent to the carrier requires a release layer or coating between the carrier and the adhesive to allow the adhesive, facestock, and ink layer to be released from the carrier during application to the article. The need for such a release layer increases the material of these conventional pressure sensitive labels, thereby increasing costs. Second, positioning the ink layer away from the carrier means that once the ink layer is applied to the article, the ink layer will become the outer surface of the label. This means that the ink layer is easily worn or damaged, thereby spoiling the aesthetic appearance of the article. This also means that metals cannot be used as inks in these conventional pressure sensitive labels (as they are easily damaged). Thus, the inks available for these labels are limited and the design is susceptible to damage. A protective layer may be added to the label (to the outside of the ink layer), but as with the release layer described above, this adds another layer to the label and increases costs.

Furthermore, if the label is to be adhered to a contoured or irregular surface and a high degree of flexibility is required, the rigidity of the facestock (and any rigidity due to the multiple layers of the label) may interfere with the application and adhesion of the label.

Furthermore, in the application of pressure sensitive labels, it is a common situation that they have various drawbacks, such as wrinkles and blisters. These defects can occur when the label is not aligned with the article to which the label is applied and/or air is trapped between the label and the article. The result is a less than optimal visual appeal (poor aesthetics), label failure due to abrasion or tearing of the unsupported label, or even a product that is not marketable.

In view of the many drawbacks of pressure sensitive labels as described above (particularly the many layers required, the use of third party infrastructure, and the possible damage to label labeling), many people often take heat transfer labels as an alternative type of labels. To avoid loss of label information, heat transfer labels are preferably resistant to abrasion and chemical action and desirably have good properties of adhering to the articles to which they are attached.

The heat transfer label is a multi-layer construction, each layer having its own function. For example, heat transfer labels typically include an adhesive layer, an ink layer, and a release layer. The release layer may be a wax release layer and is typically directly adjacent to the carrier sheet, for example on a label roll or label web. Thus, in such examples, the label may be considered to include a "support portion" (e.g., a carrier sheet and release layer and a "transfer portion" (i.e., an ink layer and an adhesive layer)). When heated, the wax release layer melts, allowing the transfer portion to separate from the carrier sheet, and the adhesive layer adheres the ink layer to the marked article. Alternatively, all or part of the wax release layer may also be transferred to provide protection to the ink layer. Additionally or alternatively, the label may include a separate protective layer overlying the ink layer to protect the ink layer from abrasion.

More specifically, during the thermal transfer labeling process, the label-bearing sheet is heated and the label is pressed against the article with the ink layer in direct contact with the article. When the paper sheet is heated, the wax layer begins to melt so that the paper sheet can be released from the ink layer. In an alternative embodiment, where the wax layer is also transferred, the wax layer may serve two purposes, (1) providing release of the ink layer from the sheet upon application of heat to the sheet, and (2) forming a protective layer over the transferred ink layer.

However, a major disadvantage of using heat transfer labels is the need to apply heat during the labelling process, which may be undesirable. It is therefore desirable to construct a pressure sensitive label structure for use as a label, for example, which avoids the need to use conventional facestock formed from paper, film or foil. It is also desirable that the pressure sensitive label constructions have properties of printability, switchability and optionally superior or equal to the prior art pressure sensitive label constructions (as described above). It is also desirable that such pressure sensitive label constructions be designed in a manner that reduces the amount of manufacturing time required to complete the construction as compared to prior art pressure sensitive constructions. Further, it is desirable to reduce and/or eliminate wrinkles and/or blisters that may form during label application. Further, it is desirable that such pressure sensitive label constructions have reduced layers, thereby reducing costs, increasing recyclability, increasing ease of application to the marked article, and reducing the incidence or likelihood of damage to the ink layer.

Disclosure of Invention

Certain exemplary aspects of the invention are described 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 set forth below.

Aspects of the present invention address any and/or all of the shortcomings of the prior art pressure sensitive labels described above by providing a pressure sensitive label that has, among other features, reduced layers, reduced cost, increased recyclability, increased ease of application to marked articles, and reduced incidence or likelihood of damage to the ink layer (as compared to prior art pressure sensitive labels described in the background). To achieve this, one aspect of the present invention provides a pressure sensitive label comprising: (a) A support portion comprising at least a carrier layer; and (b) a transfer portion comprising at least a printable layer in contacting relationship with the carrier layer. In general, the transfer portion may overlie the support portion for transferring the transfer portion from the support portion to the article upon application of pressure to the transfer portion while the transfer portion is in contact with the article. In one aspect of the invention, the carrier layer does not include any release layer between the carrier layer and the printable layer. This eliminates the prior art label layer, thereby reducing the cost of the label.

Furthermore, in another aspect of the invention, the printable layer may be applied in a softened, melted, thixotropic, liquid, etc. form that allows the printed layer to be provided as a pattern (e.g., in the shape, size, outline, etc. of the label image to be produced, i.e., graphics, text, indicia, etc.) rather than as a facestock (e.g., a prior art label) that matches (or substantially matches) the area of the carrier layer. The formulation of the printable layer allows it to receive ink thereon after cooling, curing, UV curing, etc. The ability to apply the printable layer in a pattern also reduces the amount of material required for the label web (and thus reduces costs), eliminates the need for die cutting (and waste of waste die cut material), and can be used to allow the entire label to be built in one location (as opposed to the need to obtain basic pressure sensitive label blanks from a third party supplier).

In other aspects, the label may include an ink layer positioned such that the printable layer is between the carrier layer and the ink layer. Also, the label may include an adhesive layer positioned such that the ink layer is between the printable layer and the adhesive layer. With this configuration, the pressure sensitive labels described herein include a printable layer closest to the carrier and an adhesive layer furthest from the carrier (this is a slightly opposite configuration compared to prior art pressure sensitive labels). Because of this configuration, the transfer portion (e.g., printable layer, ink layer, adhesive layer) of the pressure sensitive labels described herein does not have to be peeled off of the carrier to expose the adhesive for adhesion to the article. Instead, the label is configured such that the adhesive is already the outer layer of the label construction prior to application to the article, so the adhesive is pre-exposed and ready to contact the article, thereby increasing the ease of application to the article.

The configuration of the layers in this aspect and embodiment of the present label also results in the ink being below (and thus protected by) the printable layer once the transfer portion is transferred to the article. This results in the ink layer (indicia, graphics, designs, text, information, etc.) being protected from damage once the label is transferred to the article. This protection is achieved without having to add any additional protective lacquer layer (as is sometimes done with prior art pressure sensitive labels). The construction that allows the printable layer to protect the ink layer after transfer also increases the amount of material that may be used in the ink layer, e.g., materials that are easily damaged, such as metallic inks, can be used.

In another aspect, the pressure sensitive label may further comprise a release layer positioned such that the carrier layer is between the printable layer and the release layer. In other words, the release layer is not on the side of the carrier adjacent to the transfer portion of the label, but on the underside or back side of the carrier. The release layer, for example, allows the label web to be wound onto a roll while preventing blocking (i.e., the problem of adhesive on the label adhering to the underside of the carrier when the label web is wound onto the roll).

Another aspect of the present invention provides a pressure sensitive label comprising: (a) at least a support portion comprising a carrier layer; and (b) a transfer portion comprising at least a printable layer in facing relationship with the carrier layer, and an ink layer may be present between the printable layer and the carrier layer. Depending on the nature of the ink layer, at least a portion or portions of the printable layer may contact the carrier layer (i.e., in any region where one or more inks of the ink layer are not present). Typically, the transfer portion may overlie the support portion to transfer the transfer portion from the support portion to the article when pressure is applied to the transfer portion when the transfer portion is in contact with the article. In one embodiment, the carrier layer does not include any release layer on the side of the carrier layer facing the ink layer. This eliminates the prior art label layer, thereby reducing the cost of the label. In this configuration, the pressure sensitive label of this aspect includes an ink layer closest to the carrier and an adhesive layer furthest from the carrier. With this configuration, the transfer portion (e.g., ink layer, printable layer, adhesive layer) of the pressure sensitive label described in this aspect does not have to be peeled off of the carrier to expose the adhesive for adhering to the article. Instead, the label is configured such that the adhesive is already the outer layer of the label construction prior to application to the article, so the adhesive is pre-exposed and ready to contact the article, thereby increasing the ease of application to the article. In addition, the version of the label may also include a release layer positioned such that the carrier layer is between the ink layer and the release layer (e.g., to prevent blocking when the label web is wound on a roll).

Another aspect of the invention may include one or more methods of making a pressure sensitive label. And another aspect of the invention may include one or more methods for applying a pressure sensitive label to an article.

Drawings

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with a general description of the invention given above and the detailed description of the embodiments given below, serve to explain the principles of the invention.

FIG. 1 is a cross-sectional view of a typical pressure sensitive label construction of the prior art.

Figure 2 is a cross-sectional view of one embodiment of a pressure sensitive label construction in accordance with the principles of the present invention.

Fig. 2A is a cross-sectional view of another embodiment of a pressure sensitive label construction in accordance with the principles of the present invention.

Fig. 3 is a cross-sectional view of another embodiment of a pressure sensitive label construction in accordance with the principles of the present invention.

Fig. 3A is a cross-sectional view of yet another embodiment of a pressure sensitive label construction in accordance with the principles of the present invention.

Fig. 4 is a cross-sectional view of another embodiment of a pressure sensitive label construction in accordance with the principles of the present invention.

Fig. 4A is a cross-sectional view of yet another embodiment of a pressure sensitive label construction in accordance with the principles of the present invention.

Fig. 5 is a schematic diagram of a construction for making a pressure sensitive label in accordance with the principles of the present invention.

Fig. 6 is a schematic diagram of a completed pressure sensitive label on a label roll in accordance with the principles of the present invention.

Fig. 7 is a schematic illustration of the application of a pressure sensitive label construction to an article in accordance with the principles of the present invention.

Fig. 8 depicts an article with a pressure sensitive label according to the principles associated with the present invention.

Fig. 9 is a cross-sectional view of another embodiment of a pressure sensitive label construction in accordance with the principles of the present invention.

Fig. 10 is a schematic diagram of another embodiment of a construction for making a pressure sensitive label in accordance with the principles of the present invention.

Fig. 11 is a schematic diagram of another embodiment of a construction for making a pressure sensitive label in accordance with the principles of the present invention.

Fig. 12 is a schematic view of another embodiment of a construction for making a pressure sensitive label in accordance with the principles of the present invention.

Fig. 13 is a cross-sectional view of another embodiment of a pressure sensitive label construction in accordance with the principles of the present invention.

Fig. 13A is a cross-sectional view of another embodiment of a pressure sensitive label construction in accordance with the principles of the present invention.

Detailed Description

One or more specific embodiments of the present invention will be described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

As described above, aspects of the present invention address the above-described shortcomings of prior art pressure sensitive labels by providing a pressure sensitive label that has, among other features, reduced layers, reduced cost, increased recyclability, increased ease of application to marked articles, and reduced incidence or likelihood of damage to the ink layer (as compared to prior art pressure sensitive labels described in the background). To achieve this, one aspect of the present invention provides a pressure sensitive label comprising: (a) A support portion comprising at least a carrier layer; and (b) a transfer portion comprising at least a printable layer in contacting relationship with the carrier layer. In general, the transfer portion may overlie the support portion for transferring the transfer portion from the support portion to the article upon application of pressure to the transfer portion while the transfer portion is in contact with the article. In one aspect of the invention, the carrier layer does not include any release layer between the carrier layer and the printable layer. This eliminates the layers of prior art labels, thereby reducing the cost of the labels.

Referring now to FIG. 2, one embodiment of such a pressure sensitive label 10 is shown. As shown in fig. 2, the pressure sensitive label 10 of the illustrated embodiment is a multi-layer construction, each layer having its own function. Other embodiments also have a multi-layer construction. In general, the label includes a "support portion" 12 (e.g., carrier layer 14) and a "transfer portion" 18 (e.g., at least a printable layer 20-although various embodiments may also include, for example, an ink layer 22 and an adhesive layer 24). When subjected to pressure, as will be described in more detail below, the transfer portion 18 may be separated from the carrier 14 to adhere to an article. This occurs when the label 10 is placed in facing relation with the article 26 and pressure is applied so that the transfer portion 18 is in direct contact with the outer surface 28 of the article 26 (the article 26 may be seen in fig. 7 and 8). After the transfer portion 18 is in contact with the article 26, the carrier sheet 14 is removed, leaving the transfer portion 18 attached to the article 26 via the adhesive layer 24 of the transfer portion 18.

According to various aspects of the present invention, several embodiments of the pressure sensitive label 10 are possible. All embodiments include the general support portion 12 and transfer portion 18 described above. The support portion 12 of each embodiment includes a carrier layer 14, one side of which carrier layer 14 may have a release coating 16 (e.g., a wax or silicone coating) (which may be seen in the embodiment shown in fig. 2A). In alternative embodiments, the carrier 14 may not have a release coating, but may be otherwise treated, such as by corona treatment. In other embodiments, the carrier 14 may be untreated and have no release coating. The transfer portion 18 of each embodiment is positioned adjacent to and in facing relationship with the carrier 14 prior to transfer from the carrier 14. The transfer portion 18 of the embodiment includes at least (1) a printable layer 20 in facing relationship with the carrier 14. This facing relationship does not require contact between the two layers (although contact is possible). Although there may be one layer or coating between the carrier 14 and the printable layer 20, these layers need only be adjacent and proximate to each other-e.g., as shown in fig. 2A. Transfer portion 18 may also include an ink layer 22 and an adhesive layer 24. In the embodiment shown in fig. 2 and 2A, the ink layer 22 may be positioned such that the printable layer 20 is located between the carrier layer 14 and the ink layer 22. Also, in those embodiments, the adhesive layer 24 may be positioned such that the ink layer 22 is between the printable layer 20 and the adhesive layer 24. Additional layers may be included within transfer portion 18.

Some layers of the pressure sensitive label 10 may be made of uv curable material (and in some embodiments, all layers may include uv curable material). Uv curable materials are generally known to those of ordinary skill in the art. For example, certain inks, coatings, and adhesives are formulated with photoinitiators and resins. Polymerization occurs when exposed to the correct energy and irradiance in a particular band of ultraviolet light, and the material is cured. This reaction may take only a few seconds. The ultraviolet sources used may include ultraviolet lamps and ultraviolet LEDs. Fast processes such as flexographic printing (which may be used for some layers on some embodiments of pressure sensitive labels, or for all layers) may use high intensity light.

Still referring to fig. 2, the illustrated embodiment includes a carrier layer 14, a printable layer 20, an ink layer 22, a pressure sensitive adhesive layer 24, and a backside release layer 27. As can be seen in fig. 2, the release layer 27 is positioned such that the carrier layer 14 is located between the printable layer 20 and the release layer 27. As will be described in further detail below (in a more detailed discussion of the various layers of the label 10), the backside release layer 27 prevents blocking, for example, when the label web is wound on a roll.

As described above, various pressure sensitive label embodiments in accordance with the principles of the present invention include a carrier layer 14. The carrier layer 14 used in some embodiments (as well as the embodiment shown in fig. 2) is constructed of a material that allows the transfer portion 18 of the label 10 to be separated from the carrier layer 14 without the need for a separate release layer (e.g., a release layer as in the prior art). This allows for a reduction in the materials and costs used in the present pressure sensitive labels. And thus, in embodiments of the present invention, the carrier layer 14 is constructed of or comprises a material having a surface tension that allows the printable layer 20 to be releasably bonded to the carrier layer. Also, in more specific embodiments of the present invention, the surface of the carrier layer 14 that contacts the printable layer 20 may have a dyne (dyne) level of less than about 32.

Further, as described above, the web of labels 10 may be wound on a roll (see, e.g., fig. 6). In the wound state, the adhesive layer 24 of the label will contact the carrier portion 12 of the label web (and may in particular contact the backside release layer 27) on top of the carrier portion. In such embodiments, the transfer portion 18 needs to be bonded to the carrier 12 more strongly than any bond between the adhesive layer 24 and the release layer 27 (or the back side of the carrier 14) of the adjacent portion of the wound web. This prevents the transfer portion 18 from prematurely separating from the support portion 12 during unwinding of the roll.

The carrier layer 14 of the various embodiments of the present invention may comprise a variety of materials so long as the materials allow the printable layer 20 to be releasably bonded thereto (as described above). For example, the carrier layer 14 may be selected from materials such as plastic film, foil, parchment, light weight paper, and heavy weight paper. In a particular exemplary embodiment, the carrier layer 14 may include polypropylene. And, more specifically, in certain embodiments, the carrier layer may be a biaxially oriented co-extruded polypropylene film having an oriented polypropylene core, a treatable polyolefin layer on the underside of the core, and a corona-treated polyolefin layer on the top side of the core (i.e., the treatable polyolefin layer is the side that will face and/or contact the printable layer—the treatable layer includes a surface that receives the printable layer when the printable layer contacts the treatable layer). In one particular embodiment, the support layer may comprise Rayofce ^TM C160 film, commercially available from Innovia Films, inc.

The second film is commercially available from AmTopp Inc. of Levenston, N.J., under the product designation TT-common non-heat sealed BOPP film. The film is also a co-extruded film having an oriented polypropylene core, a treatable polypropylene layer on the underside of the laminate, and a high energy treated polypropylene layer on top of the laminate. As with the film embodiments described above, the underside is the layer to be printed.

In another embodiment of the present invention, another film may be sold under the trade name Mitsubishi polyester film company of Gri, nanlon447CRL Clear Non-Silicone RELEASE LINER. The film is coated with a chemical primer on one surface for adhesion release and low coefficient of friction, and on the opposite surface for adhesion promotion.

In other embodiments (such as the embodiment shown in fig. 2A), the carrier layer may have a coating 16, with the coating 16 applied to that surface of the printable layer 20 that will face the label 10. Thus, the carrier layer 14 has two surfaces: (1) A top surface 29 having a sufficiently low surface tension to allow the printable layer 20 to be releasably bonded thereto (as described above, this may be achieved by various treatments of the top surface, such as the use of silicone and/or wax in the embodiment of fig. 2A); and (2) a bottom surface 31 that is treated (as will be described in more detail below) to prevent adhesive 24 from adhering thereto, thereby allowing the completed label web to be wound into a roll (and subsequently unwound during label application) without damaging the labels by adhering the labels to each other and to the web (i.e., blocking).

In more specific embodiments of the carrier described above, the surface of the carrier layer 14 that contacts the printable layer 20 may have a dyne level of less than about 32.

As described above, the pressure sensitive label 10 of various embodiments further includes a printable layer 20, which printable layer 20 may be disposed on the carrier layer 14 and may be in contact with the carrier layer 14. This is in contrast to prior art pressure sensitive labels (as shown in fig. 1) which include a pressure sensitive adhesive layer 5 against a release layer 4 on a carrier layer 3. Referring again to fig. 2 and 2A, the printable layer 20 may be a film layer positioned in facing relationship with the carrier layer, or it may be a material that is printable onto the carrier layer, such as a varnish, and then cured (or cured) to a state that allows printing of ink designs (text, graphics, and all other indicia) thereon. By using a printable layer 20 that may be applied in a softened, melted, thixotropic, liquid, etc., form, the printable layer 20 may be applied in a pattern (e.g., shape, size, outline, etc. of the label to be produced) rather than being provided as a facestock (as in prior art labels) that matches (or substantially matches) the area of the carrier layer. The formulation of the printable layer 20 allows it to receive ink thereon after cooling, curing, uv curing, etc. The ability to apply the printable layer 20 in a pattern also reduces the amount of material required for the label web (and thus reduces costs), eliminates the need for die cutting (and waste of waste die cut material), and can be used to allow the entire label to be built in one location (as opposed to the need to obtain basic pressure sensitive label blanks from a third party supplier).

In certain embodiments, the printable layer 20 may comprise a material formulated from a base resin. In various embodiments, the base resin may be selected from vinyl, acrylic, urethane, epoxy, polyester, and alkyd resins. In addition, the printable layer 20 is solvent-based, water-based, or ultraviolet-based curable. The printable layer 20, including these solvent-based, water-based, and/or ultraviolet-curable chemicals (formulated from base resins), may be formulated as printable liquids at viscosities and rheologies suitable for use in various printing processes, such as screen printing, ink-jet printing, flexographic printing, gravure printing, and lithographic printing. In a particular embodiment, the printable layer may include a non-printable varnish including triacrylate monomers, diacrylate monomers, aromatic urethane acrylates, difunctional acrylates, acrylate oligomers, triethanolamine, and 4-phenylbenzophenone. In more specific embodiments, the printable layer may include a non-printable varnish including about 30% to about 50% triacrylate monomer, about 10% to about 12.5% diacrylate monomer, about 10% to about 12.5% aromatic urethane acrylate, about 10% to about 12.5% difunctional acrylate, about 5% to about 7% acrylate oligomer, about 3% to about 5% triethanolamine, and about 1% to about 2% 4-phenyl benzophenone. Such non-printable varnishes may be provided in liquid form, having a density of about 1.07g/cm ³ (about 8.92lb/gal or about 1070 g/l), having a flash point of greater than about 93 ℃ and a boiling point of about 106 ℃. An example of such a non-printable varnish is commercially available under the product name ProcureTM KCC5185 (and product code 1487893) from INX International Ink co of shamrburg, il. Another such print sensitive coating is JRX-1253, commercially available from Dyna-TECH ADHESIVES AND Coatings Inc. of Gravelton, west Virginia. JRX-1253 is a UV radiation curable printable and metallizable coating suitable for use on plastics such as PET, PE and the like. It can be printed using ultraviolet light, classical solvents and water-based inks. At 100% solids, it is transparent after curing. One of ordinary skill in the art will recognize that other materials having the same or similar characteristics may be used in embodiments of the present invention.

In other aspects, the label 10 may include an ink layer 22, the ink layer 22 being positioned such that the printable layer 20 is located between the carrier layer 14 and the ink layer 22. Also, the label 10 may include an adhesive layer 24, the adhesive layer 24 being positioned such that the ink layer 22 is between the printable layer 20 and the adhesive layer 24. With this configuration, the pressure sensitive label 10 described herein includes the printable layer 20 closest to the carrier 14 and the adhesive layer 24 furthest from the carrier 14 (this is a slightly opposite configuration compared to prior art pressure sensitive labels). With this configuration, the transfer portion 18 (e.g., printable layer 20, ink layer 22, adhesive layer 24) of the pressure sensitive labels described herein does not have to be peeled away from the carrier to expose the adhesive for adhering to the article. Instead, the label 10 is configured such that the adhesive 24 is already the outer layer of the label construction prior to application to the article 26, and thus the adhesive 24 is pre-exposed and ready to contact the article 26, thereby increasing the ease of application to the article 26.

The configuration of the layers in these embodiments of the present label (e.g., as shown in fig. 2 and 2A) also results in the ink being below the printable layer 20 (and thus protected by the printable layer 20) once the transfer portion 18 is transferred to the article 26. This results in the ink layer 22 (indicia, graphics, designs, text, information, etc.) being protected from damage once the label 10 is transferred to the article 26. This protection is achieved without having to add any additional protective lacquer layers (as is sometimes done with prior art pressure sensitive labels). The configuration that allows the printable layer 20 to protect the ink layer 22 after transfer also increases the amount of material that may be used in the ink layer 22, e.g., materials that are easily damaged, such as metallic inks, can be used.

The ink used in the ink layer 22 is used to form various indicia (e.g., text, graphics, etc.) of the label. The indicia may be printed using any printing process including, but not limited to, offset printing, flexographic printing, gravure printing, letterpress printing, digital printing, inkjet printing, and screen printing. Furthermore, combinations of standard printing effects, such as combination printing (combination of gravure printing with flexographic printing in a single printer), the use of cold and hot foil decorations, and pattern embossing, are contemplated by the invention described herein.

In one embodiment, the ink layer 22 may comprise ultraviolet curable ink. In a particular embodiment, the ultraviolet curable ink can include a blend of at least a multifunctional component and a photoinitiator. In particular, the multifunctional component may be a multifunctional acrylate. In one embodiment, the ultraviolet curable ink may include a multifunctional acrylate in an amount greater than 30% based on the total weight of the resin. More specifically, one embodiment of the ultraviolet curable ink may include a multifunctional acrylate in an amount of 65-95% and a photoinitiator blend in an amount of 1-20%. An example of such an ink is FP-500UV process red ink, commercially available from Gotham Ink Corporation of vancomte, ma. Another such ink is commercially available from INX International ink co of shamrburg, il, which uses only polyfunctional components (and thus does not include any monofunctional components) in its ink formulation and is provided under the trade name INXFlex2000 UV HTL. Another ink that may be used is the "ITX Free" ink commercially available from INX International ink co of shamrburg, il.

Another example of an ink that can be used is an ink that includes polyester acrylate, glycerol propoxytriacrylate [ e.g., poly (oxy (methyl-1, 2, -ethanediyl)), α', α "-1,2, 3-propanetri (ω - ((1-oxo-2-propenyl) oxy) -; for example, CAS No. 52408-84-1), hydroxycyclohexylphenyl ketone (CAS No. 947-19-3) and acrylic acid-propane-1, 2-diol monoester (CAS No. 25584-83-2). In one particular embodiment of the ink, the polyester acrylate can be present in an amount of about 1% to about 5%, the glycerol propoxytriacrylate can be present in an amount of about 1% to about 5%, the hydroxycyclohexylphenyl ketone can be present in an amount of about 0.5% to about 1.5%, and the acrylic acid-propane-1, 2-diol monoester can be present in an amount of about 0.1% to about 1%, the ink can have a flash point above about 93.3 ℃, a boiling point/congealing point of about 100 ℃, a density of about 1049g/l (about 8.7539 lbs/gal), and a viscosity of greater than about 2.2cm ²/s (greater than about 220 cSt) [ the ink can be present in an amount of about 0.5% to about 1.5% by weight, such a UV curable ink can be commercially available from 32 UV light LEDs 34, of the state.

In another embodiment, the ink may be a solvent-based ink, and may include ethanol, propylene glycol methyl ether, propyl acetate, isopropyl alcohol, and aluminum flakes. In one particular embodiment, the solvent-based ink may include from about 25% to about 35% ethanol, from about 20% to about 25% propylene glycol methyl ether, from about 15% to about 20% propyl acetate, from about 15% to about 20% isopropyl alcohol, and from about 3% to about 5% aluminum flakes. The ink has a density of about 0.888g/cm ³, a flash point of greater than about 23 ℃ and a boiling point of about 78.5 ℃ to about 119.9 ℃. One such ink is commercially available from INX International ink co of schlenz, il under the name "plain Plus F124 Metallic" and product code 1489010.

Other inks that may be used include digital inks such as those commercially available from Indigo Ink of columbia, maryland. However, one of ordinary skill in the art will recognize that the above-described inks are not the only inks that can be used.

Various embodiments of the pressure sensitive label 10 (such as the embodiments shown in fig. 2 and 2A) further include a pressure sensitive adhesive 24. In various embodiments of the present invention, the adhesive chemistry for the pressure sensitive adhesive 24 may include any formulation capable of being applied in a pattern that is the same as or similar to the contour, size, and shape of the printable layer 20 applied to the carrier 14.

Pressure sensitive adhesives are well known to mean adhesives that form a bond when pressure is applied to bond the adhesive to an adherend. In this case, no solvent, water or heat is required to activate the adhesive. As the name suggests, the degree of adhesion is affected by the amount of pressure applied to the surface by the adhesive. In addition, the pressure sensitive adhesive is manufactured with a liquid carrier or 100% solids form. Articles such as labels are made from liquid pressure sensitive adhesives by applying the adhesive to a support and then evaporating the organic solvent or water carrier, typically in a hot air dryer. The dry adhesive may be further heated to initiate the crosslinking reaction and increase the molecular weight. The 100% solids pressure sensitive adhesive may be a low viscosity polymer that is coated and then reacted with radiation to increase molecular weight and form an adhesive (radiation cured pressure sensitive adhesive); or they may be high viscosity materials that are heated to reduce the viscosity sufficiently to allow coating, and then cooled to their final form (hot melt pressure sensitive adhesive).

The pressure sensitive adhesive used may be consistent with typical gravure printing, but is modified to allow printing using flexographic printing techniques. The formulation for such solvent adhesives may be uv curable. In a specific embodiment of the present invention, one particular adhesive may be a high tack pressure sensitive adhesive suitable for flexographic printing and having a viscosity of 1500-2000 cPs. Such binders may include from about 37.5% to about 80% acrylate and from about 2.5% to about 10% photoinitiator (and additional materials to make up the remainder of the formulation). The adhesive provided according to the formulation may have a flash point of about 94 ℃ and a specific gravity of about 1.06g/cm ³ (about 8.85 lbs/gal) at 20 ℃. One such adhesive is commercially available from CRAIG ADHESIVES & Coatings, new jersey under the product designation Craigbond 1029BTJ UV High Tack PSA.

In one embodiment of the present invention, another such adhesive may have a formulation that includes at least nonylphenol ethoxylated acrylate (CAS No. 50974-47-5) and ethoxyethoxyethyl acrylate (CAS No. 7328-17-8), among other materials. The binder may also include 2-hydroxy-2-methyl-1-phenyl-1-propanone. One such adhesive is commercially available from CRAIG ADHESIVES & Coatings of Newark of new valance, new jersey under the product name Craigcote 1029J.

Another adhesive useful in various embodiments of the present invention includes self-crosslinking acrylic polymers that cure after removal of the solvent. Such binders may be about 53% to about 56% non-volatile and have a Brookfield viscosity at 77°f of about 3500 to about 6000. The solvent of the binder may be ethyl acetate/heptane with a solvent ratio of 83/17. The adhesive may have a density of about 7.7 to about 8.1lbs/gal (about 0.92 to about 0.98gm/cm ³) and a flash point of less than about 20°f. An example of such an adhesive is commercially available from Ashland Performance Materials of Dublin, ohio under the trade designation AROSET ^TM PS-6416.

Another adhesive that may be used in various embodiments of the present invention includes hot melt pressure sensitive adhesives. The adhesive was 100% solids, had a viscosity of about 66500 at 300 degrees Fahrenheit, a Mettler softening point of about 250 degrees Fahrenheit, and a density of about 7.8lbs/gal. Such adhesives may also include piperidine copolymers and modified terpene resins. In a specific embodiment, the adhesive may include about 10% to about 30% of the piperidine copolymer and about 10% to about 30% of the modified terpene resin. The adhesive may have a boiling point greater than about 260 ℃, a melting point of about 110 ℃, a specific gravity of about 0.98, and a flash point greater than about 260 ℃ (by the cleveland open cup method). Examples of such adhesives are commercially available from Henkel Corporation of Rogower, connecticut under the trade nameProduct number ofPS 9197。

However, one of ordinary skill in the art will recognize that these are not the only adhesives that may be used. For example, other uv curable adhesives may be used. Ultraviolet (UV) light curable adhesives, also known as Light Curable Materials (LCM), are popular in the manufacturing industry due to their fast cure times and strong adhesive strength. The photo-curable adhesive can cure in one second and many formulations can bond different substrates (materials) and withstand severe temperatures. Unlike conventional adhesives, ultraviolet curing adhesives not only adhere materials together, they can also be used to seal and coat products.

In this embodiment of the pressure sensitive label 10, the adhesive layer 24 is uv cured after the printing step. In this way, the label 10 can be wound into a roll without blocking (due to tackiness). During the decoration step, heat (or heat and pressure) is applied and the adhesive becomes soft, fluid and tacky before being applied to the point where the label 10 is adhered to the substrate.

One such uv cured heat activated adhesive is HS30, commercially available from Actega Radcure, inc. According to MSDS, HS30 is used as UV/EB curable adhesives, primers and coatings. Another such heat activated UV curable adhesive is FP-500NUV85 from Gotham Ink Corporation of Wanbao, mass. FP-500NUV85 is a proprietary hybrid material. However, one of ordinary skill in the art will recognize that these are not the only uv curable adhesives that may be used, and that other uv curable adhesives that provide similar characteristics may be used.

In another aspect, the pressure sensitive label 10 as shown in the embodiment of fig. 2 and 2A may further include a release layer 27, the release layer 27 being positioned such that the carrier layer 14 is between the printable layer 20 and the release layer 27. In other words, the release layer 27 is not on the side of the carrier 14 adjacent to the transfer portion 18 of the label 10, but on the underside of the carrier 14. The release layer 27 allows the web of labels 10 to be wound onto a roll, for example, while preventing blocking (i.e., the problem of adhesive on the labels adhering to the underside of the carrier when the label web is wound onto a roll). The presence and positioning of this release layer 27 thus allows the label web to be wound into a roll after printing the labels 10. In particular, the patterned printable layer 20 is bonded to the top surface of the continuous web of carrier layer 14 more than to the release layer 27 on the bottom side of carrier layer 14. Thus, when the roll is unwound, the label 10 is positioned with the adhesive facing upward to allow for easy application to the marked article 26.

In a particular embodiment of the invention, one particular release formulation for the release layer may comprise an ultraviolet curable release material, and in one embodiment such material may be a cationic release coating. Such release formulations may include dimethicone and silicone (CAS number 67762-95-2). One example of such a material is commercially available from CRAIG ADHESIVES AND Coatings, new jersey, under the trade name Craigcoat UV9300, and the product code UV9300. In one embodiment of the present invention, the release material may include a photocatalyst material used in combination therewith. In one embodiment, such photocatalyst materials may include 2-isopropylthioxane, C12 and C14 alkyl glycidyl ethers, bis (4-dodecylphenyl) iodonium hexafluoroantimonate, and linear alkylated dodecylbenzenes. More specifically, an embodiment may include from about 1% to about 5% 2-isopropylthioxane, from about 30% to about 60% C12 and C14 alkyl glycidyl ethers, from about 30% to about 60% bis (4-dodecylphenyl) iodonium hexafluoroantimonate, and from about 5% to about 10% linear alkylated dodecylbenzenes. One example of such a photocatalyst material is commercially available under the trade name UV9390C from CRAIG ADHESIVES AND Coatings of new vac, new jersey.

As described above, and with reference to fig. 3 and 3A, another aspect of the present invention provides a pressure sensitive label comprising: (a) at least a support portion comprising a carrier layer; and (b) a transfer portion comprising at least a printable layer in facing relationship with the carrier layer. In the label of this aspect, the ink layer may be present between the printable layer and the carrier layer. Depending on the nature of the ink layer, at least a portion or portions of the printable layer may contact the carrier layer (i.e., in any areas of the ink where the ink layer is not present). In general, the transfer portion may overlie the support portion to transfer the transfer portion from the support portion to the article when pressure is applied to the transfer portion while the transfer portion is in contact with the article. In one embodiment, the carrier layer does not include any release layer on the side of the carrier layer facing the printable layer. This eliminates the layers of the prior art labels, thereby reducing the cost of the labels. In this configuration, the pressure sensitive label of this aspect includes an ink layer closest to the carrier and an adhesive layer furthest from the carrier. With this configuration, the transfer portion (e.g., ink layer, printable layer, adhesive layer) of the pressure sensitive label described in this aspect does not have to be peeled off of the carrier to expose the adhesive for adhering to the article. Instead, the label is configured such that the adhesive is already the outer layer of the label construction prior to application to the article, so the adhesive is pre-exposed and ready to contact the article, thereby increasing the ease of application to the article.

Referring now to fig. 3, a particular embodiment of such a pressure sensitive label 10 is shown. As shown in fig. 3, the pressure sensitive label 10 of the illustrated embodiment is a multi-layer construction, each layer having its own function. Other embodiments also have a multi-layer construction. The embodiment of the label shown in fig. 3 does include the general support portion 12 and transfer portion 18 described above. The support portion 12 of each embodiment includes a carrier layer 14, which carrier layer 14 may have a release coating 16 (e.g., a wax or silicone coating) on one side thereof (as can be seen in the embodiment shown in fig. 3A). In an alternative embodiment, the carrier 14 may be free of a release coating (on the ink layer facing carrier-see the embodiment of fig. 3), but may be treated in other ways, for example by corona treatment. In other embodiments, the carrier 14 may be untreated and have no release coating. The transfer portion 18 of each embodiment is positioned adjacent to and in facing relationship with the carrier 14 prior to transfer from the carrier 14. The transfer portion 18 of this embodiment includes at least (1) a printable layer 20 in facing relationship with the carrier 14. This facing relationship does not require contact between the two layers (although contact is possible). These layers need only be close and adjacent to each other. Transfer portion 18 may also include an ink layer 22 and an adhesive layer 24. The ink layer 22 may be positioned such that it is between the carrier layer 14 and the printable layer 20. Also, the adhesive layer 24 may be positioned such that the printable layer 22 is between the ink layer 22 and the adhesive layer 24. Additional layers may be included within transfer portion 18.

Still referring to fig. 3, the illustrated embodiment includes a carrier layer 14, an ink layer 22, a printable layer 20, a pressure sensitive adhesive layer 24, and a backside release layer 27. As can be seen in fig. 3, the release layer 27 is positioned such that the carrier layer 14 is located between the ink layer 22 and the release layer 27. As will be described in further detail below (in a more detailed discussion of the various layers of the label 10), the backside release layer 27 prevents blocking, for example, when the label web is wound on a roll.

As described above, various pressure sensitive label embodiments in accordance with the principles of the present invention include a carrier layer 14. The carrier layer 14 used in some embodiments (as well as the embodiment shown in fig. 3) is constructed of a material that allows the transfer portion 18 of the label 10 to be separated from the carrier layer 14 without the need for a separate release layer (e.g., a release layer as in the prior art). This allows for a reduction in the materials and costs used in the present pressure sensitive labels. Thus, in embodiments of the present invention, the carrier layer 14 is constructed of or comprises a material having a surface tension that allows the printable layer 20 to be releasably bonded to the carrier layer. Also, in more specific embodiments of the invention, the surface of the carrier layer 14 that contacts the printable layer 20 may have a dyne level of less than about 32.

In other embodiments (e.g., the embodiment shown in fig. 3A), the carrier layer may have a coating 16, with the coating 16 applied to the surface of the ink layer 22 that will face the label 10. Thus, the carrier layer 14 has two surfaces: (1) A top surface 29 having a surface tension low enough to allow the ink layer 22 to be releasably bonded thereto (as described above, this may be accomplished by various treatments of the top surface, such as with silicone and/or wax in the embodiment of fig. 3A); and (2) a bottom surface 31 that is treated (as will be described in more detail below) to prevent adhesive 24 from adhering thereto, thereby allowing the completed label web to be wound into a roll (and subsequently unwound during label application) without damaging the labels by adhering the labels to each other and to the web (i.e., blocking).

Once the label is applied to the article, the printable layer 20 (in the embodiment of fig. 3 and 3A) will be located behind the ink or inks of the ink layer 22. Printable layer 20 is a thin film layer that provides a mass and volume to the label. In addition, the printable label may include pigments in its formulation that provide a degree of opacity (i.e., background) in any label information, text, graphics, etc. provided by the ink layer. Such opacity may be provided in any desired color. Alternatively, the printable layer may be transparent. The use of pigments to provide a degree of background coloration is well known to those of ordinary skill in the art.

The layers of the embodiments of fig. 3 and 3A of the present invention (carrier 14, ink layer 22, printable layer 20, adhesive layer 24, backside release layer 27, etc.) may comprise a variety of materials, including those described above with respect to the embodiments of fig. 2 and 2A.

As described above, various embodiments of the tag may include other layers. One such layer may be a protective layer that may be used to protect the ink layer from abrasion after the label is transferred to the article (e.g., the version shown in fig. 3 and 3A, where the ink layer would be the externally exposed layer of the label after transfer). Such an embodiment comprising a protective layer 33 is shown in fig. 4 and 4A. The transfer portion 18 of this embodiment includes at least (1) a printable layer 20 in facing relationship with the carrier 14. This facing relationship does not require contact between the two layers (although contact is possible). These layers need only be close and adjacent to each other. Transfer portion 18 may also include an ink layer 22 and an adhesive layer 24. The ink layer 22 may be positioned such that it is between the protective layer 33 and the printable layer 20. Also, the adhesive layer 24 may be positioned such that the printable layer 22 is between the ink layer 22 and the adhesive layer 24. Also, the protective layer 33 may be positioned such that it is between the carrier 14 and the ink layer 22. (the embodiment shown in fig. 4A has a similar structure, although it includes a separate release layer 16 on one side of the carrier 14).

Still referring to fig. 4, the illustrated embodiment includes a carrier layer 14, a protective layer 33, an ink layer 22, a printable layer 20, a pressure sensitive adhesive layer 24, and a backside release layer 27. As can be seen in fig. 3, the release layer 27 is positioned such that the carrier layer 14 is located between the protective layer 33 and the release layer 27. For example, the backside release layer 27 prevents blocking when the label web is wound on a roll (as described above with respect to the embodiments of fig. 2 and 3).

The protective layer 33 may be of various types including, but not limited to, uv-curable or uv-curable overprint varnishes. However, the protective layer may be of other types (e.g., solvent gravure HTL protective layer).

In one example, then, the protective layer 33 may be a coating of ultraviolet curable chemicals, wherein the formulation has been modified with additives that will increase scratch resistance and/or chemical resistance. Such coatings can have high gloss, chemical resistance, good uv reactivity, absence of benzophenone and bisphenol a, and non-yellowing properties. One particular coating of the protective layer may have a film weight of 0.40 to 0.70lbs/1000 square feet using an anilox roll of 180 to 250lpi, 60 to 90 hundred million cubic micrometers (bcm) per square inch; viscosity 160 centipoise (cps), 100 revolutions per minute (rpm) at 77°f (25 ℃) using a Brookfield RV, #3 spindle; can be cured at 150-250 feet per minute (fpm) per 400 watts per inch (wpi) lamp; may appear as a translucent liquid; may have a gloss of >90 at an angle of 60 ° (on the black part of Leneta N2A-3); the use of 200 grams of superluminescent light emitting diodes (slots) can have a measured static CoF of less than 0.30 and a dynamic CoF between 0.15-0.21; and solvent resistance that can have >50 Methyl Ethyl Ketone (MEK) double rubs (one of ordinary skill in the art will recognize that properties such as gloss CoF and solvent resistance will depend on coating film thickness, degree of cure, and substrate type). One specific example of such a coating for the protective layer isHG (high gloss) TL 4098 coating (commercially available from Sun Chemical, pa. Ni. N.J. under product number RCYFV 0484098). Such coatings may be applied using a flexographic, tower or roll coater.

While the above embodiments (fig. 4 and 4A) describe the protective layer 33 separate from the ink layer, alternative embodiments may include a protective layer in combination with providing an ink layer pattern. This may be accomplished by coloring the protective layer to the desired ink color or colors (and configuring the various desired graphics, text, etc. of the label).

As described above, and referring now to fig. 13 and 13A, another aspect of the present invention provides a pressure sensitive label comprising: (a) at least a support portion comprising a carrier layer; and (b) a transfer portion comprising at least a printable layer in facing relationship with the carrier layer. In general, the transfer portion may overlie the support portion to transfer the transfer portion from the support portion to the article when pressure is applied to the transfer portion while the transfer portion is in contact with the article.

Referring now to fig. 13, one embodiment of such a pressure sensitive label 10 is shown. As shown in fig. 13, the pressure sensitive label 10 of the illustrated embodiment is a multi-layer construction, each layer having its own function. Other embodiments also have a multi-layer construction. In general, the label includes a "support portion" 12 (e.g., carrier layer 14) and a "transfer portion" 18 (e.g., at least a printable layer 20-although various embodiments may also include, for example, an ink layer 22, a second printable layer 20a, and an adhesive layer 24). When subjected to pressure, as will be described in more detail below, the transfer portion 18 may be separated from the carrier 14 to adhere to an article. This occurs when the label 10 is placed in facing relation with the article 26 and pressure is applied so that the transfer portion 18 is in direct contact with the outer surface 28 of the article 26 (the article 26 may be seen in fig. 7 and 8). After transfer portion 18 is in contact with article 26, carrier sheet 14 is removed, leaving transfer portion 18 adhered to article 26 via adhesive layer 24 of transfer portion 18.

The support portion 12 of fig. 13 includes a carrier layer 14, one side of which carrier layer 14 may have a release coating 16 (e.g., a wax or silicone coating) (as can be seen in the embodiment shown in fig. 13A). In alternative embodiments, the carrier 14 may not have a release coating, but may be otherwise treated, such as by corona treatment. In other embodiments, the carrier 14 may be untreated and have no release coating. The transfer portion 18 of each embodiment is positioned adjacent to and in facing relationship with the carrier 14 prior to transfer from the carrier 14. The transfer portion 18 of fig. 13 and 13A includes at least (1) a printable layer 20 in facing relationship with the carrier 14. This facing relationship does not require contact between the two layers (although contact is possible). Although there may be a layer or coating between the carrier 14 and the printable layer 20, these layers need only be adjacent and proximate to each other-for example, as shown in fig. 13A. Transfer portion 18 may also include an ink layer 22, a second printable layer 20a, and an adhesive layer 24. In the embodiment shown in fig. 13 and 13A, the ink layer 22 may be positioned such that the printable layer 20 is between the carrier layer 14 and the ink layer 22. Also, in these embodiments, the second printable layer 20a may be positioned such that the ink layer 22 is between the printable layer 20 and the second printable layer 20 a. Also, the adhesive layer 24 may be positioned such that the second printable layer 20a is located between the ink layer 22 and the adhesive layer 24. Additional layers may be included within transfer portion 18.

Still referring to fig. 13, the illustrated embodiment includes a carrier layer 14, a printable layer 20, an ink layer 22, a second printable layer 20a, a pressure sensitive adhesive layer 24, and a backside release layer 27. As can be seen in fig. 13, the release layer 27 is positioned such that the carrier layer 14 is located between the printable layer 20 and the release layer 27. As will be described in further detail below (in a more detailed discussion of the various layers of the label 10), the backside release layer 27 prevents blocking, for example, when the label web is wound on a roll.

In other embodiments (such as the embodiment shown in fig. 13A), the carrier layer may have a coating 16 applied to the surface of the printable layer 20 that will face the label 10. Thus, the carrier layer 14 has two surfaces: (1) A top surface 29 having a sufficiently low surface tension to allow the printable layer 20 to be releasably bonded thereto (as described above, this may be achieved by various treatments of the top surface, such as silicone and/or wax in the embodiment of fig. 13A); and (2) a bottom surface 31 that is treated (as will be described in more detail below) to prevent adhesive 24 from adhering thereto, thereby allowing the completed label web to be wound into a roll (and subsequently unwound during label application) without damaging the labels by adhering the labels to each other and to the web (i.e., blocking).

In other aspects, the label 10 may include an ink layer 22, the ink layer 22 being positioned such that the printable layer 20 is located between the carrier layer 14 and the ink layer 22. Also, the second printable layer 20a may be positioned such that the ink layer 22 is located between the printable layer 20 and the second printable layer 20 a. Also, the adhesive layer 24 may be positioned such that the second printable layer 20a is located between the ink layer 22 and the adhesive layer 24. With this configuration, the pressure sensitive label 10 described herein includes the printable layer 20 closest to the carrier 14 and the adhesive layer 24 furthest from the carrier 14 (this is a slightly opposite configuration compared to prior art pressure sensitive labels). With this configuration, the transfer portion 18 (e.g., printable layer 20, ink layer 22, second printable layer 20a, adhesive layer 24) of the pressure sensitive labels described herein does not have to be peeled away from the carrier to expose the adhesive that adheres to the article. Instead, the label 10 is configured such that the adhesive 24 is already the outer layer of the label construction prior to application to the article 26, and thus the adhesive 24 is pre-exposed and ready to contact the article 26, thereby increasing the ease of application to the article 26.

The configuration of the layers (e.g., the layers shown in fig. 13 and 13A) in these embodiments of the present label also results in the ink being below (and thus protected by) the printable layer 20 once the transfer portion 18 is transferred to the article 26. This results in the ink layer 22 (indicia, graphics, designs, text, information, etc.) being protected from damage once the label 10 is transferred to the article 26. This protection is achieved without having to add any additional protective lacquer layers (as is sometimes done with prior art pressure sensitive labels). The configuration that allows the printable layer 20 to protect the ink layer 22 after transfer also increases the amount of material that can be used in the ink layer 22, e.g., materials that are easily damaged, such as metallic inks, can be used.

In another aspect, the pressure sensitive label 10 as shown in the embodiment of fig. 13 and 13A may further include a release layer 27, the release layer 27 being positioned such that the carrier layer 14 is between the printable layer 20 and the release layer 27. In other words, the release layer 27 is not on the side of the carrier 14 adjacent to the transfer portion 18 of the label 10, but on the underside of the carrier 14. The release layer 27 allows the web of labels 10 to be wound onto a roll, for example, while preventing blocking (i.e., the problem of adhesive on the labels adhering to the underside of the carrier when the label web is wound onto the roll). The presence and positioning of this release layer 27 thus allows the label web to be wound into a roll after printing the labels 10. In particular, the patterned printable layer 20 is bonded to the top surface of the continuous web of carrier layer 14 more than to the release layer 27 on the bottom side of carrier layer 14. Thus, when the roll is unwound, the label 10 is positioned with the adhesive facing upward to allow for easy application to the marked article 26.

The layers of the embodiment of fig. 13 and 13A of the present invention (carrier 14, ink layer 22, printable layers 20 and 20a, adhesive layer 24, backside release layer 27, etc.) may comprise a variety of materials, including those described above with respect to the embodiment of fig. 2 and 2A.

As described above, another aspect of the invention may include one or more methods for preparing a pressure sensitive label. And yet another aspect of the invention may include one or more methods for applying a pressure sensitive label to an article. Referring now to fig. 5, the pressure sensitive label 10 of the embodiment shown in fig. 2 may be prepared as follows: the printable layer 20 may be laid down on the carrier layer 14 by a first roller/cylinder 34, for example, then the ink layer 22 is laid down on the printable layer 20 by a second roller/cylinder 36, and then the adhesive layer 24 is laid down on the ink layer 22 by a third roller/cylinder 38, forming a label 10 having these separate and distinct layers. During laying of the printable layer 20, ink layer 22 and adhesive layer 24, the release layer 27 may also be applied to the side of the carrier layer opposite the transferred portion of the label by a fourth roller/drum 40. In embodiments where one or more of these layers (printable, ink, adhesive, release agent) are uv curable, they may be exposed to uv radiation provided by uv light, which cures the various uv curable layers. Such uv curing may be performed while each individual uv curable layer is laid down, or may be performed after all uv curable layers are laid down. (furthermore, although FIG. 5 is shown and described as laying down the printable layer first and then the ink layer, one skilled in the art will recognize that for embodiments of labels having different layer sequences, such as the labels shown in FIGS. 3 and 3A, the layers may be laid down in a different order than shown in FIG. 5, such as laying down the ink layer and then the printable layer).

In addition, any ultraviolet curable composition may be applied using flexographic printing techniques. The uv component does not present the problem of "swelling" when used in flexographic printing (unlike some typical gravure solvent components). Flexographic printing is a well known process to those of ordinary skill in the art. Typically, in flexographic printing processes (for uv curable inks), a flexographic plate (not shown) includes image areas raised above non-image areas. Components such as ink are transferred from an ink roller (not shown) partially submerged in the ink tank to a second roller (not shown) whose texture holds a specific amount of ink. Then, a doctor blade (not shown) removes excess ink from the second roller before inking the flexographic plate. The substrate is then positioned between a plate and an impression cylinder (not shown) to transfer the image. Although the panels are described as having "image areas," the "image" of these areas may be designed to provide a covering of protective paint layer on the substrate.

By using flexographic printing techniques on the various layers of the label 10, this aspect of the invention provides cost savings over pressure sensitive labels 10 (or labels 10 comprising ultraviolet curable layers) previously manufactured using gravure printing techniques. This is because gravure printing techniques are expensive, especially compared to printing techniques such as flexographic printing. By eliminating intaglio printing of the layers of the pressure sensitive label 10, particularly those comprising the most complex design, i.e. the ink layer 22, significant cost savings can be achieved since there is no need to provide a plurality of different etched intaglio cylinders for different production runs.

However, the layers of the label 10 are not limited to flexographic printing techniques and may be applied using other techniques, including gravure printing techniques. In gravure printing techniques (which are also well known to those of ordinary skill in the art), a printing plate (not shown) is cylindrical and includes perforations etched or engraved to different depths and/or sizes to provide one or more images. Components such as protective paint or adhesive are applied directly to the cylinder by rotating in a bath (not shown) in which each cell of the image is filled with paint or adhesive. A doctor blade (not shown) wipes off excess paint or adhesive and capillary action of the substrate and pressure from an embossing roll (not shown) pulls the paint or adhesive from the perforations and transfers it to the substrate.

Thus, the apparatus (not shown) for intaglio printing layers comprises an intaglio printing unit (not shown) for a rotary printing press with an intaglio sleeve (not shown) supplied with lacquer or adhesive from an intaglio tray (not shown) and an embossing roller (not shown) in facing relationship with the intaglio sleeve to form a roller gap (not shown) between them. As the rotary printer operates, a carrier (e.g., a sheet) to be printed is passed through the roller gap, absorbing paint or adhesive from the outer peripheral surface of the gravure sleeve. At the same time, the intaglio sleeve rotates in a specific direction opposite to the embossing roller and its rotational movement consists of a guiding rotational sector from the printing unit to the roller gap and a following rotational sector from the roller gap to the printing unit. Devices and techniques for gravure and flexographic printing are common and well known to those of ordinary skill in the art.

In addition, as described above, certain layers of the label (e.g., printable layer 20, ink layer 22, and adhesive layer 24) may be laid down or printed in a particular pattern corresponding to the size, shape, and/or contour of the desired final label image. This also results in solving the problems of the prior art (which results in the use of excessive material, thereby increasing the cost of the label). Because the ink design is printed on only a portion of the basic construction purchased from a third party (in the prior art), this requires that the facestock on which the ink is printed be a film that spans the entire carrier (die cut later). It also requires flood coating of the adhesive (which in the prior art is part of the basic construction) onto the carrier (as this is done prior to the sale of the basic construction). In other words, since the carrier vendor does not know in advance what ink designs the label manufacturer will apply, they flood the entire carrier with adhesive and cover the entire carrier with facestock to allow for any size, shape, configuration, and registration of the ink designs. The use of such large amounts of dough and flood adhesive results in large amounts of unused adhesive and dough, resulting in excess adhesive and dough, and excess dough that must be die cut and discarded. The use of such excess adhesive and facestock increases the cost of prior art labels because the excess facestock and adhesive increase the cost of the carrier and thus the cost of the label preparation and the label itself.

However, the design of the present pressure sensitive label 10 allows for printing of the printable layer 20 as well as the patterned ink layer 22 and adhesive 24 to be applied in a pattern. This is due in part to the fact that the construction of the label is somewhat out of order with previous pressure sensitive labels. In other words, the prior art labels have adhesive disposed on a carrier release, a facestock on top of the adhesive, and ink on top of the facestock. In the label of the application, a printable layer may be applied to the location of the indicia with ink on top of the printable layer and adhesive on top thereof. Since this happens at the labeling location, the entity that provides and creates the label will know what the design of the label is when the label is printed. Thus, rather than providing a facestock in the same area as the carrier, the present application does not use facestock. Instead, the typical facestock of prior art pressure sensitive labels is eliminated and instead a printable layer (e.g., non-printable varnish) may be placed on the carrier. This allows the printable layer to be printed into the shape of the final label design-this allows the label to be created without the need to die cut any additional blanks. In one embodiment, the printable layer may be applied using a 30bcm anilox roller.

In the same way, this also allows the adhesive to be printed onto the ink design in the shape of the ink design (i.e., with the same or similar outer contour as the ink design) to avoid the waste of excess adhesive created in the prior art via flood coating. In one embodiment, an 8bcm anilox roller may be used to apply the ink layer. In one embodiment, a 4.5bcm anilox roller may be used to apply the adhesive layer. In another embodiment, an anilox roll of 8bcm may be used to apply the adhesive layer.

For example, then, another aspect of the invention provides a method of applying the printable layer 20, the ink layer 22, and/or the adhesive layer 24 to a carrier, wherein the printable layer 20, the ink layer 22, and/or the adhesive layer 24 cover substantially less than the entire surface of the first side of the carrier. Thus, printable layer 20, ink layer 22, and/or adhesive layer 24 may be applied in a patterned form and/or may be applied to match any size, shape, configuration, or registration desired for the label. More specifically, the process may include contacting the material of printable layer 20, ink layer 22, and/or adhesive layer 24 with a surface having at least one etched area thereon, and facing carrier 14, for example, with the surface such that at least a portion of printable layer 20 is transferred from the surface to carrier 14. The transferred printable layer may in particular be received by and transferred from the etched areas of the surface. Thus, the process may include (a) softening the material for the printable layer 20 (e.g., by melting the formulation), (b) contacting the softened printable layer and/or adhesive formulation with a gravure sleeve having at least one etched portion, wherein the formulation is adsorbed onto the surface of the gravure sleeve, (c) removing excess printable layer from the surface of the gravure sleeve such that the printable layer formulation is adsorbed only to the etched portion of the gravure sleeve, and (d) contacting the gravure sleeve with the carrier to deposit the printable layer and/or adhesive formulation onto the carrier, thereby forming the printable layer 20 on a portion of the carrier 14. The ink layer 22 may then be printed onto the printable layer, and the adhesive layer may then be printed onto the ink layer to form a label having a support portion and a transfer portion. The transfer portion of the label may then be transferred to the article.

In use, and referring now to fig. 7 and 8, a label 10 according to the principles of the present invention is applied to an article 26, as follows. In the illustrated embodiment, the labels 10 are carried on a web that has been wound into a roll 42. The transfer portion 18 of the label 10 may be released from the support portion 12 (e.g., carrier 14) and the web travels from the feed reel 44 to the take-up roller 46. After unwinding from the rotating feed reel 44, the label web will typically pass over the proximal end of the marked article 26. Those skilled in the art will recognize that the various rollers listed above are merely exemplary and are not required for the principles of the present invention. Upon reaching access to the article 26 (see 48 of fig. 7), contact occurs between the adhesive layer 24 of the transfer portion 18 of the label 10 and the surface of the article 26. At this point, pressure may be applied to adhere the adhesive layer 24 of the label 10 to the surface of the article (by methods and apparatus generally known to those of ordinary skill in the art). Such pressure facilitates adhesion of the transfer portion of the label 10 to the article 26. After application of transfer portion 18 to article 26, the bond between adhesive layer 24 and the article is stronger than the releasable bond between printable layer 20 and carrier 14 (or printable layer 20 and release agent composition 16-or ink layer 22 and carrier 14). This causes transfer portion 18 to peel away from support portion 12 as the label web and article continue to move. The now empty carrier web (i.e., the support portion 12) may proceed to the take-up spool 46 where the carrier web may be recovered (or discarded). Those skilled in the art will recognize that the particular number, type and configuration of components described above are merely illustrative. After the web has moved past the marking point, the article 26 (as shown in fig. 8) now includes the transfer portion 18 of the label adhered thereto.

The application of the label of the present application may be performed with the label wrapped around the article in the same or similar manner as the heat transfer label, which eliminates the opportunity for wrinkling and blistering, thereby reducing and/or eliminating one of the problems with prior art pressure sensitive labels.

As described above, in various embodiments of the present invention, one or more layers of the label 10 may be applied as a pattern (e.g., shape, size, contour, etc. of the label to be produced) rather than providing a layer matching the carrier layer as a facestock (as in the prior art). Accordingly, and referring now to FIG. 9, an alternative embodiment is shown that includes an adhesive layer 24 applied in a pattern. In such embodiments, the adhesive chemistry for the pressure sensitive adhesive 24 may include any formulation capable of being applied in a desired pattern. While some of the embodiments described above are described as having the adhesive layer 24 as the outer layer of the label (i.e., away from the carrier 14), the embodiment of fig. 9 shows the adhesive layer 24 adjacent to the carrier 14. While this differs from the previous embodiment, it also solves some of the problems seen in the prior art (heretofore unsolved), such as the need for folding the coating adhesive when providing separate label facestock (as described in the background of the invention). This embodiment eliminates this excess adhesive.

Thus, referring to FIG. 9, one aspect of the present invention provides a label 10, and a method of applying a layer (e.g., adhesive layer 24) to a carrier 14, wherein the adhesive layer 24 covers substantially less than the entire surface of one side of the carrier 14. As previously mentioned, the carrier 14 may generally be paper, film or other material having a first side 29 to which other label elements may be applied and a second side 31 opposite the first side 29. Thus, the adhesive layer 24 may be applied to the first side 29 of the carrier 14 as a patterned form, and/or may be applied to match any size, shape, configuration, or registration of other layers of the ink design or label with respect to the carrier 14. In the illustrated embodiment, the carrier may be designed to facilitate release of the adhesive layer from the carrier 14 when the adhesive layer contacts the carrier 14. Thus, in such embodiments, the carrier 14 may be a silicone release liner [ i.e., the top surface of the carrier 14 (the continuous web of substrate) may have a silicone release coating that creates a releasable bond ]. The adhesive layer 14 may be applied thereto using any conventional printing process including rotary screen, flexographic printing, ink jet, and the like.

Still referring to fig. 9, additional layers may be added near the adhesive layer. As shown in the illustrated embodiment, the ink layer 22 is applied to the adhesive layer 24 such that the adhesive layer 24 is positioned between the ink layer 22 and the carrier 14. As shown in fig. 9, the ink layer 22 may be patterned to match the pattern of the adhesive layer 24. The ink layer 22 (like the adhesive layer 24) may be applied using any conventional printing process, including rotary screen printing, flexographic printing, ink jet, and the like. Although not shown in fig. 9, one of ordinary skill in the art will recognize that the label may include other layers (as previously described) in addition to or in addition to the adhesive layer 24 and the ink layer 22, and such other layers may also be patterned.

The carrier 14 may be formed from a variety of materials, and the following is a non-limiting list of materials for the various embodiments of the carrier 14: virgin polypropylene films (e.g., PSPL 10264), silicone coated paper liners, silicone coated polyester films (e.g., 2slkn 1.2 sil silicone coated polyester films commercially available from Mitsubishi), polyester films (e.g., 447CRL series 92 polyester films commercially available from Mitsubishi, or 39RL series 200 polyester films commercially available from Mitsuishi), and biaxially oriented polypropylene films (e.g., BRT35T BOPP films commercially available from intelplast). For configurations where the adhesive layer 24 is positioned adjacent to the carrier 14 (as shown in fig. 9), a silicone coated film may be used as the carrier to facilitate separation of the adhesive layer 24 from the carrier 14. For constructions having an adhesive layer 24 remote from the carrier 14 (e.g., fig. 2, 2A, 3A, 4 and 4A), polypropylene or polyester films (such polypropylene and polyester films and other possible films have been described above with respect to other embodiments of the label 10) may be used.

Various adhesive materials and various ink materials may be used for adhesive layer 24 and ink layer 22, and the following is a non-limiting list of adhesive and ink materials: SIEGWERK SF RS Opaque White MP A08 (commercially available from SIEGWWERK USA, inc.), siegwerk EXP Linerless OPV (commercially available from SIEGWWERK USA, inc.), SIEGWERK RSDC SF Extender A02 (commercially available from SIEGWWERK USA, inc.), 1249385INXFlex UV Ink Warm Red (commercially available from INX International), novamet Gravure SILVER INK 2155 (commercially available from Novamet), and 1029FST UV High Tack PSA 5G401R (commercially available from CRAIG ADHESIVES & Coatings).

One particular embodiment includes a Siegwerk white ink with 22 wires and an adhesive (1029FST UV High Tack PSA 5G401R) with 2.5 wires. Another embodiment includes Siegwerk EXP Linerless OPV and Mitsubishi 2slkn 1.2 sil silicone coated polyester films. Another embodiment includes Siegwerk EXP Linerless OPV and virgin polypropylene films PSPL20164. Different wires and manual proofreading may be used for the application of the various printable materials. The wires included #2.5, 3, 5,6, 7, 8, 12, 16, 22 as known to one of ordinary skill in the art. A manual calibrator may be used with a 500/3.32 anilox roller. One particular embodiment includes a Siegwerk white ink applied with 22 wires and an adhesive (1029FST UV High Tack PSA 5G401R) applied with 2.5 wires. In embodiments including Siegwerk EXP Linerles OPV, siegwerkEXP Linerles OPV may be applied with 2.5 wires.

Referring to fig. 10-12, a method of providing a label having a patterned layer (e.g., the label shown in fig. 9) is shown.

Fig. 10 illustrates a first exemplary embodiment of a method of providing a label 10 having a patterned adhesive layer 24 and a patterned ink layer 22. In this embodiment, one or more labels 10 are constructed without a conventional facestock, instead the substrate web is printed with indicia in registry with the adhesive pattern by depositing a pattern of adhesive 24 (e.g., a pressure sensitive adhesive) onto the top surface 29 of the continuous substrate web (carrier 14), followed by depositing the ink layer 22 adjacent to and in registry with the adhesive layer 24 pattern.

Referring to fig. 10, the pressure sensitive label 10 of the embodiment shown in fig. 9 may be prepared as follows: the adhesive layer 24 may be applied to the carrier layer 14 by a first roller/drum 34, for example, and then the ink layer 22 may be applied to the adhesive layer 24 by a second roller/drum 36, thereby forming the label 10 with these separate and distinct layers. In embodiments where one or more of these layers (ink, adhesive) are uv curable, they may be exposed to uv radiation provided by uv light, which cures the various uv curable layers. Such uv curing may be performed either while each individual uv curing layer is being laid down or after all uv curing layers are being laid down. (furthermore, although FIG. 10 is shown and described as first applying an adhesive layer and then applying an ink layer, those skilled in the art will recognize that for embodiments of labels having different layer sequences, such as the labels shown in FIGS. 3 and 3A, the layers may be applied in a different order than that shown in FIG. 10).

As described above, certain layers of the label 10 of the fig. 9 embodiment (e.g., the ink layer 22 and the adhesive layer 24) may be laid down or printed in a particular pattern corresponding to the size, shape, and/or contour of the desired final label image. This also results in solving the problems of the prior art (which results in the use of too much material, thereby increasing the cost of the label). Because the ink design is printed on only a portion of the basic construction purchased from a third party (in the prior art), this requires flood coating of adhesive (which is part of the basic construction in the prior art) onto the carrier (as this is done before the basic construction is sold). In other words, since the carrier suppliers have no prior knowledge of what ink designs the label manufacturer will apply, they flood coat the entire carrier with adhesive to allow for any size, shape, configuration, and registration of the ink designs. The use of such large amounts of flood adhesive results in large amounts of unused adhesive and thus excess adhesive. The use of such excess adhesive results in increased costs of prior art labels, as the excess adhesive results in increased costs of the basic construction purchased and thus the label preparation and the label itself.

However, the design of the pressure sensitive label 10 of the present invention (as shown in fig. 9 and 10) allows for printing of the adhesive layer 24 and the patterned ink layer 22 to be laid down in a pattern. Since this happens at the labeling location, the entity that provides and creates the label will know what the design of the label is when the label is printed. Thus, instead of providing a facestock in the same area as the carrier, the present invention does not use facestock. Instead, the typical facestock of prior art pressure sensitive labels is eliminated and instead a printable layer (e.g., printable adhesive) may be placed on the carrier. This enables one to print the adhesive and ink into the shape of the final label design, which allows one to create a label without removing any additional material from the layers of the blank basic construction of the third aspect.

Fig. 11 illustrates another exemplary embodiment of a method of providing a label 10 having a patterned adhesive layer 24 and a patterned ink layer 22. In this embodiment, one or more labels 10 are configured without a conventional facestock, instead being printed with indicia registered with the pattern of adhesive and cold foil images by depositing a pattern of adhesive 24 (e.g., a pressure sensitive adhesive) onto the top surface 29 of the continuous substrate web (carrier 14), then laminating a cold foil film onto the adhesive, curing the adhesive, removing the cold foil film, and then depositing the ink layer 22 adjacent the adhesive layer 24 and in registration with the pattern of adhesive and cold foil images.

Referring to the embodiment of fig. 11, the pressure sensitive label 10 may be prepared as follows: the adhesive layer 24 may be applied to the carrier layer 14 by, for example, a first roller/drum 34. Subsequently, the cold foil film 50 is laminated to the adhesive layer 24. The cold foil is pulled from cold foil unwind roll 52 and laminated to adhesive layer 24 at roll 54. Next, the adhesive is cured (e.g., uv cured) at 56, and then the excess cold foil film is removed onto cold foil rewind roll 58, leaving the remaining cold foil film 50' laminated to the adhesive as needed. Thereafter, the ink layer 22 is laid down by the second roller/drum 36, thereby forming the label 10 with separate and distinct layers as shown. (furthermore, although FIG. 11 is shown and described as laying down an adhesive layer, then performing a cold foil treatment, and laying down an ink layer, those skilled in the art will recognize that for embodiments of labels having different layer sequences, such as the labels shown in FIGS. 3 and 3A, the layers may be laid down in a different order than that shown in FIG. 11).

One particular embodiment of the method according to fig. 11 may be printed on top of the cold foil using an ifex stamping press. In this example, the adhesive was run on untreated polypropylene film with 3-8BCM and 33-100fpm white cold foil (or holographic foil). In one specific embodiment, the adhesive is run at 3BCM and the speed of the platen is 100fpm.

Fig. 12 illustrates another exemplary embodiment of a method of providing a label 10 having a patterned adhesive layer 24 and a patterned ink layer 22. In this embodiment, one or more labels 10 are constructed without a conventional facestock, instead by depositing a pattern of adhesive 24 (e.g., a pressure sensitive adhesive) onto the top surface 29 of a continuous substrate web (carrier 14), then applying a matching pattern of ultraviolet curable ink 60 onto the adhesive layer 24, and then printing with indicia in registry with the pattern of adhesive 24 and ultraviolet curable ink by depositing an ink layer 22 in registry with the pattern of adhesive and ultraviolet curable ink.

Referring to the embodiment of fig. 12, the pressure sensitive label 10 may be prepared as follows: the adhesive layer 24 may be applied to the carrier layer 14 by, for example, a first roller/drum 34. Subsequently, an ultraviolet curable ink 60 (e.g., in a pattern matching the pattern of the adhesive) is then deposited onto the adhesive layer 24 via a second roller 62. The cold foil is pulled from cold foil unwind roll 52 and laminated to adhesive layer 24 at roll 54. Thereafter, the ink layer 22 is laid down by the third roller/drum 64, thereby forming the label 10 with separate and distinct layers as shown. (furthermore, while FIG. 11 is shown and described as laying an adhesive layer followed by a layer of ultraviolet curable ink and aqueous acrylate ink, those skilled in the art will recognize that for embodiments of labels having different layer sequences, such as the embodiments shown in FIGS. 3 and 3A, the layers may be laid in a different order than that shown in FIG. 11).

The embodiments of the invention described herein are merely exemplary embodiments and those skilled in the art will be able to make numerous variations and modifications thereto without departing from the spirit of the invention. For example, the particular type of material used in the adhesive, ink, and protective paint layers may be selected to optimize the properties of the label, interlayer adhesion, article adhesion, and/or mechanical and chemical resistance suitable for the intended use of the article. Furthermore, the above description may include disclosure of the particular materials used in each individual layer of the label (i.e., the particular ink may be described, and thus the specification discloses the use of the particular ink with any carrier, printable layer, and adhesive). Those descriptions will also be understood by those skilled in the art to include embodiments that include the particular materials described in each layer of the label (i.e., the particular inks, particular carriers, particular printable layers, and particular adhesives described at various locations in the specification will be understood to include particular embodiments of each of these particular materials). Nevertheless, certain variations and modifications may still yield satisfactory results, although the results produced are not optimal. All such variations and modifications are intended to be within the scope of the present invention as defined in the appended claims.

Claims

1. A pressure sensitive label comprising:

(a) A support portion comprising at least a carrier layer; and

(B) A transfer portion above the support portion for transferring the transfer portion from the support portion to an article upon application of pressure thereto while the transfer portion is in contact with the article, the transfer portion comprising at least:

(1) A first printable layer in facing relationship with the carrier layer,

(2) An ink layer, and

(3) A second layer of the printable layer,

Wherein the ink layer is disposed between the first printable layer and the second printable layer.

2. The pressure sensitive label of claim 1, further comprising an adhesive layer positioned such that the second printable layer is between the ink layer and the adhesive layer.

3. The pressure sensitive label of claim 1, further comprising a silicone coating positioned on a surface of the carrier layer such that the silicone coating is between the carrier layer and the adhesive layer.

4. The pressure sensitive label of claim 1 wherein the carrier layer has a surface tension that allows the first printable layer to be releasably bonded thereto.

5. The pressure sensitive label of claim 4, wherein a surface of the carrier layer in contact with the ink layer has a dyne level of less than about 32.

6. The pressure sensitive label of claim 1 wherein the carrier layer comprises a material selected from the group consisting of polypropylene and polyester.

7. The pressure sensitive label of claim 1 wherein the carrier layer is selected from the group consisting of virgin polypropylene film, silicone coated paper liner, silicone coated polyester film, and biaxially oriented polypropylene film.

8. The pressure sensitive label of claim 1 wherein the carrier layer is selected from the group consisting of plastic film, foil, parchment and paper.

9. The pressure sensitive label of claim 1, further comprising a release layer positioned such that the carrier layer is between the first printable layer and the release layer.

10. The pressure sensitive label of claim 1, wherein each of the first and second printable layers is solvent-based, water-based, or ultraviolet curable.

11. The pressure sensitive label of claim 1, wherein the first or second printable layer is independently a non-ink varnish comprising about 30wt% to about 50wt% of a triacrylate monomer, about 10wt% to about 12.5wt% of a diacrylate monomer, about 10wt% to about 12.5wt% of an aromatic urethane acrylate, about 10wt% to about 12.5wt% of a difunctional acrylate, about 5wt% to about 7wt% of an acrylate oligomer, about 3wt% to about 5wt% of triethanolamine, and about 1wt% to about 2wt% of 4-phenyl benzophenone.

12. The pressure sensitive label of claim 1, wherein the ink layer comprises about 25wt% to about 35wt% ethanol, about 20wt% to about 25wt% propylene glycol methyl ether, about 15wt% to about 20wt% propyl acetate, about 15wt% to about 20wt% isopropyl alcohol, and about 3wt% to about 5wt% aluminum flakes.

13. The pressure sensitive label of claim 2 wherein the adhesive layer comprises from about 37.5wt% to about 80wt% acrylate and from about 2.5wt% to about 10wt% photoinitiator.

14. The pressure sensitive label of claim 9, wherein the release layer comprises dimethyl siloxane and silicone.

15. The pressure sensitive label of claim 1, wherein the label does not comprise any release layer between the carrier layer and the first printable layer.