Abstract:
A process for affixing an insulating label to a container involves applying a thermoplastic hot-melt adhesive to a first edge of the label and applying a thermoplastic hot-melt adhesive and a thermosetting adhesive to a second edge of the label. The insulating label is applied to a container, and provides improved heat resistance, thereby reducing occurrences of delamination during subsequent heating of the container.

Description:
DESCRIPTION OF RELATED ART 
       [0001]    Insulating labels have been developed for insulating containers for hot beverages while protecting the consumer from burns. One current label utilizes a polymeric film that is extrusion laminated to a non-woven polyolefin insulation layer. The label can be supplied in roll form and applied to containers, such as 9 oz. steel cans, using a Krones Contiroll labeler or similar labeling equipment. A low viscosity (e.g., 400-1200 cPs) hot-melt thermoplastic adhesive is used to affix the label to the container. One disadvantage is that the hot-melt adhesive is prone to re-softening when the beverage is heated in a suitable heating apparatus. The softening of the adhesive can result in the label becoming separated from the container, thereby compromising package integrity as well as its insulating and safety properties. 
         [0002]    Another type of insulating label is prepared by oriented polystyrene foam/polystyrene film lamination. A reverse-printed polystyrene film is adhesive laminated to a foamed polystyrene insulation layer. The structure is typically supplied in roll format and applied to containers using a Krones Contiroll labeler or similar labeling equipment. Instead of using a hot-melt adhesive, the polystyrene label is solvent-welded together. A solvent is applied to the lap portion of the label during labeling and the solvent dissolves the polystyrene polymer. The label is then seamed together where the dissolved polystyrene resin welds the two sides of the label together, thereby creating a seam without the use of glue. However, the overall heat resistance of the polystyrene label is poor, resulting in label melting and “burn-through” during heating. 
         [0003]    It would be advantageous to have a process for labeling a structure with an insulating label having improved heat resistance properties, for example to reduce the likelihood of delamination upon subsequent heating of the structure and/or label. 
       SUMMARY 
       [0004]    In one aspect, a process for affixing a label having a first edge and a second edge to a container is provided. A thermoplastic hot-melt adhesive is applied to the first edge. A thermoplastic hot-melt adhesive and a thermosetting adhesive are applied to the second edge. The process may involve applying the thermoplastic hot-melt adhesive in at least two separate locations of the second edge and applying the thermosetting adhesive in at least one location of the second edge that does not comprise the thermoplastic hot-melt adhesive. The label is affixed to the container. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0005]      FIG. 1  is a diagram showing an example of the placement of thermosetting and thermoplastic adhesives on a label. 
           [0006]      FIG. 2  is a diagram showing an alternative placement of thermosetting and thermoplastic adhesives on a label. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0007]    As used herein, the term “thermoplastic adhesive” and similar terms refer to adhesives that soften or melt to a liquid when heated. The term “thermosetting adhesive” refers to polymer material that is capable of curing to form a cross-linked structure, resulting in an adhesive with a higher melting point. Examples of thermosetting adhesives include moisture-curing polyurethane reactive adhesives, which are efficient, high performance adhesives for a wide range of applications. One specific class of moisture-curing polyurethane reactive adhesives are commonly referred to as hot-melt polyurethane reactive adhesives (sometimes abbreviated “HMPUR” or “PUR”). 
         [0008]    The process is not limited to any particular type of thermosetting adhesive. Non-limiting examples of thermosetting adhesives include moisture curable polyurethane adhesives, 2-part polyurethane adhesives produced by the combination of an isocyanate with a suitable polyol, 2-part epoxy systems having an epoxide containing resin mixed with a active hydrogen containing hardening agent, or moisture curable cyanoacrylate adhesives to name a few. In particular, a moisture curable polyurethane hot-melt adhesive may be used. These adhesives are composed predominantly of polymeric isocyanate resins that have been constructed from the reaction of polyols with an excess of polyisocyanate monomer. Typical polyols would include polyester and/or polyether polyols, where typical polyisocyanate monomers would include compounds such as methylenediphenyl diisocyanate, toluene diisocyanate, or isophorone diisocyanate. Many types of thermosetting adhesives are well known in the art. Reference is made to U.S. Pat. Nos. 6,133,400, 5,932,680, 6,221,978, 5,018,337, and 4,999,407, and published applications U.S. 2007/0155859 and US 2006/0205909, the disclosures of which are hereby incorporated by reference. 
         [0009]    The HMPUR adhesion reaction occurs in primarily two stages. The first is similar to a conventional hot melt and involves cooling the molten adhesive to a solid. The second stage occurs as the adhesive reacts with moisture from the atmosphere and/or the substrate, which produces a high temperature resistant polymer. HMPUR adhesives generally can withstand temperatures up to 250° F. and short term exposure temperatures up to 400° F. See Waites, P. Moisture-curing reactive polyurethane hot-melt adhesives Pigment &amp; Resin Technology, 26:5, 1997, pp. 300-303. The outstanding heat resistance makes HMPUR an ideal adhesive candidate for affixing an insulating label to a container that will be subjected to heating. 
         [0010]    Affixing a label to a container may be desired for several reasons. A label may have insulating properties and/or may provide aesthetic and/or informational purposes. The label is preferably made of a heat-stable film or material that can maintain its structure during exposure to high temperatures. Materials such as heat-shrinkable films are poor candidates for such applications and generally should be avoided. The container to be labeled may be made of a high temperature resistant plastic, a metal, glass, a composite material, or any other suitable material. The container may be a can, a bottle or any other storage means. 
         [0011]    In one aspect, a thermoplastic hot melt adhesive is applied to the leading edge and the trailing edge of the label. The leading edge is the edge of the label which will first come in contact with the container. The trailing edge is the opposite edge of the label. The leading edge of the label may come directly in contact with the container and may adhere directly to the surface of the container. The container may then be spun causing the label to wrap around the container. Once wrapping is complete, the trailing edge of the label lays on top of the already adhered leading edge (forming the lap joint), thereby producing a fully wrapped and bonded container. 
         [0012]    Adhesives may be applied to the edges of the label in many arrangements. A few of many adhesive arrangements are shown in  FIGS. 1 and 2 . One particular arrangement includes applying a thermoplastic adhesive to a portion of an edge of the label and also applying a thermosetting adhesive such as HMPUR to the same edge of the label. In a preferred aspect, the two types of adhesives are applied in a manner in which they do not come in contact with one another. This may occur by alternating the locations in which the adhesives are applied, or by applying the adhesives to different portions of the edge, as shown in  FIGS. 1B and 2B . Small adhesive voids may be positioned at various locations on an edge, in between regions comprising thermoplastic adhesive, and these voids may be filled with HMPUR. 1, 2, 3, 4, 5 or more small adhesive voids may be present.  FIG. 1B  shows one small adhesive void filled by HMPUR and  FIG. 2B  shows two small adhesive voids filled by HMPUR. This creates an edge that will be fully bonded with either the other edge, or the container, depending on whether the leading edge or trailing edge is manufactured in this manner. 
         [0013]    Another aspect involves the application of a conventional thermoplastic adhesive to a portion of the leading edge, which will provide adhesion to the container. The thermoplastic adhesive may also be applied to the trailing edge of the label in two regions, both being separated by a small ¼″ adhesive void. The size of the small adhesive void may vary. For example, it may be 1/16″, ⅛″, ¼″, ½″, etc, depending on size constraints and adhesive requirements. Instead of applying a full strip of conventional hot-melt to the edge, the small adhesive void is created in the center of the glue pattern. This void may preferably be located approximately in the center of the edge glue pattern, as shown in  FIG. 1B . However, the location and number of the adhesive void(s) may vary. The adhesive void may be filled with HMPUR. 
         [0014]    Regardless of the location, or the amount of HMPUR applied to the edge of the label, the HMPUR cools and sets just like the conventional hot-melt adhesives. Upon reaction of the HMPUR to atmospheric moisture, the HMPUR undergoes a chain lengthening reaction that changes the physical state of the adhesive from a thermoplastic to a thermoset. This process may be referred to as curing. After approximately 3-5 days of curing, the HMPUR is fully cured and generally does not re-melt upon exposure to heat, even at temperatures of approximately greater than 300° F. This is especially useful if a labeled container is to be heated via rapid heating devices such as microwave ovens and similar radio-frequency type technologies. The HMPUR adhered label is less likely to be removed by the consumer. 
         [0015]    Because the HMPUR adhesive generally is reactive to moisture, the adhesive should be applied using specialized equipment that does not expose the uncured adhesive to the atmosphere. The HMPUR may be supplied in a closed container, such as a sealed 5-gallon pail. The HMPUR may be melted and dispensed directly from the container. Application of the adhesive may be completed using typical hot-melt glue gun equipment as is well known in the art. 
         [0016]    Once a label is affixed to a container via applying a thermoplastic hot-melt adhesive to the first edge and applying a thermoplastic hot-melt adhesive and a thermosetting adhesive to the second edge, the label can withstand heating. The addition of the thermosetting adhesive allows the label to stay affixed to the container even when the container is subject to heating. 
       EXAMPLE 1 
       [0017]    Four low viscosity (&lt;5000 cPs) hot melt polyurethane reactive adhesives were evaluated to determine their machineability when dispensed through a typical air-open/air-closed (AO/AC) glue gun. The four formulations had viscosities ranging from 900 cPs to 4500 cPs. The physical properties for the four formulations are listed in Table 1. 
         [0000]    
       
         
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 1 
               
             
             
               
                   
               
               
                 Hot Melt PUR Formulations Evaluated 
               
             
          
           
               
                   
                   
                   
                   
                 Application 
                 Maximum 
               
               
                   
                   
                   
                 Viscosity (cPs @ 
                 Temperature 
                 Temperature 
               
               
                 Example 
                 Supplier 
                 Formulation 
                 temperature) 
                 (° F.) 
                 (° F.) 
               
               
                   
               
               
                 1 
                 National 
                 91-001A 
                  900 @ 250° F. 
                 250 
                 250 
               
               
                   
                 Starch 
               
               
                 2 
                 National 
                 91-7997 
                 2500 @ 275° F. 
                 275 
                 275 
               
               
                   
                 Starch 
               
               
                 3 
                 Bostik 
                 SG 1567-150 
                 2900 @ 250° F. 
                 250 
                 280 
               
               
                 4 
                 H.B. Fuller 
                 TL-0511 
                 4500 @ 250° F. 
                 250 
                 250 
               
               
                   
               
             
          
         
       
     
         [0018]    Of the four adhesives tested, the National Starch 91-001A formulation demonstrated the best machining characteristics with no observable stringing. 
       EXAMPLE 2 
       [0019]    All adhesive testing was completed using a Nordson BM20 melting unit equipped with standard 5/16″ transfer hoses. PUR test adhesives were supplied in 5-gallon pails, along with a 5-gallon pail of purge material from each supplier. The testing apparatus was set up so that the glue gun was fired onto a moving web of paper substrate. Web speed of the paper was variable from 0 to 300 feet per minute (fpm). Due to venting requirements, the glue gun was initially configured in the down-firing position. 
         [0020]    For initial testing, a Nordson SUREBEAD™ reduced cavity needle/seat gun system was installed onto the test apparatus. It was theorized that the SUREBEAD™ would produce better adhesive cut-off due to the smaller amount of residual adhesive remaining in the reduced cavity configuration after actuation. The first adhesive to be evaluated was the National Starch 91-001A formulation. Initial test parameters for this adhesive are listed in Table 2. 
         [0000]    
       
         
               
             
               
               
             
               
               
             
           
               
                 TABLE 2 
               
             
             
               
                   
               
               
                 Machine Set-Up Parameters for Evaluation of National 91-001A 
               
               
                 Adhesive 
               
             
          
           
               
                 Parameter 
                 Value 
               
               
                   
               
             
          
           
               
                 Platen Temperature 
                 250° F. 
               
               
                 Transfer Hose Temperature 
                 250° F. 
               
               
                 Gun Body Temperature 
                 250° F. 
               
               
                 Glue Pump Pressure 
                   250 psi 
               
               
                 Glue Gun Assembly 
                 SUREBEAD ™ AO/AC reduced cavity 
               
               
                 Glue Nozzle (orifice and 
                 0.016″, no engagement 
               
               
                 engagement) 
               
               
                   
               
             
          
         
       
     
         [0021]    After the adhesive and glue gun were up to temperature, testing commenced. At a line speed of 300 fpm the SUREBEAD™ gun applied a ¼″ bead with a small amount of stringing. While the glue stringing was relatively minor, it was significant enough to not be applicable for the application. Therefore, the SUREBEAD™ needle/seat gun was removed and replaced with a SOLIDBLUE™ ball/seat design. Temperatures and pressures were kept the same, and a 0.018″/0.050″ engagement nozzle was fitted onto the tip. Once the SOLIDBLUE™ gun was up to temperature testing recommenced. At a full machine speed of 300 fpm, no stringing was observed while dispensing the National 91-001A PUR adhesive with a Nordson SOLIDBLUE™ gun. In order to observe for glue build-up on the tip, the machine was run for ˜2 minutes at full speed, then the tip and substrate was observed. Once again, no stringing was seen and the glue tip was free from any build-up. 
       EXAMPLE 3 
       [0022]    Testing of the 91-001A formulation was concluded and the melter purged using National Starch 34-3180 PUR purge compound. After purging was complete, the melter was reloaded with the National 91-7997 formulation. The initial test parameters for the 91-7997 adhesive are shown in Table 3. 
         [0000]    
       
         
               
             
               
               
             
           
               
                 TABLE 3 
               
             
             
               
                   
               
               
                 Machine Set-Up Parameters for Evaluation of National 91-7997 
               
               
                 Adhesive 
               
             
          
           
               
                 Parameter 
                 Value 
               
               
                   
               
               
                 Platen Temperature 
                 275° F. 
               
               
                 Transfer Hose Temperature 
                 275° F. 
               
               
                 Gun Body Temperature 
                 275° F. 
               
               
                 Glue Pump Pressure 
                   320 psi 
               
               
                 Glue Gun Assembly 
                 SOLIDBLUE ™ AO/AC 
               
               
                 Glue Nozzle (orifice and engagement) 
                 0.018″, 0.050″ engagement 
               
               
                   
               
             
          
         
       
     
         [0023]    Because the 91-7997 formulation was considerably higher in viscosity than the 91-001A formulation, the pump pressure was boosted from 250 psi to 320 psi. Initial testing showed that the 7997 adhesive possessed very little (if any) stringing. However, the adhesive did build up on the nozzle after 1-2 minutes of running. This build-up would grow in size until a large enough drop of glue would fall away from the nozzle, causing a streak on the web. In an attempt to eliminate this, pump pressure was increased to 400 psi, but the increased pressure did not have an effect on glue build-up. 
         [0024]    The third adhesive tested was the H.B. Fuller TL-0511 formulation. This adhesive had a published viscosity of 4500 cPs at 250° F., making it the highest viscosity candidate. 
       EXAMPLE 4 
       [0025]    Table 4 shows the results of adhesive bond testing. Bond strength was obtained by using a tensile testing device equipped with a 2000 g load cell. Test labels were adhered to a 9 oz. steel water-filled can using an adhesive as discussed above. The labeled can was heated until the internal liquid temperature reached 140° F. At the same time, the surface of the metal container reached a temperature of 250° F. The bond strength of the adhesive was then tested. 
         [0026]    The adhesives with a bond strength exceeding 400 g have a superior ability to withstand heating and have labels which are difficult for a consumer to remove. Table 4 shows that standard hot melt adhesives have bond strengths ranging from 67 g to 212 g. Most HMPUR adhesives have bond strengths above 400 g. 
         [0000]    
       
         
               
               
               
             
           
               
                 TABLE 4 
               
               
                   
               
               
                   
                 Bond Strength After Heating 
                   
               
               
                   
                 Liquid to 140° F. and 
                 Adhesive 
               
               
                 Adhesive 
                 Container to 250° F. 
                 Weight 
               
               
                   
               
             
             
               
                 Henkel 362 
                 114 g 
                 0.18 
               
               
                 Thermoplastic Adhesive 
               
               
                 Trial # 1 
               
               
                 Henkel 362 
                  67 g 
                 0.06 
               
               
                 Thermoplastic Adhesive 
               
               
                 Trial #2 
               
               
                 Henkel 362 
                 146 g 
                 0.22 
               
               
                 Thermoplastic Adhesive 
               
               
                 Trial #3 
               
               
                 Henkel 362 
                 155 g 
                 0.23 
               
               
                 Thermoplastic Adhesive 
               
               
                 Trial #4 
               
               
                 Bostik SG1567 
                 148 g 
                 n/a 
               
               
                 HMPUR Spot 
               
               
                 Henkel 362 Trial #4 - 
                 212 g 
                 0.32 
               
               
                 Heavy Glue Deposition 
               
               
                 NSC 91-7997 
                 466 g 
                 n/a 
               
               
                 HMPUR Spot 
               
               
                 H.B. Fuller TL0511 
                 474 g 
                 n/a 
               
               
                 HMPUR Spot 
               
               
                 NSC 91-001A 
                 580 g 
                 n/a 
               
               
                 HMPUR Spot 
               
               
                   
               
             
          
         
       
     
         [0027]    While particular embodiments of the present invention have been described and illustrated, it should be understood that the invention is not limited thereto since modifications may be made by persons skilled in the art. The present application contemplates any and all modifications that fall within the spirit and scope of the underlying invention disclosed and claimed herein. All patents, patent applications, and references cited in this disclosure are expressly incorporated herein by reference.