WO2013025699A1 - Multiple step forming and labeling process - Google Patents

Abstract

Methods for forming labeled polymeric articles such as bottles, packages, and containers are described. The methods utilize thermoforming or blow molding techniques to form an article into a desired shape, configuration, or size. Prior to completion of formation of the article, one or more labels are applied. The label(s) are applied to the intermediate article at a particular stage or phase of the process. After label application, article formation is continued to form a labeled polymeric article.

Description

MULTIPLE STEP FORMING AND LABELING PROCESS

CROSS REFERENCES TO RELATED APPLICATIONS

[0001] The present application claims the benefit of U.S. Provisional Patent Application No. 61/524,648 filed August 17, 2011, which is incorporated herein by reference in its entirety.

FIELD

[0002] The present su bject matter relates to a multiple step process for forming and la beling a polymeric article. One or more of the forming operations may use thermoforming or blow molding techniques.

BACKGROUND

[0003] A wide array of processes are known for forming polymeric materials into desired shapes or configurations. Two particularly well known techniques are thermoforming and blow molding. In each technique, a polymeric material typically in sheet or blank form, is su bjected to heating in conjunction with one or more forming operations that impart a desired shape or configuration to the article produced.

[0004] In many applications, it may be desired to apply one or more la bels to the article. For example, if the article is a container such as for a health and beauty aid composition, la bels are applied to provide information concerning the contents of the container, instructions for use of the container contents, information concerning the supplier, and in many instances decorative designs, logos and/or trademarks for improving aesthetics and consumer appeal. [0005] Application of labels typically occurs after formation of the container. However, strategies are known in the art in which a label is applied to a container precursor such as a material blank or section of material. The label is designed to accommodate and/or stretch as the container of interest is formed from the material blank or section.

[0006] However, if the extent of label expansion or stretch exceeds the draw capacity of the label, the label or at least markings or indicia carried thereon, frequently will become distorted. In severe cases, the label may crack, sever, or tear.

[0007] Accordingly, a strategy is needed for producing a labeled polymeric article in which a label is applied prior to article completion, yet which avoids the problems of label distortion or failure.

SUMMARY

[0008] The difficulties and drawbacks associated with previously known methods and articles are addressed in the present method and apparatus for a multistep process for forming a labeled polymeric article such as for example a consumer good container.

[0009] In one aspect, the present subject matter provides a method for forming a labeled polymeric article. The method comprises providing a polymeric material or preform and heating the polymeric material or preform. The method also comprises subjecting the heated polymeric material or preform to at least one process in which at least one of the shape, configuration, and size of the material or preform is changed. The method additionally comprises prior to completion of forming the polymeric article, applying at least one label to the material or preform at a process completion of from about 10% to about 95%. And, the method further comprises completing the at least one process in which at least one of the shape, configuration, and size of the material or preform is further changed in a region including at least a portion of the at least one label, to thereby form a labeled polymeric article. [0010] In another aspect, the subject matter provides a method for forming a polymeric article with enhanced barrier properties. The method comprises providing a polymeric material or preform, and heating the polymeric material or preform. The method also comprises subjecting the heated polymeric material or preform to at least one process in which at least one of the shape, configuration and size of the material or preform is changed. The method further comprises prior to completion of forming the polymeric article, applying at least one barrier label to the material or preform at a process completion of from about 10% to about 95%. And, the method additionally comprises completing the at least one process in which at least one of the shape, configuration, and size of the material or preform is further changed in a region including at least a portion of the at least one label, to thereby form a polymeric article having enhanced barrier properties.

[0011] In yet another aspect, the subject matter provides a method for forming a structurally enhanced polymeric article. The method comprises providing a polymeric material or preform, and heating the polymeric material or preform. The method also comprises subjecting the heated polymeric material or preform to at least one process in which at least one of the shape, configuration, and size of the material or preform is changed. The method also comprises prior to completion of forming the polymeric article, applying at least one structural label to the material or preform at a process completion of from about 10% to about 95%. And, the method further comprises completing the at least one process in which at least one of the shape, configuration, and size of the material or preform is further changed in a region including at least a portion of the at least one structural label, to thereby form a structurally enhanced polymeric article.

[0012] In still another aspect, the subject matter provides a method for decorating a polymeric article. The method comprises providing a polymeric material or preform, and heating the polymeric material or preform. The method also comprises su bjecting the heated polymeric material or preform to at least one process in which at least one of the shape, configuration, and size of the material or preform is changed. The method further comprises prior to completion of forming the polymeric article, applying at least one decorative label to the material or preform at a process completion of from about 10% to about 95%. And, the method additionally comprises completing the at least one process in which at least one of the shape, configuration, and size of the material or preform is further changed in a region including at least a portion of the at least one decorative label, to thereby form a decorative polymeric article.

[0013] As will be realized, the subject matter is capable of other and different embodiments and its several details are capable of modifications in various respects, all without departing from the subject matter. Accordingly, the drawings and description are to be regarded as illustrative and not restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 illustrates a representative forming station for producing a labeled polymeric article.

[0015] Figures 2A - 2C illustrate several preferred embodiment labeled polymeric containers.

[0016] Figure 3 is a schematic cross sectional view taken across a length dimension of a container such as shown in Figure 2, identifying regions undergoing different extents of stretching during article forming.

[0017] Figure 4 is a schematic process diagram illustrating a preferred embodiment thermoforming method for producing a labeled polymeric article.

[0018] Figure 5 is a schematic process diagram illustrating a preferred embodiment blow molding method for producing a labeled polymeric article. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0019] In accordance with the present subject matter, new strategies are provided for forming a labeled polymeric article, preferably by thermoforming or blow molding. The strategies apply one or more labels to an article blank or article precursor, prior to completion of article formation. Preferably, the one or more labels are applied to the article blank or article precursor during formation of the article, for example at a particular intermediate stage of article formation. After label application, formation of the article is continued to completion thereby producing a finished labeled article. This strategy avoids problems associated with previously known methods of applying labels prior to completion of article formation which resulted in distortion of label markings and/or label failure.

[0020] In a preferred embodiment, a method of forming a labeled polymeric article using thermoforming is provided. In another preferred embodiment, a method of forming a labeled polymeric article using blow molding is provided. The subject matter also includes the labeled polymeric articles produced by the present methods, and particularly those produced by the thermoforming and blow molding processes described herein.

[0021] Generally, the present subject matter is directed to forming methods such as thermoforming and blow molding which can produce polymeric articles having a wide array of shapes and three dimensional configurations. In accordance with the su bject matter, an article precursor or intermediate is subjected to one or more forming operations, preferably by thermoforming or blow molding. The forming operation(s) preferably change at least one of the shape, configuration, and size of the article precursor or intermediate. After formation of the article precursor or intermediate, one or more labels are applied or partially applied to the article precursor or intermediate. After application of one or more labels, the article precursor or intermediate is subjected to one or more additional forming operations to produce an article in final or desired form. Preferably, the forming operation(s) are completed whereby at least one of the shape, configuration, and size of the article precursor or intermediate is further changed. Preferably, this change occurs in a region of the article precursor or intermediate that includes at least a portion of the label(s). Preferably, the forming operation is a thermoforming operation, blow molding operation, or partial operation thereof.

[0022] Preferably, the one or more labels are applied to the article precursor or intermediate at a particular phase in the process of forming the completed labeled article. Preferably, the one or more labels are applied at from about 10% to about 95% of process completion, more preferably from about 20% to about 94%, more preferably from about 25% to about 91%, more preferably from about 30% to about 87%, more preferably from about 35% to about 84%, more preferably from about 40% to about 82%, more preferably from about 45% to about 81%, and most preferably from about 50% to about 80% of process completion. The various percentages for process completion noted herein are with regard to extents of dimensional change in a region of the container which undergoes the greatest extent of dimensional change. For example, for a container that is drawn 2.0 cm out of plane and which is formed from a planar or flat web, at a stage of about 50% to about 80% process completion, the region of the container (which is ultimately drawn 2.0 cm out of plane), is drawn out of plane to a dimension of from about 1.0 cm to about 1.6 cm. For articles that are formed from a non-planar material blank such as a preform that is subjected to a blow molding operation, the region of greatest extent of dimensional change is determined by comparing the partially formed article to the article in its initial form or preform state. For cylindrical or pseudo-cylindrically shaped articles, the region of greatest dimensional change is the region having the greatest increase in radial dimension. Thus for example, a cylindrical preform that is formed into a bottle having an oval cross section, having a major radius of 2.5 cm at a location midway between the bottle ends, reaches a process completion stage of 70% when the major radius of the bottle at the noted midway location is 1.75 cm.

[0023] The various preferred methods can also be implemented with the use of particular labels to impart desired characteristics to various polymeric articles which receive such labels. As described in greater detail herein, certain barrier labels can be applied to polymeric materials or preforms to impart desired barrier characteristics to a labeled article formed with the label. Similarly, certain structural labels can be applied to polymeric materials or preforms to impart desired structural properties to a labeled article formed with the label. Likewise, certain decorative labels can be applied to polymeric materials or preforms to impart desired decorative properties to a labeled article formed with the label.

[0024] Figure 1 illustrates a representative system 10 for forming a labeled polymeric article. In the particular version depicted, the system forms a recessed bottom container shell which is labeled, from a supply of bottom web laminate 12 or other polymeric film, and sealingly mates the bottom container shell with a top container shell formed from a top web laminate supply 24. Specifically, upon drawing a portion of the bottom web laminate 12, one or more labels 14 are applied. The labeled web laminate is then directed to a heated forming station generally shown as 16. After heating to a temperature typically greater than the softening temperature of the material, the web is then directed to a formed pocket 18 having a configuration corresponding to the preferred configuration for the bottom container shell. After forming, such as for example by thermoforming or blow molding, the formed region of material is directed to a loading position 20 at which container contents may be administered. Concurrently, a top web laminate 24 is selectively positioned, such as by use of an electric eye or other sensor 22, to mate with the formed and labeled bottom shell container including contents. The top web laminate 24 is engaged and sealed with a corresponding bottom shell at station 26. The station 26 may include provisions for reducing the pressure of the interior of the container after sealing, and/or other functions as typical in the packaging arts. The assembled, sealed, and labeled container is then optionally subjected to a cross cut operation at station 26 and/or a longitudinal cut operation at station 30. It will be appreciated that in no way is the subject matter limited to the particular system 10 and associated process. Instead, the subject matter includes a wide array of other systems, processes, and strategies for forming labeled articles such as containers. [0025] Figures 2A - 2C illustrate several preferred embodiment labeled polymeric containers 50 formed from the preferred embodiment system 10 depicted in Figure 1. Each container 50 comprises a bottom shell 12 having a label 14 applied thereto, and a corresponding top shell 24 that initially sealingly encloses the container and its contents.

[0026] Figure 3 is a schematic illustration of a typical container 100. The container includes an outer lip or ridge 110, a bottom 120, and one or more sidewalls 130 extending between the outer ridge and the bottom. Typically, an aperture or opening is defined along an upper face of the container to provide access to the interior of the container. Figure 3 illustrates various regions of the container 100 which undergo different degrees or extents of stretching during forming. For example during forming of the container 100, such as at station 18 of system 10 in Figure 1, region A undergoes moderate stretching, region B undergoes maximal stretching, and region C undergoes minimal stretching.

[0027] As will be appreciated, typical labels which may be used by applying to an article prior to forming the article, have a limited draw or stretch capacity. By identifying the draw capacity of the label, identifying the region of a container to receive the label, and identifying the extent of stretching of the container region during forming, one may efficiently determine at what degree of container formation the label is ideally applied to the container. For example, referring to Figure 3 again, it will be understood that for a given label having a certain draw capacity, if the label is to be applied in region B (a high extent of stretching), then such application should occur at a point at which container formation has progressed to a greater extent than if the same label were to be applied to region C (a low extent of stretching).

[0028] Figure 4 illustrates a multistep process 200 using thermoforming to produce a labeled polymeric article 240. A polymeric web or material 210 is provided in step A. In step B, the material 210 is partially formed into a desired configuration. For example, in step B, the material 210 is preferably formed to about 50% to 80% of its final configuration. Preferably, forming is by thermoforming. In step C, one or more labels 232 and 234 are applied to the material 210. In step D, the material 210 and labels 232 and 234 are subjected to further forming, such as by thermoforming. In this step, the remaining 20% to 50% of forming is preformed to thereby produce the labeled polymeric article 240.

[0029] Figure 5 illustrates a multistep process 300 using blow molding to produce a labeled polymeric article 340. A polymeric preform, intermediate, or material 310 is provided in step A. In step B, the preform 310 is partially formed into a desired configuration such as a container having an upper throat 312. For example, in step B, the preform 310 is preferably formed to about 50% to 80% of its final configuration. Preferably, forming is by blow molding. In step C, one or more labels 320 are applied to the preform 310. In step D, the preform 310 and label 320 are subjected to further forming, such as by blow molding. In this step, the remaining 20% to 50% of forming is performed to thereby produce the labeled polymeric article 340. Preferably, the label 320 is sized and/or configured to extend around a majority of the outer perimeter of the preform 310. Most preferably and in certain applications, the label 320 extends from about 330° to about 360° around the outer periphery of the preform 310 and maintains this orientation as the preform 310 is expanded. Also, during step D, one or more additional structural features of the article may be formed such as container shoulders 314.

Thermoforming

[0030] When utilizing one or more thermoforming operations, preferred aspects of the various materials and components are as follows.

[0031] A wide array of materials can be used for the sheet(s) or film(s) that receive labels and which are then subjected to thermoforming to form the article(s) of interest. For example, polymeric films or sheets made from standard thermoformable materials and their blends such as polystyrene (PS), poly(ethylene terephthalate) (PET), poly(ethylene terephthalate glycol) (PETG), acrylic polymers, polycarbonates, polyethylene or other polyolefins, or other polymers and combinations thereof typically used in thermoforming in applications such as trays, food/vegetable packages, cups, decorative or functional items, etc. are all suitable for the preferred embodiment methods.

[0032] Additional specific examples of polymeric materials suitable for the sheet or film to be thermoformed include polypropylene and modified polypropylene. When thermoforming polypropylene, high-performance nucleating agents may be used to improve speed, physical properties and part aesthetics. And, various clarifying agents can be included in the polymeric material to provide clarity approaching that of glass and amorphous polymers. High performance nucleating agents can improve the quality of extruded polypropylene sheet feedstock. Further, clarifying agents for polypropylene enable this polymer to replace polystyrene and poly(ethylene terephthalate) in see- through articles, particularly shallow draw lids and containers and high end applications.

[0033] Homopolymer polypropylene is widely used in sheet extrusion and thermoforming applications because of its stiffness, clarity and cost effectiveness. Random copolymer polypropylene may be used to provide even higher levels of clarity and gloss and better cold temperature impact properties. From an environmental standpoint, polypropylene's low density helps reduce the amount of material needed as well as overall packaging weight, which helps minimize landfilling and reduce fuel usage during shipping. Polypropylene also has a low carbon footprint, as a result of fewer emissions released during manufacture. Polypropylene is easily recycled in existing waste management systems, allowing the material to be reused indefinitely. In addition, polypropylene is generally free from undesirable side effects during recycling, such as crosslinking and forming a gel, or outgassing.

[0034] In addition, or instead of polymeric materials for the sheet(s) or films, the present subject matter includes the use of certain paper-based materials. For example, paper-based materials formed primarily from renewable resources are believed to also be suita ble candidates for sheets or films to be thermoformed. [0035] Furthermore, various composite materials can be used such as paper-based materials coated or coextruded with polymeric materials and in particular, polymer barrier materials such as polyethylene (PE) and ethylene vinyl alcohol (EVOH). Composite materials can include polymeric material(s), paper-based materials(s), metal(s) and alloy(s) which can for example be in the form of foils, and combinations thereof.

[0036] The material(s) forming the sheet(s) or film(s) can also include one or more additives. For example, various structural additives could be included such as fibrous high tensile strength materials. Agents providing certain barrier properties such as oxygen or water permeability can be included. Density adjusting agents, coloring agents, environmental protective agents such as for UV protection, and other agents for imparting particular properties or characteristics to the article can be used in the material of the sheet or film.

[0037] The sheet or film which forms the article(s) of interest can be of a single or monolayer, or can comprise multiple layers. For multilayer assemblies, the layers may be formed from different materials or from the same materials. In addition, it is contemplated that a variety of coatings and/or functional additives can be included in the sheet or film which forms the article(s) of interest. It is also contemplated that a wide array of packaging provisions could be included such as layer assemblies that provide resealing or closure function, tamper indicators, and the like.

[0038] Any material selected for use as the sheet or film to be thermoformed preferably exhibits a softening point that is suitable for the end use application and for the thermoforming equipment to be used in forming the finished and labeled articles. The term "softening point" as used herein refers to the temperature at which a material becomes sufficiently pliable so that the material can be thermoformed, however does not excessively flow or deform. For many materials, their softening point may be within a range of temperatures. For end use applications at ambient temperatures, it is generally preferred that the softening point of the material forming the sheet or film is greater than about 60°C. However, the present subject matter includes the use of materials having softening points less than 60°C.

[0039] Another preferred characteristic of the material selected for use in the sheet or film to be thermoformed is that the material not tear, rip, or fracture during thermoforming. This characteristic also depends upon the particular thermoforming process and configuration of the thermoforming mold and surface. It will be appreciated by those skilled in the art of thermoforming that in many if not most thermoforming operations, the material is stretched, drawn, and/or expanded in one or more directions. This occurs as a result of the material deforming as it adopts the contour and/or configuration of the thermoforming surface.

[0040] The label material used in the preferred embodiment methods has characteristics such that the label material stretches or expands with the sheet or film during the thermoforming process without tearing. The label material therefore can be made from the same material as that of the sheet or film being thermoformed to ensure their compatibility during the thermoforming process. However, the label material and the base sheet do not necessarily need to be made from the same material. It is the ability of the label to stretch or otherwise deform at the thermoforming temperature which is important for formation of a labeled thermoformed piece. That is, at the thermoforming temperature, the stretching characteristics of the label and the base sheet are compatible with one another and preferably at least equal or substantially so. A label and a sheet are deemed to be compatible with one another if at the temperature at which thermoforming occurs, neither the label nor the sheet tears or fractures during the particular thermoforming operation. For example, a PETG film can be used as the label film material for a finished article made from PETG. At the thermoforming temperature, if the label does not stretch to the same magnitude and/or at the same rate as that of the base sheet, the label could potentially tear during the process. On the other hand, at the thermoforming temperature, if the label is capable of higher stretch magnitudes than the base sheet desirable results may be obtained. For instance, a PETG label material could be used in applications where the base sheet/film polymer is PET since a PETG label would exhibit compatible stretch characteristics at the PET forming temperature. On the other hand, a PET label film is generally not desirable for labeling a thermoformed container made from PETG as the label film will not stretch sufficiently at PETG forming temperatures. Similarly, a PET label film material will not be suitable in applications were the forming sheet material is made from low density polyethylene (LDPE). The reverse of this latter example is also not feasible as the LDPE label could melt at PET thermoforming temperatures. Thus, the materials of the label and the sheet to be thermoformed must exhibit compatible stretch characteristics and preferably exhibit equivalent stretch characteristics at the temperature at which thermoforming occurs.

[0041] In addition to the stretch magnitudes, softening and melting points of the label and the base sheet must be considered and chosen properly. As will be appreciated, the materials of the label and sheet are preferably selected such that neither material undergoes excessive melting at any point in the process. Thus, it is preferred that the melting points of the materials of the label and sheet are significantly greater than the temperature at which thermoforming occurs. It is also preferred that the softening points of the label and the sheet are similar to one another. In certain embodiments, it is preferred that the difference in softening points of the label and of the sheet to be thermoformed is less than 10°C, and more preferably less than 5°C. When comparing softening point temperature ranges to one another, the difference is determined by using the upper or lower temperatures that are closest to one another. The closer the softening points of the label and sheet are to one another, and more similar the stretching characteristics of the label and sheet are to one another at the thermoforming temperature, the better the labeling quality and uniformity in the finished article.

[0042] In another aspect of the subject matter, the label material can be selected, formed, and/or have particular characteristics so as to impart desired functionalities to the finished article. That is, a "functional label" can be used to impart its functionality to the finished article. For example, the label could be partially drawn during an initial extrusion process. Once such label is drawn further during the thermoforming process, the barrier properties of the finished article could be improved. A label formed from a barrier film could impart such characteristic(s) to the finished article. Another example of a functional label is the use of colorant or UV resistant additives in the label to impart the same to the finished article. In addition to imparting additional container functionality, such a labeling technique could result in an overall cost reduction as the quantity of a specific additive or colorant needed for the film would be much less than the same required for the base sheet if instead, the base sheet were to be thermoformed and labeled with a pressure sensitive label. Additional non-limiting examples of functional agents that can be incorporated into a label or label assembly for subsequent affixment to layer(s) prior to thermoforming include fragrance agents, light enhancement agents, gloss promoting or gloss reduction agents, and other aesthetic or appearance promoting agents.

[0043] As previously described for the sheets or films, the label can be a single layer or comprise multiple layers. For multilayer label assemblies, the layers may be formed from different materials or from the same materials. The label can include one or more functional agents as noted, or be free of such agents.

[0044] In certain embodiments, the label is preferably attached to the thermoformable sheet by use of an adhesive that can withstand the thermoforming conditions and retain its adhesive properties at the thermoforming temperatures and draw magnitudes. Non-limiting examples of such adhesives include solvent based adhesives, and UV and/or thermally curable epoxy and/or acrylic or rubber adhesives which are designed to endure these harsh processing conditions. For a successful operation, in addition to the adhesive properties at high temperatures, viscosity of the adhesive is preferably chosen such that the adhesive will not become fluid at the thermoforming temperature and flow out from the label and sheet interface. [0045] Use of an adhesive, however, may not be required in certain preferred methods of thermoform labeling. For instance, if the label and the forming film/sheet are fully miscible or compatible with one another such as a PETG label and a PETG base sheet, and if the label is maintained in a suitable position by mechanical means or air flow, etc.; the label could soften and adhere to the sheet at elevated thermoforming temperatures without the aid of an adhesive. In this manner, partial miscibility of the label film and the base sheet may also suffice. An example is the use of a label that contains styrene ethylene butylene styrene (SEBS) copolymer in its surface structure when such label is used in conjunction with a polystyrene base sheet. Even if such a label could not be kept in place on the sheet by any other means but by use of an adhesive, its partial miscibility with the base sheet increases adhesion and hence allows reduction of the amount of adhesive otherwise needed for labeling, thereby resulting in a substantial cost reduction. Inclusion of adhesive polymers in the label skin side which will be attached to the article using polymers such as ethylene vinyl acetate (EVA), ethylene butyl acrylate (EBA), or others could also allow adhesion of the label to the base sheet without the use of an adhesive depending on the chemistry of the base sheet. Additional examples of suitable adhesive polymers which could be included in the label skin side for subsequent contact with the sheet forming the article of interest are certain ethylene vinyl acetate, polyethylene, polypropylene, acid copolymers, and ethylene/acrylate copolymers commercially available from DuPont under the designation ΒΥΝΕΐΛ These polymers are functionalized with reactive monomers, such as acid groups or anhydride groups.

[0046] The preferred embodiment label can be printed with an ink prior to its application or attachment to the thermoforming sheet. The ink, similar to the adhesive, preferably exhibits appropriate characteristics such that the ink can withstand high thermoforming temperature(s) and the required draw magnitudes. If the ink cannot stretch with the label, the ink will potentially crack or fracture, and will have an unacceptable appearance. After stretching, the ink should not excessively lose its opacity as the quality of the printed material may not be acceptable. For example, inks formulated with polyurethanes or similar elastic polymers in their compositions are suitable materials for such an application. The incorporation of polyurethane in the ink composition generally allows stretching of the ink. The amount or percentage of polyurethane or other similar elastic polymer component in the ink formulation can most likely be correlated to the amount of stretch that the thermoformed article endures. Non-limiting examples of preferred inks include LIOVALUE and AQUALIONA inks from Toyo Ink Company of Japan. These inks have been developed for packaging applications where the printed (and laminated) package containing food is sterilized at elevated temperatures of from about 121°C (250°F) to about 135°C (275°F). Similar inks that are designed for package boiling applications may also be suitable. The amount of pigment in the ink formulation and the required stretch magnitude of the label during thermoforming are factors affecting print quality and opacity. Metallic inks containing polyurethane may also prove advantageous in providing prints with high gloss enabling application on contoured shape thermoformed containers. Other materials and ink formulations known by those skilled in the art to meet such requirements may also be utilized.

[0047] The labels are typically formed to exhibit graphics. Graphics can include for example, designs, indicia, markings, text, or patterns. The graphics can be incorporated in or upon the label in nearly any fashion. As described in greater detail herein, the graphics are preferably formed by printing one or more inks on the label.

[0048] The graphics of the printed la bel typically distort during the stretching stage of the thermoforming process. This distortion will therefore need to be accounted for when designing and constructing a printing cylinder or plate in anticipation of printing. Preferably, a distortion printing process that compensates for the expansion that the label will undergo during the thermoforming process is used. In one approach, the stretch magnitude at various locations of a thermoformed piece is first determined. A grid patterned printed label facilitates distortion measurements at various locations on the formed piece, similar to a method described by Marcinkowski, Stanley, Michael, et al. in International Publication WO 2008/111000 Al. The distortion profile along with an accurate measure of thickness variation at various part locations are parameters typically used for print cylinder or plate design in order to print the graphics "distortedly". Upon stretching of the printed label during thermoforming, the graphics of the finished article will then appear normal. Because stretch magnitudes differ from one application or object to another, each label may need its own "distortion" printing depending upon its material, location on the finished article, and thermoforming operation.

[0049] Printing on the label can be performed in nearly any manner. Although conventional printing techniques such as offset, flexographic, and gravure printing can be used, it is generally preferred to use digital printing processes for forming the desired markings, indicia, text, patterns, and/or designs on the label especially if the inks used in digital printing have the desired stretch characteristics. These are collectively referred to herein as "visual designs." Digital printing is performed by an electronic controller or processer that stores information as to the subject matter to be printed, and one or more printheads or other components that form the desired markings, indicia, text, patterns, and/or designs, i.e. the visual designs. As previously noted, if desired, the visual designs may be initially formed or deposited in a distorted fashion. After thermoforming, such distorted visual designs appear in their intended manner.

Blow Molding

[0050] When utilizing one or more blow molding operations, preferred aspects of the various materials and components are as follows.

[0051] A blow molding preform is preferably produced by either a traditional injection molding process or by extrusion blow molding. For extrusion blow molding, typically, a cylindrically shaped, hollow member of polymer is extruded, pinched off at both ends, and then immediately inflated into a bottle or other chamber while the hollow member is still hot. Extrusion blow molding is the preferred method for forming most polyolefin containers such as milk jugs and shampoo bottles. As extrusion blow molding typically involves hotter polymer temperatures where melt strength is lower, care is taken to ensure that the preform is sufficiently hot and pliable, otherwise the preform will not expand or stretch properly. Fortunately, the hotter temperatures tend to soften the preform more quickly. The term "blow molding" as used herein includes stretch blow molding processes and extrusion blow molding processes. The present subject matter includes all of the various forms of stretch blow molding, for example single stage blow molding and 2-stage blow molding, and the various forms of extrusion blow molding, for example wheel type extrusion blow molding and accumulator head type processes.

[0052] The preforms used in the present subject matter preferably include conventional thermoplastic molding polymers such as polyester, polyolefins, polycarbonates, and combinations thereof. The preforms may be monolayer or multilayer combinations of various polymers. Other polymers may be used to form certain layers of multilayer containers. Such polymers are well known in the art and include recycled polymers such as polyesters, performance polymers such as copolymers of ethylene and vinyl alcohol, e.g. ethyl vinyl alcohol polymers or EVOH, polyamides, wholly aromatic polyesters, polyethers, blends, and copolymers thereof.

[0053] Polyesters are the preferred class of polymers useful as preforms in the present subject matter. Suitable polyesters comprise a dicarboxylic acid component preferably comprising terephthalic acid or isophthalic acid, preferably at least about 50 mole percent terephthalic acid, and in certain embodiments, preferably at least about 75 mole percent terephthalic acid and a diol component comprising at least one diol selected from ethylene glycol, cyclohexanedimethanol, diethylene glycol, butanediol and mixtures thereof. The polyesters may further comprise comonomer residues in amounts up to about 50 mole percent of one or more different dicarboxylic acids and/or up to about 50 mole percent of one or more diols on a 100 mole percent dicarboxylic acid and a 100 mole percent diol basis. In certain embodiments, comonomer modification of the dicarboxylic acid component, the glycol component or each individually of up to about 25 mole percent or up to about 15 mole percent may be preferred. Suitable dicarboxylic acid comonomers comprise aromatic dicarboxylic acids, esters of dicarboxylic acids, anhydrides of dicarboxylic esters, and mixtures thereof. More specifically, suitable dicarboxylic acid comonomers include aromatic dicarboxylic acids preferably having 8 to 14 carbon atoms, aliphatic dicarboxylic acids preferably having 4 to 12 carbon atoms, or cycloaliphatic dicarboxylic acids preferably having 8 to 12 carbon atoms. Examples of dicarboxylic acid comonomers include but are not limited to phthalic acid, isophthalic acid, naphthalene-2,6-dicarboxylic acid, cyclohexanedicarboxylic acid, cyclohexanediacetic acid, diphenyl-4,4'-dicarboxylic acid, dipheny-3,4'-dicarboxylic acid, succinic acid, glutaric acid, adipic acid, azelaic acid, sebacic acid, mixtures thereof and the like.

[0054] The polymers and preferably the polyesters useful in the preforms may also comprise additives typically used in polyesters, if desired. Such additives include, but are not limited to colorants, toners, pigments, carbon black, glass fibers, fillers, impact modifiers, antioxidants, stabilizers, flame retardants, reheat aids, acetaldehyde reducing compounds, oxygen scavengers, barrier enhancing aids, UV inhibitors and combinations thereof.

[0055] Preforms are formed via methods well known in the art, such as by injection molding or, less commonly, by pipe extrusion and swaging. The preforms are first reheated to the desired blow temperature (usually around about 100°C for poly(ethylene terephthalate) (PET) preforms) using a bank of infrared lamps such as on a SIDE L™ type of machine. After infrared heating, the hot preforms are then directly conveyed to a blow wheel where they are inflated into a mold. It will be appreciated that the present subject matter may utilize preforms that are produced in nearly any manner.

[0056] The label film stock includes any polymer that can survive the necessary stretch conditions during the blow molding process. Typically, this requires that the polymer either have a glass transition temperature ("Tg") that is less than the selected blow temperature (PET used for many soda bottles has a Tg of 77°C) or that the label be suitably heated just prior to blow molding. Any polymer than can significantly distort without tearing at temperatures of from about 23°C to about llfXC can likely be used as a label material in the preferred embodiments of the present subject matter. Numerous such polymers are known to skilled artisans. Preferably, the label includes a thermoplastic polymer. Suitable polymers include, but are not limited to, polyesters, copolyesters, polyolefins, polyamides, ethyl vinyl alcohol (EVOH), polymers elastomer polymer blends, copolymers of elastomer blends, and mixtures thereof. Polyesters, copolyesters, and polyolefins such as polyethylene and polypropylene are preferred. Polyesters such as poly(ethylene terephthalate) (PET) and copolyesters having orientation properties similar to the container are preferred so that stretching characteristics of the label are more closely matched with the inflating preform. Polypropylene is preferred as a label material because it is the current label material of choice in the industry due to its low cost. Polypropylene is also preferred because it is easily separated in a recycle stream via flotation as polypropylene's density is less than that of water.

[0057] Labels may be in the form of single film materials or assemblies of multiple films or layers. For multilayer label assemblies, the materials for each layer can be different or the same. It is preferred however, that for multilayer assemblies using multiple materials, that the stretch characteristics of the various materials are similar or at least compatible with one another. The reference to label materials being compatible with one another refers to their behavior relative to one another during preform expansion such that the layer(s) do not detrimentally fracture, tear, or otherwise separate.

[0058] The label film used in the preferred embodiments is preferably printed with the desired label design using methods known to skilled artisans. Preferably, a distortion printing process that compensates for the expansion that the label will undergo during the blow-molding process is used. Since expansion will vary from point to point, e.g., a container neck will expand less than a sidewall, the distortion-printing pattern will be varied accordingly. Printing is usually performed on flat label film in which edges are subsequently bonded together to make a label tube. The most desirable label printing process for a particular application will depend upon the pattern desired and the type of equipment that will be used to produce the container.

[0059] In addition and as described in greater detail herein, blown film is suitable for applications where printing is not required but functional additives are desirable. For example, a colorant or pigment can be added to the polymer to produce colored labels. Similarly, as described in greater detail herein, a UV blocking concentrate, barrier layer, or other functional additive can be incorporated into a polymer used to produce the label and/or a functional film. Similarly, a pigmented tu be can be fitted around the preform to change the overall color of the container and a traditional adhesively applied label then applied over the top of the pigmented tube.

[0060] Depending upon the particular application, the label may be formed and/or its materials may be selected, such that during expansion of the labeled preforms, the label stretches or expands in all directions, in only certain directions, and/or in all directions but to different extents. The latter version of the present subject matter may be preferred when forming labeled articles in which the label resides over complex curvatures.

[0061] Although various techniques can be used for securing and/or attaching one or more labels to a preform, generally the label(s) are applied to the preforms using adhesive. A wide array of adhesives can be used such as but not limited to non-reactive adhesives such as pressure sensitive adhesives, hot adhesives, and drying adhesives. Various reactive adhesives may be useful such as multipart adhesives and one-part adhesives.

[0062] Preferably, the adhesive is a pressure sensitive adhesive and exhibits suitable properties so that the adhesive expands in a compatible fashion with the preform and the label. Representative pressure sensitive adhesives which may be acceptable include those described in the following patent documents: US Patent 5,558,913; US Patent 6,187,432; US Patent 5,622,783; US Patent 5,183,841; US Patent 5,593,759; US Patent 5,100,963; US Patent 5,262,216; and US Patent 5,180,635. [0063] It will be appreciated that in no manner is the present su bject matter limited to the use of any particular adhesive. Instead, the subject matter includes the use of nearly any adhesive that satisfactorily adheres the label(s) of interest to the preform and to the containers or products formed from the preform, and which exhibits suitable properties so as to be compatible with expansion of the preform and label. This practice may facilitate stretching of the label and reduce the potential for interference along the label and preform interface.

[0064] The adhesive(s) may be applied to the preform and/or label(s) according to one or more patterns. The use of patterned adhesive layers may be beneficial in certain applications. For example, portions or the entirety of label edge regions can be adhered to a preform using adhesive. Adhesive may not be necessary for interior region(s) of the label.

[0065] Labels can be applied to the preforms at any point just prior to the preforms entering a molding chamber or wheel. The labels are preferably cut to the appropriate length, depending on how much contour label coverage is desired on the final article. This can be done in-situ as the labels are placed over or upon the preforms or the labels can be precut into discrete units. Using either technique, an appropriate web/film handling system is preferred to rapidly place the labels over the preforms. Systems commonly used for regular in-mold labeling in the industry can be modified to handle the labels.

[0066] In a blow molding process, the preform and label will enter the blow mold and be inflated to the final container shape. Preferably, the residual heat of the preform will serve to heat the label so that it will be pliable enough to expand. Alternately, hot air or radiant heat can be blown/applied across the components. Because the label and preform will be tacky at higher temperatures, the potential for the label sliding off as the preform is inverted (as is the case with some blow molding machines) is negligible. Indexing and registration equipment can be used to hold the label in place relative to the preform if necessary. As the preform expands, the label also expands. Ultimately, the label will adopt the final shape of the article as it will stretch until it contacts the mold wall. Thus, a tight fitting, contour label is created without the need for biaxially oriented film, or a shrink tunnel.

[0067] In one embodiment, the label is placed over the preform prior to reheating. For infrared heating of preforms, this is preferably done if the label and the inks used to print the label do not excessively absorb the infrared radiation. If for example, the inks blocked the I radiation, the label would have hot spots at the ink location and the preform would have cold spots below the label. This could result in uneven stretching of both preform and label.

[0068] Preferably, the labels applied to preforms as described herein include one or more decorative, print, and/or indicia-containing layers. Such decorative, print or indicia are formed by application of inks or other colored formulations to one or more label layers. Preferably, the ink compositions used in conjunction with the labels and strategies described herein are expandable such that upon expansion of a labeled preform to a fully formed labeled container, the ink composition also expands. The degree of expansion is such that during and after label and preform expansion, e.g. after a blow molding operation, the ink composition is not fractured, cracked, and/or debonded from the underlying label substrate. Thus, it is preferred that the ink formulation exhibits suitable properties so that the ink expands in a compatible fashion with the preform and the la bel.

[0069] Although not wishing to be bound to any particular aspect or composition, a preferred class of ink formulations includes a modified epoxy acrylate prepolymer composition, which is preferably modified with polyester or urethane oligomers to enhance its flexibility and adhesion to difficult substrates. Such oligomers for enhancing flexibility and adhesion to difficult substrates, include dimers, trimers, tetramers and other co-polymerized sub-units. In addition, the composition may be further modified to provide enhanced viscosity by the addition of monomeric and oligomeric components such as acrylates and methacrylates. [0070] Representative examples of inks and ink formulations that may be suitable for use with the expanda ble or stretchable labels and/or preforms described herein are provided in WO 03/106143.

[0071] In certain preferred aspects, the inks used in the labels and methods described herein are curable by methods other than by curing by exposure to UV radiation.

[0072] Although a wide array of inks (or ink formulations) are contemplated for use in the subject matter, it has been surprisingly discovered that an ink comprising from about 10 percent to about 20 percent by weight of polyurethane exhibits properties such that the ink, upon printing on a label and labeling of a preform, can withstand expansion at typical high temperatures associated with blow molding preforms. Preferably, the inks can undergo expansion of up to 150 percent, more preferably up to 200 percent, more preferably up to 300 percent, and most preferably up to 400 percent without exhibiting any detrimental effects. As previously explained, detrimental effects include fracturing, cracking, and/or debonding of the ink from the label. For example, black and red inks containing 10 to 20 percent polyurethane printed on a label applied to a preform, exhibit stretch magnitudes of up to 200 percent and 400 percent biaxially and circumferentially respectively, during preform expansion on a biaxial stretching machine at 100°C, without exhibiting detrimental effects. It will be appreciated that the proportion of polyurethane in the ink formulation can be readily adjusted to accommodate higher temperatures, different stretch magnitudes, different preform and container geometries, and combinations of these factors. It is contemplated that generally, inks comprising from about 10 percent to about 20 percent polyurethane are suitable for biaxial stretching at temperatures within a range of about 100°C to about 130°C, and to magnitudes of 4x in one direction and 2x in another direction. Representative examples of such inks include, but are not limited to those available under LIOVALUE or AQUALIONA from Toyo Ink America, LLC of Addison, IL or FK002e from IIMAK of Amherst, NY.

[0073] Generally, the methods of the present subject matter utilizing one or more blow molding operations comprise providing a label or label assembly, providing a preform, applying the label to the preform, and forming a finished or fully formed labeled article from the preform. Details and preferred aspects associated with providing the label(s) and preform(s), applying the label(s) to preform(s), and forming a finished article therefrom are provided herein.

[0074] The labels can be applied to the preforms using a variety of different techniques. Label application techniques such as using pressure sensitive adhesive between the preform and the label can be used. Alternatively, labels can be applied to the preforms by in-mold labeling techniques. For example, one or more labels having appropriate stretch characteristics can be disposed along a wall of a mold cavity within which is formed the preform. Upon molding the preform, such as by injection molding, the one or more labels are secured and affixed to the outer periphery of the preform.

[0075] After forming the labeled preform, the labeled preform is then subjected to one or more operations to form the desired article having labeling as desired. Preferably, the labeled preform is blow molded to form the labeled article. In this technique, the labeled preform is heated to a temperature greater than the glass transition temperatures of both the preform and the label. After the labeled preform has been sufficiently heated, the labeled preform is then stretched, expanded, and/or blown as desired to form the article of interest. In so doing, the label also undergoes expansion such that the label stretches, deforms, and changes shape with the preform. Most preferably, the glass transition temperature of the label is less than or equal to the glass transition temperature of the preform.

[0076] A preferred and significant aspect of the present subject matter methods is that after application of the label(s) to the preforms, the labels undergo expansion concurrently with the preform. Thus, as the preform is being inflated or otherwise undergoing expansion to form the desired article of interest, the label(s) associated with the preform also undergoes expansion. Most preferably, the extent of expansion of the preform and that of the label is the same or substantially so.

[0077] In yet another aspect, the subject matter provides a film or relatively thin layer containing one or more agents disposed about the outer periphery of a preform such that upon expansion of the preform, the fully formed article contains an outer layer having the one or more agents incorporated about the outer periphery of the formed article. For example, the one or more agents can be colorants, toners, pigments, carbon black, antioxidants, stabilizers, flame retardants, oxygen scavengers, barrier additives, UV inhibitors, and combinations thereof. Such agents can be readily incorporated about the outer periphery of an article in this manner. Films or polymeric layers containing such agents and/or other additives can be formed by known extrusion techniques or other processes.

[0078] The agent-containing film, generally referred to herein as a "functional layer," may be attached to a preform in nearly any manner. In certain preferred aspects, the agent-containing film can be attached to the preform by one or more adhesives. However, in many applications, it may be preferred to avoid the use of adhesive. Constructions free of adhesive may result in cost savings. For example, a label in the form of a tube can be appropriately positioned about a preform. The tube can be a closed tube with a seam that is formed chemically or mechanically, e.g. fused, welded, etc. Alternatively, a stretch tube can be formed from appropriate label material(s) and positioned about the outer periphery of a preform. In certain embodiments, it is preferred to form the tube and/or label from the same polymeric material as the preform. Doing so will facilitate recycling efforts of labeled articles produced from labeled preforms. Furthermore, it is contemplated that the use of biodegradable additives or partially water soluble polymers when utilized in the labels described herein may result in easier separation of the printed label during recycling from the remaining container.

[0079] Typically, for applications using one or more functional films, it is preferred that such film(s) be applied prior to, i.e. underneath, any label(s). However, the subject matter includes embodiments in which one or more functional films are applied over a labeled preform. It is also contemplated that one or more label(s) could be disposed between two or more functional films.

[0080] In certain embodiments, one or more labels having particular qualities and/or characteristics may be provided, which when applied to an article provide particular qualities and/or characteristics to the article. For example, a label having certain barrier properties may be applied to the article during article formation in order to provide the article with desired barrier properties. Non- limiting examples of barrier properties include oxygen limiting films such as EVOH. It is contemplated that a wide array of barrier agents could be incorporated into one or more labels to thereby impart desired barrier characteristics to the article(s) receiving such labels. For example, agents which block or reduce effects of UV radiation could be included in the label. Labels with certain desired barrier properties are referred to herein as "barrier labels." In another embodiment, a structurally enhanced article may be provided by applying one or more labels having certain structural characteristics to the article during article formation. Examples of structural characteristics include for example rigidity, resistance to deformation, and resistance to tearing. For example, it may be desirable to apply structural promoting labels to thin wall beverage containers or containers having relatively low hoop and longitudinal strength. Labels having desired structural characteristics for imparting such to an article are referred to herein as "structural labels." In still other embodiments it may be desirable to provide one or more decorative labels to an article to impart certain decorative characteristics to the article. Examples of decorative labels may include labels with certain colors, color combinations, and/or patterns or designs. In certain embodiments, it may be preferred to use a colored or decorated label for application to an article that is transparent or substantially so. Use of a transparent article may be desirable from a recycling perspective. Labels having desired decorations and/or colors are referred to herein as "decorative labels."

[0081] In certain embodiments, it may be desirable to use a high color density ink or coating in regions of the article that undergo high stretching or deformation. For example, a flood coat of white ink may be utilized which is preferably positioned under a colored ink or coating in order to achieve a higher opacity. [0082] It is also contemplated to provide a label or label assembly which can be applied to a polymeric material or preform as described herein in which the label or label assembly can be subsequently removed such as after use of the article. For example, when recycling labeled containers it may be desirable to remove labels or portions of labels adhered to the container prior to recycling of the container. For these applications, it is preferred that the polymeric material or preform is transparent or generally color-free. A label and preferably a decorative label as described herein can be applied to the transparent or color-free polymeric material or preform in accordance with the preferred methods. The label, once applied, then provides desired background color or design.

[0083] The present subject matter includes the use of other adhesives in addition to, or instead of, pressure sensitive adhesives. And, as previously noted, the present subject matter is not limited to the use of adhesive(s). Instead, sleeves or other assemblies which are either entirely free or partially free of adhesives such as pressure sensitive adhesives, can be used in accordance with the present subject matter. A nonlimiting example of a sleeve component is a thin laminate formed from a material having a stretch capability, which is positioned on or about a container or other object of interest.

[0084] Many other benefits will no doubt become apparent from future application and development of this technology.

[0085] All patents, applications, and articles noted herein are hereby incorporated by reference in their entirety.

[0086] As described hereina bove, the present subject matter solves many problems associated with previous type devices. However, it will be appreciated that various changes in the details, materials and arrangements of components and/or operations, which have been herein described and illustrated in order to explain the nature of the subject matter, may be made by those skilled in the art without departing from the principle and scope of the subject matter, as expressed in the appended claims.

Claims

WHAT IS CLAIMED IS:

1. A method for forming a labeled polymeric article, the method comprising:

providing a polymeric material or preform;

heating the polymeric material or preform;

subjecting the heated polymeric material or preform to at least one process in which at least one of the shape, configuration, and size of the material or preform is changed;

prior to completion of forming the polymeric article, applying at least one label to the material or preform at a process completion of from about 10% to about 95%;

completing the at least one process in which at least one of the shape, configuration, and size of the material or preform is further changed in a region including at least a portion of the at least one label, to thereby form a la beled polymeric article.

2. The method of claim 1 wherein the label is applied at a process completion of from about 20% to about 94%.

3. The method of claim 1 wherein the label is applied at a process completion of from about 25% to about 91%.

4. The method of claim 1 wherein the label is applied at a process completion of from about 30% to about 87%.

5. The method of claim 1 wherein the label is applied at a process completion of from about 35% to about 84%.

6. The method of claim 1 wherein the label is applied at a process completion of from about 40% to about 82%.

7. The method of claim 1 wherein the label is applied at a process completion of from about 45% to about 81%.

8. The method of claim 1 wherein the label is applied at a process completion of from about 50% to about 80%.

9. The method of any one of claims 1-8 wherein the process in which at least one of the shape, configuration, and size of the material or preform is changed, is one of thermoforming and blow molding.

10. The method of claim 9 wherein the process is thermoforming.

11. The method of claim 9 wherein the process is blow molding.

12. A labeled article produced by any of the methods of claims 1-11.

13. A method for forming a polymeric article with enhanced barrier properties, the method comprising:

providing a polymeric material or preform;

heating the polymeric material or preform; subjecting the heated polymeric material or preform to at least one process in which at least one of the shape, configuration, and size of the material or preform is changed;

prior to completion of forming the polymeric article, applying at least one barrier label to the material or preform at a process completion of from about 10% to about 95%;

completing the at least one process in which at least one of the shape, configuration, and size of the material or preform is further changed in a region including at least a portion of the at least one label, to thereby form a polymeric article having enhanced barrier properties.

14. The method of claim 13 wherein the label is applied at a process completion of from about 20% to about 94%.

15. The method of claim 13 wherein the label is applied at a process completion of from about 25% to about 91%.

16. The method of claim 13 wherein the label is applied at a process completion of from about 30% to about 87%.

17. The method of claim 13 wherein the label is applied at a process completion of from about 35% to about 84%.

18. The method of claim 13 wherein the label is applied at a process completion of from about 40% to about 82%.

19. The method of claim 13 wherein the label is applied at a process completion of from about 45% to about 81%.

20. The method of claim 13 wherein the label is applied at a process completion of from about 50% to about 80%.

21. The method of any one of claims 13-20 wherein the process in which at least one of the shape, configuration, and size of the material or preform is changed, is one of thermoforming and blow molding.

22. The method of claim 21 wherein the process is thermoforming.

23. The method of claim 21 wherein the process is blow molding.

24. A labeled article produced by any of the methods of claims 13-23.

25. A method for forming a structurally enhanced polymeric article, the method comprising: providing a polymeric material or preform;

heating the polymeric material or preform;

subjecting the heated polymeric material or preform to at least one process in which at least one of the shape, configuration, and size of the material or preform is changed;

prior to completion of forming the polymeric article, applying at least one structural label to the material or preform at a process completion of from about 10% to about 95%; completing the at least one process in which at least one of the shape, configuration, and size of the material or preform is further changed in a region including at least a portion of the at least one structural label, to thereby form a structurally enhanced polymeric article.

26. The method of claim 25 wherein the label is applied at a process completion of from about 20% to about 94%.

27. The method of claim 25 wherein the label is applied at a process completion of from about 25% to about 91%.

28. The method of claim 25 wherein the label is applied at a process completion of from about 30% to about 87%.

29. The method of claim 25 wherein the label is applied at a process completion of from about 35% to about 84%.

30. The method of claim 25 wherein the label is applied at a process completion of from about 40% to about 82%.

31. The method of claim 25 wherein the label is applied at a process completion of from about 45% to about 81%.

32. The method of claim 25 wherein the label is applied at a process completion of from about 50% to about 80%.

33. The method of any one of claims 25-32 wherein the process in which at least one of the shape, configuration, and size of the material or preform is changed, is one of thermoforming and blow molding.

34. The method of claim 33 wherein the process is thermoforming.

35. The method of claim 33 wherein the process is blow molding.

36. A labeled article produced by any of the methods of claims 25-35.

37. A method for decorating a polymeric article, the method comprising:

providing a polymeric material or preform;

heating the polymeric material or preform;

subjecting the heated polymeric material or preform to at least one process in which at least one of the shape, configuration, and size of the material or preform is changed;

prior to completion of forming the polymeric article, applying at least one decorative label to the material or preform at a process completion of from about 10% to about 95%;

completing the at least one process in which at least one of the shape, configuration, and size of the material or preform is further changed in a region including at least a portion of the at least one decorative label, to thereby form a decorative polymeric article.

38. The method of claim 37 wherein the label is applied at a process completion of from about 20% to about 94%.

39. The method of claim 37 wherein the label is applied at a process completion of from about 25% to about 91%.

40. The method of claim 37 wherein the label is applied at a process completion of from about 30% to about 87%.

41. The method of claim 37 wherein the label is applied at a process completion of from about 35% to about 84%.

42. The method of claim 37 wherein the label is applied at a process completion of from about 40% to about 82%.

43. The method of claim 37 wherein the label is applied at a process completion of from about 45% to about 81%.

44. The method of claim 37 wherein the label is applied at a process completion of from about 50% to about 80%.

45. The method of any one of claims 37-44 wherein the process in which at least one of the shape, configuration, and size of the material or preform is changed, is one of thermoforming and blow molding.

46. The method of claim 45 wherein the process is thermoforming.

47. The method of claim 45 wherein the process is blow molding.

48. The method of any one of claims 37-47 wherein the polymeric material or preform is transparent or color-free.

49. A labeled article produced by any of the methods of claims 37-48.