Abstract:
A method of manufacturing an extended content label involves receiving label stock comprising a liner layer and a face stock layer, and de-laminating the liner layer from the face stock layer. The face stock layer and the liner layer each have a top surface and a bottom surface. The bottom surface of the face stock layer has an adhesive layer that adheres the face stock layer to the liner layer. A first face stock image is printed onto the top surface of the liner layer. The printed face stock image is transferred to the bottom surface of the face stock layer, and a second face stock image is printed onto the top surface of the face stock layer. The transferring the printed face stock image involves re-laminating the face stock layer with the liner layer.

Description:
FIELD OF THE INVENTION 
     This patent application relates to a self-adhesive label and, in particular, to a method and system of manufacturing a pressure sensitive label having front and back print surfaces. 
     BACKGROUND 
     Extended content labels (“ECLs”) have two or more print surfaces and, therefore, are often used for package labeling where there is a need to provide a large amount of information in a small labeling space. A conventional ECL comprises a pressure-sensitive web and a silicon-coated release liner. The pressure-sensitive web includes a top face stock layer, and a bottom face stock layer laminated to the top face stock layer. An adhesive is provided on the back surface of the top layer and the back surface of the bottom layer. The release liner protects the adhesive of the bottom layer until the label is applied to the package. Supplemental information printed on the front surface of the bottom layer and the back surface of the top layer is revealed when the top layer is pulled away from the bottom layer. 
     Conventional ECLs are manufactured using an inline flexographic print process in which a top roll of pressure-sensitive label stock is laminated to bottom roll of pressure-sensitive label stock via a series of processing stations. Each roll of label stock comprises a face stock layer, adhesive provided on the back surface of the face stock layer, and a release liner that protects the adhesive. The top roll of label stock is fed to a processing station that removes the release liner from the face stock layer. The bottom roll of label stock is fed to one or more flexographic print stations that print a first image on the front surface of the bottom face stock layer. A silicon release layer is then applied over the image, and an adhesive deadener is applied over the silicon release layer. A second image is printed on the adhesive deadener via one or more flexographic print stations. The top face stock layer is then laminated to the bottom face stock layer, and a third image is printed on the front surface of the top face stock layer. A die cutting station removes the label stock outside the label area, and the processed label stock is wound into a finished roll. 
     SUMMARY 
     This patent application describes an extended content label, and a method and system for manufacturing same. 
     In accordance with a first aspect of the disclosure, there is provided a method of manufacturing an extended content label that involves receiving label stock comprising a liner layer and a face stock layer, and de-laminating the liner layer from the face stock layer. The face stock layer and the liner layer each have a top surface and a bottom surface. The bottom surface of the face stock layer has an adhesive layer that adheres the face stock layer to the liner layer. A first face stock image is printed onto the top surface of the liner layer. The printed first face stock image is transferred to the bottom surface of the face stock layer, and a second face stock image is printed onto the top surface of the face stock layer. The printed first face stock image is transferred to the face stock layer by re-laminating the face stock layer with the liner layer. 
     In accordance with a second aspect of the disclosure, there is provided a system for manufacturing an extended content label, that comprises first through fourth label processing stations. The first label processing station is configured to receive label stock comprising a liner layer and a face stock layer, and to de-laminate the liner layer from the face stock layer. The face stock layer and the liner layer each have a top surface and a bottom surface. The bottom surface of the face stock layer has an adhesive layer that adheres the face stock layer to the liner layer. 
     The second label processing station is configured to print a first face stock image onto the top surface of the liner layer. The third label processing station is configured to transfer the printed first face stock image to the bottom surface of the face stock layer by re-laminating the face stock layer with the liner layer. The fourth label processing station is configured to print a second face stock image onto the top surface of the face stock layer. 
     Preferably, a further label processing station applies an adhesive deadener layer to the liner layer at less than an entire surface area of the face stock layer, and the second label processing station prints the first face stock image onto the adhesive deadener layer. The adhesive layer at a remainder of the surface area adheres the face stock layer to the liner layer. 
     In one implementation, the second face stock image is printed as a non-inline process with the printing of the first face stock image. The first face stock image may be printed with a flexographic printer, and the second face stock image may be printed with an electrostatic printer. The re-laminating may comprise generating a web from the face stock layer and the liner layer, and forming a roll of labels from the web. The electrostatic printer may print to the roll of labels. 
     In another implementation, the second face stock image is printed as an inline process with the printing a first face stock image. The first and second face stock images may both be printed with a flexographic printer. 
     In accordance with a third aspect of the disclosure, there is provided an extended content label that includes a liner layer and a face stock layer. The face stock layer has a top surface and a bottom surface. An adhesive layer is applied to the bottom surface. A first face stock image is disposed below the adhesive layer over less than an entire surface area of the face stock layer. An adhesive deadener layer is disposed below the first face stock image. The adhesive layer at a remainder of the surface area adheres the face stock layer to the liner layer. A second face stock image is applied to the top surface. 
     Since the extended content label does not require both a top face stock layer and a bottom face stock layer, material costs and waste are less than conventional extended content labels. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The extended content label, and the method and system of label manufacturing will now be described, with reference to the accompanying drawings, in which: 
         FIG. 1  is a flow chart that depicts the method of label manufacturing; 
         FIG. 2  is a perspective view of label stock used in the method of label manufacturing; 
         FIG. 3  is a schematic view of a first embodiment of the label manufacturing system, depicting the first through fourth label processing stations; 
         FIG. 4  is a schematic view of a second embodiment of the label manufacturing system; and 
         FIG. 5  is a perspective view of an extended content label manufactured using the method of label manufacturing. 
     
    
    
     DETAILED DESCRIPTION 
     The general operation of the label manufacturing system will be discussed first, with reference to  FIGS. 1 and 2 , followed by a detailed discussion of two embodiments of the label manufacturing system, with reference to  FIGS. 3 and 4 . At step S 100 , the label manufacturing system receives a web of label stock from a roll or spool of label stock. As shown in  FIG. 2 , the web  202  of label stock comprises a substantially flexible face stock layer  204  disposed on a substantially flexible liner layer  206 . The face stock layer  204  is substantially planar and is usually formed from polypropylene or paper. 
     The bottom surface of the face stock layer  204  has an adhesive layer  208  that adheres the face stock layer  204  to the liner layer  206 . The adhesive layer  208  is usually formed from a rubber-based adhesive or an acrylic-based adhesive. 
     The liner layer  206  is substantially planar and is usually formed from polyester or paper. The top surface of the liner layer  206  has a silicon release coating  210  that protects the adhesive layer  208  until the label is attached to a package. 
     Returning to  FIG. 1 , after receiving the web  202  of label stock, at step S 102  the label manufacturing system de-laminates the liner layer  206  from the face stock layer  204 . At step S 104 , the label manufacturing system prints a first face stock image onto the liner layer  206 . To do so, the label manufacturing system applies an adhesive deadener layer to the top surface of the liner layer  206  at less than the entire surface area of the face stock layer  204 , and prints the first face stock image onto the adhesive deadener layer. The adhesive layer at the remainder of the surface area adheres the face stock layer  204  to the liner layer  206 . Typically, the adhesive deadener layer  212  comprises an ultra-violet or water-based deadener. 
     The first face stock image typically comprises supplemental product information pertaining to the product for which the label will be used. For example, the supplemental product information may include recipes, product handling/use instructions, warranty information, and/or manufacturer/distributor contact information. The supplemental product information may comprise text, graphics or a combination of text and graphics. 
     At step S 106 , the label manufacturing system transfers the first printed face stock image to the bottom surface of the face stock layer  204  and also prints a second face stock image onto the top surface of the face stock layer  204 . At this step, the label manufacturing system transfers the first printed face stock image by re-laminating the face stock layer  204  with the liner layer  206 . 
     The second face stock image typically comprises primary product information pertaining to the product for which the label will be used. For example, the primary product information may include the name/trade-mark of the product, and/or the name of the distributor. The primary product information may comprise text, graphics or a combination of text and graphics. 
     In one embodiment of the label manufacturing system, the second face stock image is printed inline with the first face stock image, such that the first face stock image and the second face stock image are printed as respective parts of a common process. In this embodiment, preferably the first face stock image and the second face stock image are printed with a flexographic printer. 
     In another embodiment of the label manufacturing system, the second face stock image is not printed inline with the first face stock image. Rather, the first face stock image and the second face stock image are printed as separate and distinct processes. In this embodiment, preferably the re-laminating comprises generating a web from the face stock layer  204  and the liner layer  206 , and forming a roll of uncut labels from the resulting web. The second face stock image is then printed to the resulting web. Further, in this embodiment, preferably the first face stock image is printed with a flexographic printer, and the second face stock image is printed with an electrostatic printer. 
     The label manufacturing system will now be discussed in detail below.  FIG. 3  is a schematic view of a first embodiment of the label manufacturing system, denoted generally as  100 . As shown in  FIG. 3 , the label manufacturing system  100  includes first through fourth label processing stations  102 ,  104 ,  106 ,  108 . As will be explained, one or more of the label processing stations  102 ,  104 ,  106 ,  108  may provide multiple functions. However, it should be understood that the label manufacturing system  100  may include additional label processing stations, and the functionality of one or more of the label processing stations  102 ,  104 ,  106 ,  108  may be split amongst the additional label processing stations. 
     The first label processing station  102  is configured to de-laminate the face stock layer  204  of the web  202  of label stock. Therefore, the first label processing station  102  includes a de-lamination apparatus  110  that is configured to receive the web  202  of label stock from a roll/spool  200  of label stock and to remove the liner layer  206  from the face stock layer  204 . 
     After de-lamination of the face stock layer  204 , the liner layer  206  is received by the second label processing station  104 . At the same time, the face stock layer  204  is diverted around the second label processing station  104  and travels through the label manufacturing system  100  to the third label processing station  106  along a path that is separate from the path taken by the liner layer  206 . 
     The second label processing station  104  is configured to print a first face stock image  218  onto the liner layer  206 . Therefore, the second label processing station  104  includes a deadener dispenser  112  and a web printing apparatus  114 . The deadener dispenser  112  is configured to apply an adhesive deadener layer  212  to the top surface of the liner layer  206  over an area that is less than the entire surface area of the face stock layer  204 . The adhesive deadener layer  212  is applied with a density sufficient to allow the face stock layer  204  to be easily peeled back from the package while still allowing the adhesive layer  208  to secure the face stock layer  204  to the package. 
     The web printing apparatus  114  is configured to print the first face stock image  218  onto the adhesive deadener layer  212 . Preferably, the web printing apparatus  114  comprises a flexographic printer. The first face stock image  218  may be a multi-colour image. Accordingly, the web printing apparatus  114  may comprise a series of flexographic printers, each configured to dispense one colour of ink (e.g. red, green, blue) for rendering of the first face stock image  218 . 
     As will be explained, the first face stock image  218  is transferred from the liner layer  206  to the face stock layer  204  when the liner layer  206  is re-joined to the face stock layer  204  via the fourth label processing station  104 . Therefore, the deadener dispenser  112  applies the adhesive deadener layer  212  to the liner layer  206  over the region that corresponds to the region of the face stock layer  204  intended to be occupied by the first face stock image  218 . 
     Typically, the first face stock image  218  comprises one or more lines, symbols and/or high density regions of ink. Accordingly, instead of the adhesive deadener layer  212  being applied to the liner layer  206  over the entire region corresponding to the region of the face stock layer  204  intended to be occupied by the first face stock image  218 , the deadener dispenser  112  may apply the adhesive deadener layer  212  instead to the liner layer  206  only over the regions of the liner layer  206  corresponding to the regions of the face stock layer  204  intended to be occupied by the lines, symbols and/or high density regions of ink of the first face stock image  218 . 
     After the first face stock image  218  is printed, the liner layer  206  is received by the third label processing station  106 . The third label processing station  106  is configured to re-laminate the face stock layer  204  with the liner layer  206 . In the embodiment shown in  FIG. 3 , the third label processing station  106  includes a re-lamination apparatus  116  that is configured to receive the face stock layer  204  (from the first label processing station  102 ) and the liner layer  206 , and to re-laminate the face stock layer  204  by rejoining the liner layer  206  to the face stock layer  204 . 
     When the face stock layer  204  is re-laminated with the liner layer  206 , the face stock image  218  printed on the liner layer  206  is transferred from the liner layer  206  to the bottom surface of the face stock layer  204 . At the same time, the adhesive characteristics of the adhesive layer  208  are deadened/reduced at the regions thereof corresponding to the regions where the adhesive deadener layer  212  was applied to the liner layer  206 . 
     Since the adhesive deadener layer  212  is applied to the liner layer  206  over an area that is less than the entire surface area of the face stock layer  204 , the face stock layer  204  adheres to the liner layer  206  over the remainder of the surface area of the face stock layer  204  via the non-deadened regions of the adhesive layer  208 . Therefore, after re-lamination of the face stock image  218  with the liner layer  206 , the adhesive layer  208  comprises an adhesive that allows the face stock layer  204  to be peeled back from the package without leaving adhesive residue behind, and the face stock layer  204  to be re-applied to the package without the face stock layer  204  subsequently separating from the package. 
     After the face stock layer  204  is re-laminated with the liner layer  206 , the resulting web  202  is received by the fourth label processing station  108 . The fourth label processing station  108  is configured to print a second face stock image  220  onto the face stock layer  204 . 
     In the embodiment shown in  FIG. 3 , the fourth label processing station  108  includes a web printing apparatus  118 , a die cutting apparatus  120 , and a web winding apparatus  122 . In this embodiment, the web printing apparatus  118  comprises a flexographic printer that is configured to print the second face stock image  220  onto the top surface of the face stock layer  204 . As above, the second face stock image  220  may be a multi-colour image. Accordingly, the web printing apparatus  118  may comprise a series of flexographic printers, each configured to dispense one colour of ink for rendering of the second face stock image  220 . 
     The die cutting apparatus  120  is configured to cut into the face stock layer  204  and to remove the face stock layer  204  outside the region occupied by the larger of the first and second face stock images  218 ,  220 , but without cutting into the liner layer  206 , and to remove waste face stock  204  outside the cut area. The web winding apparatus  122  is configured to wind the processed web  202  into a roll/spool  214  of finished labels. As will be apparent, the fourth label processing station  108  prints the second face stock image  220  from the web  202  that is received from the third label processing station  106 . Therefore, in this embodiment, the fourth label processing station  108  is configured to print the second face stock image  220  inline, or as part of a common process, with the printing of the first face stock image  218 . 
       FIG. 4  is a schematic view of a second embodiment of the label manufacturing system, denoted generally as  100 ′. The label manufacturing system  100 ′ is substantially identical to the label manufacturing system  100  shown in  FIG. 3  and, therefore, identical reference numerals are used in  FIG. 4  to reflect the same functionality as in  FIG. 3 . 
     As shown, the label manufacturing system  100 ′ includes the aforementioned first and second label processing stations  102 ,  104 . However, instead of the third label processing station  106  and the fourth label processing station  108 , the label manufacturing system  100 ′ includes a third label processing station  106 ′, a fourth label processing station  108 ′ and a fifth label processing station  111 ′. 
     In the embodiment shown in  FIG. 4 , the third label processing station  106 ′ includes the re-lamination apparatus  116 , the web printing apparatus  118 , and the web winding apparatus  122 . After the face stock layer  204  is re-laminated with the liner layer  206 , the web printing apparatus  118  prints index marks on the top surface of the face stock layer  204 , outside the region corresponding to the region occupied by the first face stock image  218 . The web winding apparatus  122  then winds the resulting web  202  into a roll/spool  216  of partially-finished labels. The roll  216  of partially-finished labels is then transferred to the fourth label processing station  108 ′. 
     The fourth label processing station  108 ′ is configured to receive the web  202  of partially-finished labels from the roll/spool  216  of partially-finished labels and to print a second face stock image  220  onto the face stock layer  204 . The fourth label processing station  108 ′ includes a web printing apparatus  124  and a web winding apparatus  126 . In this embodiment, preferably the web printing apparatus  124  comprises a digital printer that is configured to electrostatically print the second face stock image  220  onto the top surface of the face stock layer  204 . Further, the web printing apparatus  124  is configured to read the index marks to properly align the second face stock image  220  with the first face stock image  218 . In contrast to the embodiment shown in  FIG. 3 , the web printing apparatus  124  need not comprise a series of printers to print a multi-colour second face stock image  220 . The web winding apparatus  126  is configured to wind the web  202  into a roll/spool  215  of uncut labels. 
     As will be apparent, the fourth label processing station  108 ′ prints the second face stock image  220  from the roll  216  of partially-finished labels, instead of from the web  202  received from the third label processing station  106 . Therefore, in this embodiment, the fourth label processing station  108 ′ does not print the second face stock image  220  inline with the printing of the first face stock image  218 , but is configured instead to print the second face stock image  220  as a separate and distinct process from the printing of the first face stock image  218 . 
     The fifth label processing station  111 ′ is configured to receive the web  202  of uncut labels from the roll/spool  215  of uncut of labels and to varnish and cut the varnished labels. The fifth label processing station  111 ′ includes a varnishing/laminating apparatus  128 , the die cutting apparatus  120  and a web winding apparatus  130 . The varnishing/laminating apparatus  128  is configured to apply a protective varnish or laminate to the top surface of the face stock layer  204 , over the second face stock image  220 . As above, the die cutting apparatus  120  is configured to cut into the face stock layer  204  and to remove the face stock layer  204  outside the region occupied by the larger of the first and second face stock images  218 ,  220  (and thereby also remove the index marks), but without cutting into the liner layer  206 , and to remove waste face stock  204  outside the cut area. The web winding apparatus  130  is configured to wind the processed web  202  into a roll/spool  214  of finished labels. 
     As will be apparent, the fourth label processing station  111 ′ cuts the labels from the roll  215  of uncut labels, instead of from the web  202  received from the web printing apparatus  124 . Therefore, in this embodiment, the fifth label processing station  111 ′ does not cut the face stock layer  204  inline with the printing of the second face stock image  220 , but is configured instead to cut the face stock layer  204  as a separate and distinct process from the printing of the second face stock image  220 . 
     Regardless of the embodiment of the label manufacturing system, each finished label consists of the face stock layer  204  and the liner layer  206 , as shown in  FIG. 5 . The bottom surface of the face stock layer  204  has a adhesive layer  208 , a first face stock image  218  disposed below the adhesive layer  208  over less than the entire surface area of the face stock layer  204 , and an adhesive deadener layer  212  disposed below the first face stock image  218 . The adhesive layer  208  at a remainder of the surface area (area A) adheres the face stock layer  204  to the liner layer  206 . The top surface of the face stock layer  204  includes a second face stock image  220  printed thereon. As a consequence, traversing a cross-section of the finished label in a direction from the top surface of the face stock layer  204  towards the liner layer  206 , the label comprises the varnish/laminate layer, the second face stock image  220 , the face stock layer  204 , the adhesive layer  208 , the first face stock image  218 , the adhesive deadener layer  212  and the liner layer  206 . 
     The scope of the monopoly desired for the invention is defined by the claims appended hereto, with the foregoing description being merely illustrative of the preferred embodiments of the invention. Persons of ordinary skill may envisage modifications to the described embodiment which, although not explicitly suggested herein, do not depart from the scope of the invention, as defined by the appended claims.