Cut and stack pressure sensitive adhesive substrates and process

• US 10,710,762 B1
• Filed: 08/03/2016
• Issued: 07/14/2020
• Est. Priority Date: 08/03/2015
• Status: Active Grant

• Current Assignee: Polymeric Converting LLC
• Original Assignee: Polymeric Converting LLC
• Inventors: Dronzek, Jr., Peter J.
• Primary Examiner(s): Osele, Mark A
• Assistant Examiner(s): Caillouet, Christopher C
• Application Number:
  US15/227,903
• Time in Patent Office: 1,441 Days
• CPC Class Codes: B31D 1/021 Making adhesive labels having a multilayered structure, e.g. provided on carrier webs
• CPC Class Codes: B31D 1/026 Cutting or perforating B31D1/022 takes precedence
• CPC Class Codes: B31D 1/027 involving, marking, printing or coding
• CPC Class Codes: B32B 2519/00 Labels, badges
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/308 comprising acrylic (co)polymers
• CPC Class Codes: B32B 7/06 permitting easy separation
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B65C 1/00 Labelling flat essentially-rigid surfaces labelling of fabrics B65C5/00
• CPC Class Codes: B65C 2009/0018 Preparing the labels
• CPC Class Codes: B65C 9/0015 Preparing the labels or articles, e.g. smoothing, removing air bubbles
• CPC Class Codes: B65C 9/0065 Cutting tubular labels from a web
• CPC Class Codes: B65C 9/20 Gluing the labels or articles
• CPC Class Codes: G06Q 10/08 Logistics, e.g. warehousing, loading or distribution; Inventory or stock management
• CPC Class Codes: G06Q 30/06 Buying, selling or leasing transactions
• CPC Class Codes: G09F 2003/0241 Repositionable or pressure sensitive adhesive
• CPC Class Codes: G09F 3/02 Forms or constructions layered products B32B
• CPC Class Codes: G09F 3/0297 including a machine-readable marking, e.g. a bar code digitally marked record carriers in general G06K19/00
• CPC Class Codes: G09F 3/10 by an adhesive layer

Abstract

A process of producing printed variably imaged labels cut to individual label sheets in a pre-defined sequence of variable information synchronized with the planogram of a retail store for labeling, output from a factory assembly line for unique product labeling or labeling of shipments from a fulfillment or distribution warehouse that all have unique data and follow a planogram or planned sequence. The labels are cut into single sheets using a cutter/stacker and either use a crack and peel liner or a stripped matrix around the label to facilitate easy removal and application. The cutter/stacker processes converted label stock that is either pre-printed and die cut and/or variably imaged.

Claims

1. A method of printing a single ply transparent or pigmented opaque film label substrate having a top surface and a bottom surface, in a variable imaging printer and then cutting and stacking the labels into stacks of single labels imaged in a sequence that is predetermined and synchronized with a planogram, production schedule or distribution plan, said method comprising sequentially carrying out the following steps:

(a) coating said bottom surface of said single ply transparent or opaque film substrate with a layer consisting of pressure sensitive adhesive and optionally coating said top surface of said adhesive coated substrate with a functional top coating to receive the variable image;

(b) laminating a layflat liner onto said layer of pressure sensitive adhesive to form a laminated transparent or pigmented opaque film substrate; and

(c) converting said laminated transparent or pigmented opaque film substrate into roll or fan-fold laminated transparent or pigmented opaque film substrate, by placing scores, die cuts and or optional pin holes for tractor feed, and

(d) passing said laminated substrate obtained in step (c) through a variable image printer to affix printed indicia to said laminated transparent or pigmented opaque film substrate obtained in step (c) to form a variable imaged roll or fan-fold following a sequence that is a predetermined and synchronized sequence with a planogram, production schedule or distribution plan; and

(e) processing the variable imaged roll or fan-fold through a cutter/stacker machine by feeding said cutter/stacker machine with said variable imaged roll or fanfold as a continuous sheet wherein said cutting and stacking machine slits said variable imaged roll or fan-fold in the machine direction and cuts the imaged roll transversely with a knife mechanism while maintaining the synchronized sequence and delivering discrete individual labels into stacks of discrete individually cut labels that are then easily applied by hand where the volume resistivity of the laminated transparent or pigmented opaque film substrate is 10⁹-10¹⁴ ohms-cm.

2. A method of printing a transparent or pigmented opaque film label substrate as defined in claim 1 where the volume resistivity of the laminated transparent or pigmented opaque film substrate is 10¹¹-10¹² ohms-cm.

3. A method of printing a single ply transparent or pigmented opaque film label substrate having a top surface and a bottom surface, in a variable imaging printer and then cutting and stacking the labels into stacks of single labels imaged in a sequence that is predetermined and synchronized with a planogram, production schedule or distribution plan, said method comprising sequentially carrying out the following steps:

(a) coating said bottom surface of said single ply transparent or opaque film substrate with a layer consisting of pressure sensitive adhesive and optionally coating said top surface of said adhesive coated substrate with a functional top coating to receive the variable image;

(b) laminating a layflat liner onto said layer of pressure sensitive adhesive to form a laminated transparent or pigmented opaque film substrate; and

(c) converting said laminated transparent or pigmented opaque film substrate into roll or fan-fold laminated transparent or pigmented opaque film substrate, by placing scores, die cuts and or optional pin holes for tractor feed, and

(d) passing said laminated substrate obtained in step (c) through a variable image printer to affix printed indicia to said laminated transparent or pigmented opaque film substrate obtained in step (c) to form a variable imaged roll or fan-fold following a sequence that is a predetermined and synchronized sequence with a planogram, production schedule or distribution plan; and

(e) processing the variable imaged roll or fan-fold through a cutter/stacker machine by feeding said cutter/stacker machine with said variable imaged roll or fanfold as a continuous sheet wherein said cutting and stacking machine slits the variable imaged roll or fan-fold in the machine direction and cuts the imaged roll transversely with a knife mechanism while maintaining the synchronized sequence and delivering discrete individual labels into stacks of discrete individually cut labels that are then easily applied by hand where the surface resistivity of the laminated transparent or pigmented opaque film substrate is 10⁹-10¹³ ohms-cm.

4. A method of printing a transparent or pigmented opaque film label substrate as defined in claim 3 where the surface resistivity of the laminated transparent or pigmented opaque film substrate is 10¹¹-10¹² ohm-cm.

5. A method for labeling the shelves in a retail store which comprises sequentially carrying out the following steps:

(a) developing a planogram of an arrangement of all or part of displayed items in a particular retail store;

(b) printing pressure sensitive labels on a top side of a roll of a single-ply substrate consisting of a polyester film having on a bottom side, a layer consisting of a pressure sensitive adhesive coating covered with a layflat release liner said pressure sensitive labels being arranged in a sequence that follows all or part of a planogram of an arrangement of displayed items in a particular retail store to form a printed single ply substrate;

(c) cutting and stacking said pressure sensitive labels from a roll of said printed single ply substrate on a cutting and stacking machine by feeding said cutting and stacking machine with said roll of said printed single ply substrate as a continuous sheet wherein said cutting and stacking machine slits said roll of a printed single ply substrate in the machine direction and cuts the imaged roll transversely with a knife mechanism before individually stacking cut and stacked pressure sensitive labels so that said cut and stacked pressure sensitive labels will be arranged in a sequence that follows all or a part of a planogram of an arrangement of all or part of displayed items in said particular retail store, and;

(d) applying said pressure sensitive labels to all or part of said shelves by following the planogram of said store so that said pressure sensitive labels will correspond to said all or part of displayed items in a particular retail store where the volume resistivity of the laminated transparent or pigmented opaque film substrate is 10⁹-10¹⁴ ohms-cm.

6. A method for labeling the shelves in a retail store as defined in claim 5 where the volume resistivity of the laminated transparent or pigmented opaque film substrate is 10¹¹-10¹² ohms-cm.

7. A method for labeling the shelves in a retail store which comprises sequentially carrying out the following steps:

(a) developing a planogram of an arrangement of all or part of displayed items in a particular retail store;

(b) printing pressure sensitive labels on a top side of a roll of a single-ply substrate consisting of a polyester film having on a bottom side, a layer consisting of a pressure sensitive adhesive coating covered with a layflat release liner said pressure sensitive labels being arranged in a sequence that follows all or part of a planogram of an arrangement of displayed items in a particular retail store to form a printed single ply substrate;

(c) cutting and stacking said pressure sensitive labels from a roll of said printed single ply substrate on a cutting and stacking machine by feeding said cutting and stacking machine with said roll of said printed single ply substrate as a continuous sheet wherein said cutting and stacking machine slits said roll of a printed single ply substrate in the machine direction and cuts the imaged roll transversely with a knife mechanism before individually stacking cut and stacked pressure sensitive labels so that said cut and stacked pressure sensitive labels will be arranged in a sequence that follows all or a part of a planogram of an arrangement of all or part of displayed items in said particular retail store, and;

(d) applying said pressure sensitive labels to all or part of said shelves by following the planogram of said store so that said pressure sensitive labels will correspond to said all or part of displayed items in a particular retail store where the surface resistivity of the laminated transparent or pigmented opaque film substrate is 10⁹-10¹³ ohms-cm.

8. A method for labeling the shelves in a retail store as defined in claim 7 where the surface resistivity of the laminated transparent or pigmented opaque film substrate is 10¹¹-10¹² ohms-cm.

9. A method of printing a single ply transparent or opaque polyester, polypropylene, polyethylene, cellophane or vinyl film label substrate having a top surface and a bottom surface, in a variable imaging printer and then cutting and stacking the labels into stacks of single labels imaged in a sequence that is predetermined and synchronized with a planogram, production schedule or distribution plan, said method consisting of:

(a) coating said bottom surface of said single ply transparent or opaque polyester or vinyl film substrate with a layer consisting of pressure sensitive adhesive and optionally coating said top surface of said pressure sensitive adhesive coated single ply transparent or opaque polyester or vinyl film substrate with a functional top coating to receive the variable image;

(b) laminating a layflat coated paper liner onto said layer of pressure sensitive adhesive to form a laminate with said single ply transparent or opaque polyester or vinyl film substrate; and

(c) converting said laminate with a single ply transparent or opaque polyester or vinyl film substrate into roll or fan-fold format with non-variable printing, placing scores, die cuts and or optional pin holes for tractor feed, and

(d) passing said laminate with a single ply transparent, pigmented or opaque polyester or vinyl film substrate through a variable image laser printer to affix printed indicia to said laminate with a single ply transparent or opaque polyester or vinyl substrate following a sequence that is a predetermined and synchronized sequence with a planogram, production schedule or distribution plan; and

(e) processing the variable imaged roll or fan-fold through a cutter/stacker machine by feeding said variable imaged roll or fan-fold into said cutter/stacker machine while maintaining the synchronized sequence and delivering discrete individual labels into stacks of discrete individually cut labels that are then easily applied by hand where the volume resistivity of the laminated transparent or pigmented opaque film substrate is 10⁹-10¹³ ohms-cm.

10. A method of printing a transparent or opaque film label substrate as defined in claim 9 where the volume resistivity of the laminated transparent or pigmented opaque film substrate is 10¹¹-10¹² ohms-cm.

11. A method of printing a single ply transparent or opaque polyester, polypropylene, polyethylene, cellophane or vinyl film label substrate having a top surface and a bottom surface, in a variable imaging printer and then cutting and stacking the labels into stacks of single labels imaged in a sequence that is predetermined and synchronized with a planogram, production schedule or distribution plan, said method consisting of:

(a) coating said bottom surface of said single ply transparent or opaque polyester or vinyl film substrate with a layer consisting of pressure sensitive adhesive and optionally coating said top surface of said pressure sensitive adhesive coated single ply transparent or opaque polyester or vinyl film substrate with a functional top coating to receive the variable image;

(b) laminating a layflat coated paper liner onto said layer of pressure sensitive adhesive to form a laminate with said single ply transparent or opaque polyester or vinyl film substrate; and

(c) converting said laminate with a single ply transparent or opaque polyester or vinyl film substrate into roll or fan-fold format with non-variable printing, placing scores, die cuts and or optional pin holes for tractor feed, and

(d) passing said laminate with a single ply transparent, pigmented or opaque polyester or vinyl film substrate through a variable image laser printer to affix printed indicia to said laminate with a single ply transparent or opaque polyester or vinyl substrate following a sequence that is a predetermined and synchronized sequence with a planogram, production schedule or distribution plan; and

(e) processing the variable imaged roll or fan-fold through a cutter/stacker machine by feeding said variable imaged roll or fan-fold into said cutter/stacker machine while maintaining the synchronized sequence and delivering discrete individual labels into stacks of discrete individually cut labels that are then easily applied by hand labels into stacks of discrete individually cut labels that are then easily applied by hand where the surface resistivity of the laminated transparent or pigmented opaque film substrate is 10⁹-10¹⁴ ohms-cm.

12. A method of printing a transparent or opaque film label substrate as defined in claim 11 where the surface resistivity of the laminated transparent or pigmented opaque film substrate is 10¹¹-10¹² ohms-cm.