Refinements in method and apparatus for manufacturing linerless labels

Claim 1

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 linerless 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 face 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 the practice of steps (b), (c) or (d), and (e); (g) occasionally changing over from step (c) to step (d) and vice versa; and wherein step (b) is practiced using a flexographic unit having at least one print cylinder, and comprising the further step of immediately detaching the at least one print cylinder from the web when the common equipment is turned off.

Claim 2

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 linerless 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 face 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 the practice of steps (b), (c) or (d), and (e); (g) occasionally changing over from step (c) to step (d) and vice versa; and wherein step (b) is practiced using a flexographic unit having at least one print cylinder, and comprising the further step of immediately detaching the at least one print cylinder from the web when the common equipment is turned off.

Claim 3

A method of automatically manufacturing a web of permanent adhesive linerless labels from a web of substrate material having first and second faces, comprising the steps of: (a) imaging indicia on at least one face of the substrate; (b) perfing the substrate web to define labels; (c) applying a barrier coat to the first face of the substrate; (d) hot air drying the barrier coat; (e) applying a UV silicone release coat to the first face of the substrate; (f) UV curing the UV silicone release coat; (g) applying a permanent adhesive to the second face; (h) taking up the web of linerless labels produced; and wherein step (g) is practiced by applying a hot melt permanent adhesive with a temperature uniformity of +/- five degrees F. across the width of the web and with an adhesive coat thickness uniformity of +/- about 0.0001 inches across the width of the web; and wherein step (g) is practiced using a heated slotted die head having die lips that are flat and form a slot therebetween through which adhesive flows, the lips having a quadrate shape in cross-section, and each having a thickness of about 0.06 inches and defining a slot having a thickness, corresponding to the spacing between the lips, of about 0.012 inches, to apply an adhesive coating thickness of about 0.0005-0.001 inches.

Claim 4

A method of automatically manufacturing a web of permanent adhesive linerless labels from a web of substrate material having first and second faces, comprising the steps of: (a) imaging indicia on at least one face of the substrate; (b) perfing the substrate web to define labels; (c) applying a barrier coat to the first face of the substrate; (d) hot air drying the barrier coat; (e) applying a UV silicone release coat to the first face of the substrate; (f) UV curing the UV silicone release coat; (g) applying a permanent adhesive to the second face; (h) taking up the web of linerless labels produced; and wherein step (g) is practiced by applying a hot melt permanent adhesive with a temperature uniformity of +/- five degrees F. across the width of the web and with an adhesive coat thickness uniformity of +/- about 0.0001 inches across the width of the web; and wherein step (g) is practiced using a heated slotted die head having die lips that are flat and form a slot therebetween through which adhesive flows, the lips having a quadrate shape in cross-section, and each having a thickness of about 0.06 inches and defining a slot having a thickness, corresponding to the spacing between the lips, of about 0.012 inches, to apply an adhesive coating thickness of about 0.0005-0.001 inches.