CA2127195C

CA2127195C - Method and apparatus for manufacturing linerless labels

Info

Publication number: CA2127195C
Application number: CA002127195A
Authority: CA
Inventors: John R. Soltysiak; Frank L. Benchik; Paul M. Cummings; Dennis D. Hubbell; Joseph W. Langan; Daniel P. Ratka; John C. Bane; Francis R. Smith; Jimmie A. Harrod; Khaled M. Khatib; Nancy G. Mitchell; Timothy J. Russ
Original assignee: Moore North America Inc; Moore Wallace North America Inc
Current assignee: Moore Wallace North America Inc
Priority date: 1994-06-03
Filing date: 1994-06-30
Publication date: 2004-05-11
Anticipated expiration: 2014-06-30
Also published as: US5792296A; AU684925B2; US5656116A; CA2127195A1; US6153045A; US5518762A; AU2045795A

Abstract

An apparatus and method provide for the alternate manufacture of permanent adhesive or repositional linerless labels utilizing the same equipment. Indicia is applied such as by using an intelligent imaging system by at least one print station. With repositional labels, a tie coat is applied and dried, whereas with permanent labels a barrier coating is applied. Coating stations apply a repositional adhesive and release coat in the construction of repositional adhesive labels. The coating station is followed by a dryer and chill rolls. In the construction of permanent adhesive labels a coating station for applying a release coat and a release coat curing station, as well as permanent adhesive application station, are also provided. Changeover time from the manufacture of one type of label to the other is short.

Description

METHOD AND APPARATUS FOR MANUFACTURING
LINERLESS LABELS
BACKGROUND AND SU1~~IARY OF THE INVENTION
Linerless labels are becoming increasingly more popular due to the inherent advantages associated therewith, as a result of not requiring a separate release sheet.
Typical linerless labels are disclosed in U.S. patents 5,292,713, 4,978,415, 5,354,588, 5,674,345, 5,417,783 and 6,129,965.
There are several major types of linerless labels that are common: repositional adhesive labels, removable adhesive labels and permanent adhesive labels. Different types of equipment are necessary in order to make these different types of linerless labels because of the widely divergent characteristics, drying methods, and the like of the adhesives and release coats that are used in the manufacture thereof. Since it is highly desirable to print or otherwise image the labels during manufacture thereof, equipment costs can be high to construct and maintain different equipment lines. Therefore if the demand for the different types of labels varies significantly, as often occurs in practice, some equipment may be left idle while other equipment is stressed to capacity.
According to the present invention a method and apparatus are provided which allow the alternative construction of either permanent adhesive or repositional adhesive labels utilizing the same equipment. According to the invention the changeover time from the manufacture of one type of labels to the other is short, and many of the components can be used for both types of J;JN 30 ' 94 8 : 44 FROM D100RE LEGAL DEPT TO SMART B I GGAR OT~J PAGE .

2~2'~~.9~

labels despite their signi~rant differexes. This allows a minimum expenditure of capital at><d maximum flexibility in accommodating market coeds.
According to one aspect of the present invention, apparatus is provided for alternatively manufa~uring permanent adhesive or repositional adhesive linerless labels, The apparatus includes a plurality of components spaced from each other in a first direction which comprises the direction of ~3vel of a t~reb acted upon by the apparatus to produce the linerless labels. The components comprise the fotlowirtg: An indicia applying station. A first coating station for applying the tie coat in the construction of repositional adhesive lab~Is. A
t~ second coating station for optionally applying a barrier coat in the construc-ion of permanent adhesive labels, ox repositional adhesive in rife construction of rcpositional adhesive labels. A third coating stauon for applying a release coat in the construction of repositicnal adhesive labels. A dryer capable of drying both sides (faces) of a web at the same time, located downstream of the second I5 coating station. Ch-t1I rolls for cooling a web and pulling a web frota the dryer. A fourth coating station for applying a release coat in the construction of pcrtaanent adhesive labels. A release coat curing station for curing a release coat in the construction of pe.- .tnanent adhesive labels. And, a permanent adhesive application station.
Zo The indic;a applying section may comprise a variab:e intelligent imaging system such as ion deposition (e.g. MIi7AX~. Indigo, Xeikon), ink bet, or like imaging equipment, and at least one print station such as that rypic~.tly provided on an in-line web printing press, such as a Webtron press, available from Webtron of Fort Lauderdale, Florida. if four color priatitt:g of 25 both sides of the linerless labels is desired, eight print stations will be provided .
The components may be in the sequence recited above (with the imaging system being the most upstream component and the permanent adhesive station the most downstream component in the first direction), or the JUN 30 '94 8:44 FROM MOORE LE~RL DEPT TO SMRRT BIG:;AR OTW PR6E.007r025 sequence can be changed, as long as there is appropriate drying or oaring of the various coats once applied.
A web unwind assembly is typically provided upstream of the variable intelligent imaging system in the first direction, and a web rewind assembly downstream of the permanent adhesive application station. A perf station_for applying perfs in a second direction Eenerally perpendicular to tl~e first direction a also preferably provided typically before the second coating station. .
A video inspection station may be provided immediately ad,~acern anal downstream of the perf station. A shenter and longitudinal perf station may be to disposed between the permanent adhesive station and the rewind assembly, and a metered infecd assembly may be prrn~ided between the unwind asser~tbly and the imaging system.
'The fourth coating station may comprise a uV silicone release coat application station. The release coat curing station may comprise a W curing IS station including nitrogen inerted W curing and an oxygen analyzer with a nitrogen flow control system. A turning me~clianism rnay be associated with the variable intelligent imaging system and first coating station to allow two-sided imaging of a web used to product the labels in Ji mrvenient manner, and bypass means J;sasch as the diverter roll or rollers) may be provided for 2o bypassing an individual component when riot in use.
The invention also relates to a method of alternatively manufacturing either permanent adhesive linerless labels or repositional adhesive linerless labels utilising common eduipment. The method comprises the seeps of automatically: (a) Continuously feeding a web of label substrate material 25 having first and second faces so that it moves in a first direction. And while practicing step (a): (b) hr~agit!g indicia on one or both of the fas;;es of the web.
Alternatively practicing step 'c} or step (d) as follows: (c) If repositional adhesive lixrless labels are being manufactured, applying arid drying a tie coat to ripe first face of the web, ar~plying a repositional adhesive to the first face of 30 the web, applying a release coat to the second lace of the web, and drying the JUI~i 3L ' 94 8 :4~ FROM MOORE LEGRL DEPT TO SMfaRT B I GGAR CTW r~r;~aE .
a0$/~~5 release coat and repositiona! adhesive at the same time. (d) Tf permanent adhesive linerless Labels are being manufactured, applying a barrier coat to the first face of the web, drying the bar: ier coat, and then applyatg a release coating over the barrier coat and curing the release coat, and appiyittg a permanent adhesive to the second face. (e) ApplYiaB pegs to the web is a second direction substantially transverse to the first direction to define labels in the web. (f) Taking up the web after the practice of steps (b), (c} or (d), and (e}: and (g) occasiottaily (e.g. periodically, intermittently, or t~,~rpi~lly simply when desired) changing over from step (c} to step (d}, and vice versa.
1o boring the practice of step (c) a de coat may be applied to rye web first face prior to the repositionai adhesive being applied to the first face. '~he barrier coat or the repositional adhesive may be applied by the same water depending upon whether step (c) or step (d) is practiced. During the practice of step (c) the repositianal adhesive and release coat are dried simultaneously t5 by a taro sided hoc al.- dryer. Step (d) may be practiced by applying a LfV
silicone release coat, and UV curing release coat prior to the application of the permanent adhesive, which tray be hot melt, water based or the like adhesives_ Video inspection of the perfs formed after the practiced of step (e} may also be effected. The application of permanent adhesive and the barrier coat may be 2o pattern coated or applied in a continuous format, depending ca the particular application.
The invention also relates to a method of automatically manufacturing a web of permanent adhesive linerless labels from a web of substrate tnarerial having first and second faces. Tills method comprises the steps of: Itraaging 25 ittdicia on at feast one face of the substrate. Optionally, perfing the substrate web to define labels. Alternatively, the labels may be severed from the web by a cutter and then fed to a sheerer to collect the cut :abets in a snack.
Applying a barrier coat to the fast face of the substrate. Hat air drying the bare ier coat. Applying a UV silicone release coat to the first face of the 3o substrate. UV curing the UY silicon release coat. Applying a permanent JUN 3E ' 94 8 :4S FR~JM P'I~JORE LEGAL DEPT TO SMART B ~ GGAR CiT!d PAGE. ~09:

adhesive to the second face of the substrate. And, taking up the web of iizteriess labels produced. The steps as recited above are preferably practiced seQuenaaliy. The repositionabie adhesive and the tie root tray 4e pattern coated or applied in a continuous forma;, depending on the particular 5 application.
The invention also contemplates a method of autatz:atically manufact~~tring a web of repositional adhesive Einerless labels from a w~ of substrate material having first and second faces. The method comprises, the steps of: imaging indicia on at Ieast one face of the substrate. Optionally, to perfcng the substrate web to define labels. Applying a tie coat to the fast face of the web and dryir3g the tie co2t: Applying a repositior~al adhesive to ase first fact of the substrate and a release coal w the second face.
Sirnuttaneousiy hot air drying the adhesive and release coats. Aud, taking up the web of repositional adhesive tinerless iaheis produced. 'The steps cited above may be t s pr a~..ticed sequentially.
It is the primary object of the present invention to provide a simple yet effective apparatus and method for the alternative manufacture of repositiona!
adhesive lineriess labels or permanent adhesive linerless labels. This and other objects of the invention will become clear from an inspection of i>~e detailed 20 description of the invention, and from the appended claims.
~Ri~F DESCRIPTION Q)F 'I'HE D>Z.AW~IGS
FIGURE 1 is a schematic representation of the method steps chat may 2 be practiced according to the present invention;
FIGUR~ 2 is a side elevationat view showing exemplary apparatus according to the present invention, for practice of the method of FIGURE 1: and JlJN 30 '94 8:45 FROM MOORE LEGAL_ DEPT TO S~~IART BIGGAR OTW PNfaE.010i22S
.."

FIGURES 3 and 4 are xhea~atic side views (greatly enlarged for clarity of illustration) of an exemplary repositional adhesive linerless label and an exemplary permanent adhesive linerless label, respectively, produced according to the present invention.
s ~.~TAiLED DESCRTfTION OF '1~E DRA'WI1V'GS
FIGLIRE I schematically illustrates a process 1 Ci which may be utilized to produce either repasitional adhesive lineries~ !abets (FIGURE 3) or to permanent adhesive linerless iaixls (FIGURE 4f. The steps that are used to produce both types of labels are shown in line. while those specific to the regositional adhesive label manufacture are shown above and those specific to the permanent adhesive label manufacture are shown below.
The web is typically unwound at box 11. A wide variety of webs may ~5 be utilized for the rttanufaeture of the lapels, and conventional web substrates include band paper, coated papers, and films suca as vinyl, palypropylene and polyethylene films. The web may be meter in-rai - as indicated by box IZ -- -to an intelligent imaging stage, indicated at 13 is FIGURE 1. Associated with tfe intelligent imaging stage I3 may an inverting stage indicated at 14. Where 2o repositional adhesive labels are to be produced_ a tie coal application stage 15 is provided, whereas for both types of labels one or a plurality of print stages -- indicated schematically at 16 in FIGURE 1 - ~e provided.
Desirably perfing is done early in the a-eb processing, as indicated st stage 17 in FIGURE 1, horizontal per>'s being c~tionally applied to define the 25 different labels in the direction of web moveme=t (the first direction), which is indicated schematically by the direction of arrows in FIGURE 1, Alternatively, the lalxls may be severed from tie web by a cutting means (riot shown). .4 video inspection station 1$ may be provided after the perf station 17_ After video inspection, the same equipment can be utilized to practice the 3E3 repositianal adhesive coat stage 19, or a barrier coat stage 21, for the JUN 30 ' :34 8 : 46 FROM MOORE LEGHL DEPT TO SMART B I GGHf:? G'f I~1 Ffat;E .
0 l l :'025 21~'~~~~
repasitional or perrnaaent adhesive labels, respectively. A release coat station ZU for the manufacture of repositional adhesive labels is also desirably provided here in the sequence too.
After stages 19 through 21, drying is necessary, therefore rheweb s passes to cite drying stage 22. '':'he drying stage 22 is capable of drying both farxs or shies at the same time although if a barrier coat is applied to only one of the fakes in the manufacture of permanent adhesive linings one of the heat sources associated with the dryer 22 can be turned cff. Typically the heated web is cooaed by being driven by the chill rolls of tae chill roll take-up station 23. Normally downstream of the station 23 stages specific to the man~,~fac~,ue of perrnaneht adhesive linerless labels are provided, i.e. the release coat stage 24, release coat curing stage 2~, a!xf pern~aneut adhesive application stage 26.
After construction of the labels, in web form, they are often sheeted or longitudinally (la the rust direction, the direction of web movement) perfed as indicated at stage 27, and then rewound as indicated at stage 28.
While a wide variety of materials may be used in each of the application stations set forth above. some materials leave been found to be particularly useful. For example. in the practice of step Z 1 barrier coatings available from Franldin International Corporation and sold under the trade name Luracet I22 may be applied, e.g. at a dry coat weight t~f alaout 3.76 grams per square meter t 109.
In the practice of step 24 a U'V silicone coating is particr~larly useful since it not o~nfy provides the release coat for permanent adhesive moved against it, hut also acts as a protective and Vise;;aLy pleasing coating over the 2s product. Two different types of tJ~I sili~:one products may be used. tine is General Electric Silicone U~' 930 with photo initiator UV 93Lt?G (2.5~).
Another is Gotds;,hrnidt Silicone, such as a mix of Goldschmidt RC726 (65 ~) with RC711 t35 ~?, with photo initiator 1173 (2~) added. Horh UV silicones are typically provided at a dry coat weight of about 1.5 grams per square JUN 3a '94 8:46 FROM MOORE LEGAL DEPT TO SMART BIGGRR OT~J PAGE.E12~025 g meter t 10%- Otfler overcoatings, such as varnishes or the like, rnay be used to provide additional protective layer s over the printing.
At tire permanent adhesive application stage 26 hot melt permanent adhesive may be applied, such as Duratek 3414.4. available from National Starch. Application temperatures typically about 300-350°F, and the dry coat -weight is typically about 25.4 grams per square meter t 10%. The hot meat adhesive cools and cures instantly, therefore no separate drying or curing stage is necessary.
In the practice of step 15 as described above, a desirable tie coat to solution is 2.56 parts Cabosperse (20°~ solids) and one part polyviayl alcohol (5 ~ solids), applied with a dry coal weight of about i.13 grams per square meter t 10 ~ .
The repositional adhesive added at station 19 may be any suitable commercially available repositiottal adhesive. One particularly desirable t5 adhesive is CLEAhTAC~ adhesive available front ivloare Business Forms, Inc.
of Lake Forest, Illinois. This may topically be applied at a dry coat weight of about 4.4 grams per square meter ~ 10~.
The rclcasc coat applied at sation 20 preferably is an aqueous release coat, such as a solution of ~0 to Quillon C and SQ o water. It may be applied 20 with a dry coat weight of about 0.15 grams per square meter t 14~. iii this instance, Quiilon or other similar release coatings provide protection for the indicia. Overprint vartlishes or the like may also be provided.
In order to practice the Inettlod xhematicaily illustrated in FIGURE 1, equipment such as illustrated in FIGURE 2 may be utilised. 'Fhe equipmetlt is 2s shown in FIGURE 2 in a particularly advantageous sequence in ate direction of l weo travel (from left to right in FIGURE 2), however some of the stations may be moved around. Far exarnpie the imaging and print stations described and illustrated may come after applicati4n of release or adhesive coats as long as the stations are capable of applying indicia to coated substFate.

JUhI 30 ' 94 8 :46 FROM MOORE LEGf~L DEPT TO SMNRT H I GGE1R OT~J F~GE. 01 One advantage of the eqt:ipment illustrated in FIGURE ? is th2t it is all c;omrnercially available. ?he basic equipment to which ail the components are applied may be a lithographic press sucl3 as a Topazan Moore TMSW2(~V.
available from ?optnaa Moore Co., Ltd. of 3apart, a flexographic press such as a WebtFOn 1618 press, or the like. In a typical sequence for the manufacture of .
permanent lincrless labels the equipment may print, apply a barrier coat, dry, tJV silicone coat, (3~' cure, apply hat melt adhesive, and rewind. In a typical , repositional endless label process the equipment rnay apply and dry a tie s:oat, print, apply reposirional adhesive: appy a release coat, dry both the adhesive and the release coat, and rewind. "1"he equipment is capable of running at a normal operating speed of between 14C~ and 1504 feet per minute but preferably 500 feet per minute.
The first pied of equipment in t:~e sequence illustrated in FIGURE
comprises a web unwind apparatus 30, which is optionally followed by an edge guide 31 and a metered web itifeed 32 apparatus. ?hen is provided intelligent imaging suclx as utilizing the intelligent imaging printheads 33, 3~ which have a set of turn bars 34 disposed between tbern. The comportet?ts 33 through 35 collectively form an intelligent imaging system 36, which ma~~ be of s..ny suitable conventional type such as one employing ion depasitiott technioues 9 (e.g. MIDAXm printing r.ecimology, or indigo or Xeikon technology, ink jet, laser or impact printer. Typically do~'nstrearn of the intelligent imaging system 36 are a plurality of print stations indicated collectively at 37.
Standard flexography ur lithography cant be used. Six stations 3: are illusu-ated in FIGURE z but any ntunber can be provided from one through eight. In the tnanufactute of repositional adhesive linerless labels t~~pically the first print statxen 38 applies a tie roan, while the other stations print. In t,'te embodiment illustrated in FIGURE 2, then, in the manufacture of per:vanent lineriess labels six color print stations are available wtiile for repositional adhesive 3inerless labels five are available. ?urn bars 39 may be provided as illnstr aced. The earn 3o bars 34, 39 allow printing on both sides with use.

JUN 30 '94 8:46 FROM MOORE LEGRL DEPT TG SP1PRT BIGGRR OTW pHGF.014~025 Io w main drive unit for a rVebaon press is illustrated schematically at 40 in FIGURE 2, followed by perf station 41, which may comprise two diffueut single die perf units 42, 43. ~Tidea inspection is provided downstream of the perf station 4I, as by video cameras 44, 45 having monitors 46, 47.
After video inspearon a coatu 49 is provided far alter natively applying the barrier coat when tuanufactuting permanet:t adhesive labels, or repositional adhesive when trsanufactztring repoSFtional adhesive labels. The water 4Q is easily cleaned daring cha>Elgeover from one type of label to the other.
Downstream of the water 49 is another coater 50. The water 5fl -- which t0 typically applies Quillon C release coat, in rbe manufacture of repositional adhesive labels -- may comprse a 16.5 inch wide Dahlgren type water.
After the application of the repositaonal adhesive on the same face to which the de coat was applied, and the application of the release coat at 50 to the opposite face, in the manufacture of reposaional adhesive labels, tl~e labels IS pass to the dryer S I. In order to be able to dry both the release coat and the repositional adhesive easily and ~uickiy at the same time, the dryer 51 preferably comprises an air flotation, two-sided dryer with two tt2ttutal gas fired burners. Each burner can provide about 880,t10o BTUIhr. The web temperature leaving the dryer is typically 23u°F, and cooling is typically 20 provided by acting on the web with the pulllchzll rotls 52. Typit~lly a gait of driven chill/pull rolls 52 are provided which are supplied with cooling water by a two ton chiller to cool the web down to about 150°F.
When permanent adhesive lineriess labels are constructed and the water 49 is used to apply the barrier coat, only one face of the ~reb is "wet", Z5 therefore the dryer 51 preferably is provided with zone controls for each of the two faces so that drying a~etion to one of the faces can be turned off when permanent adhesive labels are being constructed.
Downstream of the pulllchill rolls 52 is the water 53 for applying die release coat (typically UV siliconey in the manufacture of permanent adhesive 30 labels. The cure system 55 preferably is a Fusion UY curing system having JUN ~0 '94 8:47 FRGM MOORE LEGaL DEFT TO SMHRT BIGGHR OTW PAGE.015~025 ,...

600 watts per inch power. Standard "H" bulbs are used for curing and a light shield provides nitrogen inerting. An oxygen analyzer 54 tray be associated therewith to monitor oxygen levels and control niaogert flaw to the LTV light shield. The UV cure system is illuszxated schematically at 55. Niuogen inerting is necessary for curing Goldschmidt UY silicone or GE 9~OQ silicone (which must occur at oxygen levels below 50 ppm) and in such case nitrogen flow is approximately 47 scftn, at 7p°F and I4.7 psi. A iiQuid nitrogen supply .
tank may be provided to supply the reauired flow and purity of nitrogen.
Niuogen iner~ing is not yet necessar~~ for some UV curing syst~ns. such as for to the GE silicone earlie: described.
In the embodiment illustFatcd in FlGUItE 2, turn bars 56 are provided between the W cure equipment 55 and the permanent adhesive application equipment 57. The equipment 5 % preferably is for applying hot molt adhesive utilizing a hat melt slot die head. The hat melt adhesive is applied by the head :E to the web against an elastomer covered chill roll supplied with cooling water.
For example an elastotner covering of about a half an inch thick (e.g. 90 durometer silicone) may be provided. A standard hopper type melt system with a gear pump may be used to deliver adhesive to the slot die head through a heated hose. The pump raay be driven by adc motor with a drive that tracks 20 the press speed to maintain the constant coat weight up to the desired 5()a feet per minute operation.
After permanent adhesive application, a sheeterlperf unit 59 may be provided to form sheets andlor lan~itudinal (in the direction of web movement) perfs. The unit 59 may comprise an in-fine slitter. Rewind is provided by the 25 apparatus 60, and site linerless labels are produced during rewind the adhesive face (whether permanent or repasitional) of the web substrate comes against the release coat face, which it readily releases from when used by the cor<surtler of the Labels.
For each of the pieces of equipment illustrated in FlGiIRE 2, when the 3o evuipmcnt is not being used it is 'deac;ivated" either by cieatung it so that if J~JN 3G '94 8:47 FROM rlOORE LEGAL DEFT T~~ SM~,RT EIGGf~R OTW PAGE.01Bi0r5 ~~.2'~~~5 the web moves past it no material is applied (e.g. for the coaser 50), or a bypass means may be provided to bypass that piece of equipment. The bypass means may be of any suitable conventional type, such as one or more diver ter rolls, loops, or the like. For example illustrated in dotted line and schematically at 62 in FIGUR~ 2 is a diverter roll about which the web may .
be passed in order to bypass tile hot melt adhesive applicator 57 if repositiotlal adhesive labels are being constructed, in that case the wets z:loving directly from preceding units to the apparatus 59.
FTGURES 3 and 4 schematicailv illustrate reposicional adhesive and to per:~nanent adhesive lintrless labels, respectively, that can be produced according to the intention using the method of FIGUR~ 1 and the apparatus of FIGURE 2. In FIGURE 3 the release coat, e.g. Quiilon C, is provided on one face at indicated at 64, which may have printing (indicia) 65 below it, followed by the suoscate of the web (e.g. paper) 66, Oa the opposite side of t5 the paper web 66 may be ~e tie coat 67 with printing (indici.a) 68 thereon, and with the repositioral adhesive 69 on the opposite face from the release coat 54.
>ror the permanent adhesive linerless label illustrated in FIGURE 4, one face is provided by the release coat (e.g. L'W silicone) ?0, adjacent the barrier coal ?1. prirainglindicia ?2 tray be procrided between the barrier coat ?t and 2o the web substrate (e.g. papery 73. On the opposiue side of the paper 73 may.
be additional printingiindicia 74, and then the hot melt or like permanent adhesive 75 on the opposite face >ftorn the release coat 7Q. It is understood that during the manufacture of either repositional or permanent labels, the adhesive may be pattern coated or applied in a continuous fashion. Litcewse.
25 the barrier and tie coats tray also be pattern coated or applied continuously to match the coating of the adhesive.
It will thus be seen that according to the present invention an advantageous mctnod and apparatus are provided for alternatively constructing permanent adhesive or repositionaI adhesive linerless. labels, with a minimum 30 of W angeover time and difficulty, and utilizing many equipment cotrlponen~s in JIJhJ 30 ' 94 8 : 47 FROM MOORE ~ErFiL DEPT TO SMRRT B I G aF'~R OThJ PAGE. 01 7:~ 0~c5 w 2~2'~ ~9~

common so as to minimize capital expenditure and equipment attention. While the inveJation has bean herein shown. and described in what is prese~.rly conceived to be the most pracxicaI and preferred embodiment thereof it will i~
apparent to those of ordinary skill in the art that many modifxations may be made thereof within t_~e scope of the invention, which scope is to be accorded, the broadest interpretation of the appended claims so as to e>VCOmpass ati .
eauivalent structtues and me~ods.

Claims

1. Apparatus for alternatively manufacturing permanent adhesive or repositional adhesive linerless labels, comprising a plurality of components spaced from each ocher in a first direction which comprises the direction of travel of a web acted upon by the apparatus to produce linerless labels, said components comprising:
an indicia applying station:
a second coating station for optionally applying a barrier coat in the construction of permanent adhesive labels, or repositional adhesive in the construction of repositional adhesive labels;
a third coating station for applying a release coat is the construction of repositional adhesive labels;
a dryer capable of drying both sides of a web at the same time, located downstream of said second coating station;
chill rolls for pulling a web from the dryer;
a fourth coating station for applying a release coat in the construction of permanent adhesive labels;
a release coat curing station for curing a release coat in the construction of permanent adhesive labels; and a permanent adhesive application station.

2. Apparatus as recited in claim 1 wherein said indica applying section comprises:
an intelligent imaging system;
a first coating station for applying a tie coat in the construction of repositional adhesive labels; and at least one print station.

3. Apparatus as recited in claim 2 wherein said components are in the sequence recited in said first direction, said imaging system bring the most upstream component, and said permanent adhesive station the most downstream component in said first direction.

4. Apparatus as recited in claim 3 further comprising a web unwind assembly upstream of said intelligently imaging system in said firts direction, and a web rewind assembly downstream of said permanent adhesive application station.

5. Apparatus as recited in claim 1 further comprising a perf station for applying perfs in a second direction generally perpendicular to said first direction.

6. Apparatus as recited in claim 5 further comprising a video inspection station immediately adjacent and downstream of said perf station.

7. Apparatus as recited in claim 4 further comprising a sheeter and longitudinal perf station between said permanent adhesive station and said rewind assembly.

8. Apparatus as recited in claim 4 further comprising a metered infeed assembly between said unwind assembly and said imaging system.

9. Apparatus as recited in claim 1 wherein said fourth coating station comprises a UV silicone release coat application station including an oxygen analyzer and control system; and wherein said release coat curing station comprises a UV curing station including nitrogen inerted UV curing.

10. Apparatus as recited in claim 2 further comprising a turning mechanism associated with the intelligent imaging system and first coating station to allow two sided imaging of a web used to produce the labels.

11. Apparatus as recited in claim 1 further comprising bypass means for bypassing an individual component when not in use.

12. A method of alternatively manufacturing either permanent adhesive linerless labels or repositional adhesive linerless labels utilizing common equipment, comprising the steps of automatically:
(a) continuously feeding a web of label substrate material having first and second faces so that it moves in a first direction; and while practicing step (a):
(b) imaging indicia on one or both of the faces of the web;
alternatively practicing step (c) or step (d) as follows:
(c) if repositional adhesive lineriess labels are being manufactured, applying and drying a tie coat, applying a repositional adhesive to the first face of the web, applying a release coat to the second race of the web, and drying the release coat and repositional adhesive at the same time;
(d) if permanent adhesive linerless labels are being manufactured, applying a barrier coat to the first face of the web, drying the barrier coat, and then applying a release coat over the barrier coat and applying a permanent adhesive to the second face;
(e) applying perfs to the web in a second direction substantially transverse to the first direction to define labels in the web;
(f) taking up the web after rise practice of steps (b), (c) or (d), and (e);
and (g) occasionally changing over from step (c) to step (d) and vice versa.

13. A method as recited in claim 12 comprising the further step during the practice of step (c) of applying a tie coat to the web first face prior to the repositional adhesive being applied to the web first face.

14. A method as recited in claim 12 wherein the barrier coat or the repositional adhesive are applied by the same coater depending upon whether step (c) or step (d) is being practiced.

15. A method as recited in claim 12 wherein during the practice of step (c) the repositional adhesive and release coat are dried simultaneously by a two sided hot air dryer.

16. A method as recited in claim 12 wherein step (d) is further practiced to apply a UV silicone release coat, and UV cure the release coat.

17. A method as recited in claim 16 wherein step (d) is further practiced to cure the release coar prior to application of the permanent adhesive.

18. A method as recited in claim 17 wherein step (d) is further practiced to apply hot melt adhesive as the permanent adhesive.

19. A method as recited in claim 12 wherein step (g) is practiced by deactivating some equipment components and activating others.

20. A method of automatically manufacturing a web of permanent adhesive lineriess labels from a web of substrate material having first and second faces, comprising the steps of:
imaging indicia on at least one face of the substrate;
perfing the substrate web to define labels;
applying a barrier coat to the first face of the substrate:

hot air drying the barrier coat;
applying a UV silicone release coat to the first face of the substrate;
UV curing the UV silicon release coat;
applying a permanent adhesive to the second face; and taking up the web of linerless labels produced.

21. A method as recited in claim 20 wherein said steps are practiced sequentially.

22. A method of automatically manufacturing a web of repositional adhesive linerless labels from a web of substrate material having first and second faces, comprising the steps of sequentially:
applying a tie coating to the first of the substrate;
imaging indicia on at least one face of the substrate;
perfing the substrate web to define labels;
applying a repositional adhesive to the first face of the substrate and a release coat to the second face;
simultaneously hot air drying the adhesive and release coats; and taking up the web of repositional adhesive linerless labels produced.

23. A method as recited in claim 22 wherein said steps are practiced sequentially.