COMBINED RECEIPT AND LABEL ROLL HAVING OPTIMAL ADHESIVE PATCH PATTERNS AND A METHOD OF MANUFACTURING THEREOF

Abstract

A combined receipt and label roll comprises a core, and a web having a longitudinally-extending axis and wound on the core along the axis. The web includes (i) a substrate having a front side and a back side opposite the front side, (ii) a thermally-sensitive coating disposed on the front side of the substrate, and (iii) a water-based microsphere adhesive disposed on the back side of the substrate along the web axis. The water-based microsphere adhesive comprises at least four separate adhesive patches. The at least four adhesive patches are both sized relative to each other and positioned relative to each other on the back side of the substrate such that additional tack desired can be obtained by increasing volume of the adhesive patches without having to increase coat weight of the adhesive patches.

Claims

1. (canceled)

2. A combined receipt and label roll, comprising: a core; a web wound on the core, the web including: i) a substrate having a front side and a back side opposite the front side, ii) an adhesive disposed on the back side of the substrate as a plurality of adhesive patches, each adhesive patch positioned relative to each other on the back side of the substrate such that additional tack can be obtained by increasing volume of the adhesive patches without increasing coat weight for the adhesive coated on the adhesive patches.

3. The combined receipt and label roll of claim 2, wherein the front side of the substrate includes a thermally-sensitive coating.

4. The combined receipt and label roll of claim 2, wherein the front side of the substrate includes a release coating that is coated on top of the thermally-sensitive coating.

5. The combined receipt and label roll of claim 2, wherein the adhesive is a water-based microsphere adhesive.

6. The combined receipt and label roll of claim 2, wherein the plurality of adhesive patches includes at least four adhesive patches.

7. The combined receipt and label roll of claim 2, wherein each of the plurality of adhesive patches are aligned along the back side relative to one another.

8. The combined receipt and label roll of claim 2, wherein a size of each of the plurality of adhesive patches is varied.

9. The combined receipt and label roll of claim 2, wherein the plurality of adhesive patches comprises four adhesive patches with a first set of two of the adhesive patches having a same size and a second set of two of the adhesive patches have a smaller size than the first set.

10. The combined receipt and label roll of claim 8, wherein positions of the four adhesive patches on the back side of the substrate are staggered relative to one another such that one adhesive patch from the first set is aligned next to one adhesive patch from the second set.

11. The combined receipt and label roll of claim 8, wherein a size for the first set is predetermined and a size for the second set is calculated based on the size for the first set.

12. The combined receipt and label roll of claim 11, wherein positions of the four adhesive patches on the back side are determined based on the size for the first set and the calculated size for the second set.

13. The combined receipt and label roll of claim 2, wherein positions of the four adhesive patches on the back side of the substrate are staggered into quadrants such that each adhesive patch of a particular quadrant is not adjacent to another adhesive patch in an adjacent quadrant having a same sized adhesive patch.

14. A combined receipt and label, comprising: a substrate having a first side and a second side; wherein the back side includes four adhesive patches coated with an adhesive, a first set of the four adhesive patches have a first size and a second of the four adhesive patches having a second size, and wherein the first set is aligned diagonally to one another and the second set is aligned diagonally to one another.

15. The A combined receipt and label of claim 14, wherein the front side includes a thermally-sensitive coating.

16. The A combined receipt and label of claim 15, wherein the front side includes a release coating coated on top of and over the thermally-sensitive coating.

17. The A combined receipt and label of claim 14, wherein the adhesive is a microsphere adhesive.

18. The A combined receipt and label roll of claim 17, wherein the microsphere adhesive is a water-based microsphere adhesive.

19. The A combined receipt and label of claim 14, wherein the first size is predetermined and the second sized is calculated as a smaller size than the first size based on the first size.

20. A method, comprising: calculating a first size of a first set of two adhesive patches based on a predetermined second size of a second set of two adhesive patches; and applying adhesive on a backside of a substrate in a pattern as the first set and second set of adhesive patches in the first size and the second size, wherein applying further includes aligning the first set of two adhesive patches in a diagonal relationship to one another on the substrate and aligning the second set of two adhesive patches in a diagonal relationship to one another on the substrate.

21. The method of claim 20, wherein calculating further includes calculating further includes calculating the first size as a size that less than half the second size.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] FIG. 1 is a perspective view of a known combined receipt and label roll, and showing front side of the roll.

[0011] FIG. 2 is a perspective view, looking generally in the direction of arrow A shown in FIG. 1, and showing back side of the known combined receipt and label roll.

[0012] FIG. 3 is a cross-sectional view, taken approximately along line 3-3 shown in FIG. 2, and showing layers of material of the known combined receipt and label roll.

[0013] FIG. 4 is a front view of a combined receipt and label which has been cut from the known combined receipt and label roll of FIGS. 1-3.

[0014] FIG. 5 is a perspective view similar to the perspective view of FIG. 2, and showing a combined receipt and label roll constructed in accordance with one embodiment.

[0015] FIG. 6A is a back side view of an individual combined receipt and label which has been cut from the combined roll of FIG. 5, and showing an adhesive patch pattern in accordance with one embodiment.

[0016] FIGS. 6B-6J are back side views similar to the back side view of FIG. 6A, and showing adhesive patch patterns in accordance with other embodiments.

[0017] FIG. 7 is a table showing number of adhesive patches and relative sizes of the adhesive patches for each of the embodiments shown in FIGS. 6A-6J.

[0018] FIG. 8 is a line graph illustrating peel force associated with the adhesive patches of FIG. 7 for each of the embodiments shown in FIGS. 6A-6J.

[0019] FIG. 9 illustrates adhesive volume and location in the quadrant affect peel force.

[0020] FIG. 10 is a line graph illustrating coat weight of three different types of adhesives used in four of the embodiments shown in FIGS. 6A-6J.

[0021] FIG. 11 is a line graph illustrating peel force associated with each of the three types adhesives of FIG. 10 used in the four of the embodiments shown in FIGS. 6A-6J.

DETAILED DESCRIPTION

[0022] Referring to FIG. 5, example combined receipt and label roll 110 includes a web 112 of material having a longitudinally-extending axis 124 along a longitudinally-running direction of the web. The web 112 of material is wound on core 114 along web axis 124.

[0023] Web 112 includes substrate 116 having front side (not shown) and back side 120 opposite the front side. Thermally-sensitive coating 126 is disposed on an area covering the front side of substrate 116. A pattern of water-based microsphere adhesive patches 153A, 154A are disposed on the back side 120 of substrate 116 along web axis 124.

[0024] FIG. 6A is a back side view of an individual combined receipt and label 150A which has been cut from the combined roll 110 of FIG. 5, and shows an adhesive patch pattern in accordance with one embodiment. There is a size relationship among the adhesive patches shown in FIG. 6A. More specifically, each adhesive patch of a first pair 153A of four adhesive patches is substantially of a first predetermined adhesive patch size, and each adhesive patch of a second pair 154A of the four adhesive patches is substantially of a second predetermined adhesive patch size which is different from the first predetermined adhesive patch size. As shown in FIG. 6A, the size of each of the first pair 153A of adhesive patches is smaller than the size of each of the second pair 154A of adhesive patches. Size relationship between the first predetermined adhesive patch size and the second predetermined adhesive patch size for the pattern of adhesive patches 153A, 154A shown in FIG. 6A will be described in more detail later with reference to the table shown in FIG. 7 after other embodiments of adhesive patch patterns are described hereinbelow.

[0025] Also, there is a positional relationship among the adhesive patches 153A, 154A shown in FIG. 6A. More specifically, the adhesive patches of the first pair 153A are aligned relative to each other in a diagonal relationship on the back side of the substrate, and the adhesive patches of the second pair 154A are aligned relative to each other in a diagonal relationship on the back side of the substrate.

[0026] Release coating 128 is disposed on the front side of substrate 116 along web axis 124 to prevent adhesive from sticking to the front side of substrate 116 when web 112 is wound on core 114. Release coating 128 may be disposed on the entire front side of substrate 116, or on only a portion of the front side of substrate 116. Sense marks 123 are disposed between adhesive patches. Color of sense marks 123 may be black, for example. Sense marks 123 tell the printer where a cut should be made to provide an individual combined receipt and label, such as shown in FIG. 6A and designated with the reference numeral 150A.

[0027] The pattern of adhesive patches 153A, 154A shown in FIG. 6A is one embodiment. Adhesive patch patterns in other embodiments, such as shown in FIG. 6B through FIG. 6J, are possible. Since embodiments illustrated in FIGS. 6B-6J are generally similar to the embodiment illustrated in FIG. 6A, similar numerals are utilized to designate similar components, the suffix letter B, C, D, E, F, G, H, I, J being associated with the embodiments of FIGS. 6B, 6C, 6D, 6E, 6F, 6G, 6H, 6I, 6J, respectively, to avoid confusion.

[0028] As shown in FIG. 6B, combined receipt and label 150B includes at least seven adhesive patches 153B of substantially the same adhesive patch size. The at least seven adhesive patches 153B are aligned relative to each other to form a substantially U-shape arrangement of the adhesive patches on the back side of the substrate, as shown in FIG. 6B.

[0029] As shown in FIG. 6C, combined receipt and label 150C is similar to combined receipt and label 150A of FIG. 6A. The positions of a first pair 153C and a second pair 154C of adhesive patches of FIG. 6C are swapped as compared with the positions of the first pair 153A and the second pair 154A of adhesive patches of FIG. 6A.

[0030] As shown in FIG. 6D, combined receipt and label 150D is similar to combined receipt and label 150B of FIG. 6B. The positions of at least seven adhesive patches 153C of FIG. 6D are aligned relative to each other to form a substantially U-shape arrangement of the adhesive patches pointing in a direction which is different from the direction in which the substantially U-shaped arrangement of adhesive patches 153B of FIG. 6B is pointing.

[0031] As shown in FIG. 6E, combined receipt and label 150E includes at least six adhesive patches in which two adhesive patches 154E of the six adhesive patches are substantially a first predetermined adhesive patch size, and four adhesive patches 153E of the six adhesive patches are substantially a second predetermined adhesive patch size which is smaller than the first predetermined adhesive patch size. The at least six adhesive patches 153E, 154E are aligned relative to each other to form a substantially C-shape arrangement of the adhesive patches on the back side of the substrate, as shown in FIG. 6E.

[0032] As shown in FIG. 6F, combined receipt and label 150F includes two pairs of adhesive patches. Each adhesive patch of a first pair 153F of the at least four adhesive patches is substantially of a first predetermined adhesive patch size. Each adhesive patch of a second pair 154F of the at least four adhesive patches is substantially a second predetermined adhesive patch size which is greater than the first predetermined adhesive patch size. The at least four adhesive patches 153F, 154F are aligned relative to each other to form a substantially I-shape arrangement of the adhesive patches on the back side of the substrate, as shown in FIG. 6F.

[0033] As shown in FIG. 6G, combined receipt and label 150G includes at least nine adhesive patches 151G of substantially the same adhesive patch size. The at least nine adhesive patches 151G are aligned relative to each other to form a substantially X-shape arrangement of the adhesive patches on the back side of the substrate, as shown in FIG. 6G.

[0034] As shown in FIG. 6H, combined receipt and label 150H includes at least five adhesive patches 152H of substantially the same adhesive patch size. The at least five adhesive patches 152H are aligned relative to each other to form a substantially V-shape arrangement of the adhesive patches on the back side of the substrate, as shown in FIG. 6H.

[0035] As shown in FIG. 6I, combined receipt and label 150I is similar to combined receipt and label 150H of FIG. 6H. The positions of at least five adhesive patches 152I of FIG. 6I are aligned relative to each other to form a substantially V-shape arrangement of the adhesive patches pointing in a direction which is different from the direction in which the substantially V-shaped arrangement of adhesive patches 152H of FIG. 6H is pointing.

[0036] As shown in FIG. 6J, combined receipt and label 150J includes at least five adhesive patches 151J of substantially the same adhesive patch size. The at least five adhesive patches 151J are aligned relative to each other to form a substantially diagonal line arrangement of the adhesive patches on the back side of the substrate, as shown in FIG. 6J.

[0037] As mentioned, there is a size relationship between adhesive patches when there are different sizes of adhesive patches in the above-described embodiments of adhesive patches. Size relationships can be better explained with reference to the table of FIG. 7 when different size patches are involved. Columns II, III, IV, and V show four different adhesive patch sizes (i.e., S1, S2, S3, and S4) associated with each adhesive patch pattern shown in column I of FIG. 7. Size S1 is a base size from which the other three sizes (i.e., S2, S3, and S4) are calculated. More specifically, size S2 is 1.8 times the size S1, size S3 is twice the size S1, and size S4 is twice the size S2 or 3.6 times the size S1. Column VI shows the total number of adhesive patches in multiple terms of size S1. Column VII shows the absolute total number of adhesive patches with no reference to any particular adhesive patch size.

[0038] A number of advantages result by providing combined receipt and labels 150A-150J shown in FIGS. 6A-6J, respectively. One advantage is that increased tack of adhesive patches can be achieved by increasing adhesive volume without having to increase either viscosity or coat weight of adhesive patches. This advantageous feature is illustrated in the line graph of FIG. 8 which shows the peel force (and therefore the adhesive tack) associated with the different adhesive patch sizes of FIG. 7 for each of the embodiments shown in FIGS. 6A-6J.

[0039] As can be seen from FIG. 8, the highest adhesive tack was obtained from adhesive patch pattern A with a peel force of 4.7 lbf (pound-force). The lowest adhesive tack was obtained from adhesive patch pattern J with a peel force of 0.7 lbf. The line graph FIG. 8 can be explained further using the following equations to calculate results shown in FIG. 8.

[0040] To calculate the amount of adhesive per quadrant to determine an optimal configuration of the adhesive patches to achieve higher peel strength, the procedures are as follows:

Equation 1 is used to calculate the coat weight (dry mass) of adhesive on the patches (S.sub.i) in each quadrant.

A.sub.1=[(CW.sub.Si)/P.sub.iS.sub.i)](P.sub.iS.sub.i)(Equation 1)

Where:

[0041] A.sub.i=adhesive dry mass in gsm (grams per square meter) in each quadrant
CW.sub.Si=adhesive coat weight (measured)

[0042] The combined receipt and label is divided into four quadrants. The number of adhesives patches (whole or fraction of a patch) in each quadrant is multiply by the size of the patch (expressed in terms of S.sub.1 as demonstrated in Equation 2 below:

P.sub.iS.sub.i=P.sub.1S.sub.1+P.sub.2S.sub.2+P.sub.3S.sub.3+P.sub.4S.sub.4(Equation 2)

The first term of the equation P.sub.1S.sub.1 represents the first quadrant of the combined receipt and label. [0043] P=number of patches (the number can be whole or fraction) [0044] i=refers to the patch in each quadrant (1 refers to the first quadrant, 2 to the second quadrant, and so forth) [0045] S.sub.i=is the size of the patch in each quadrant, with: [0046] a. S.sub.1=the smallest patch that has a value of 1 [0047] b. S.sub.2=1.8 S.sub.1 [0048] c. S.sub.3=2S.sub.1 [0049] d. S.sub.4=3.6 S.sub.1

Example

[0050] To calculate the number of patches of size S.sub.1 for FIG. 6E, the equation would be:

[00001]$\begin{array}{c}.Math..Math.P_i.Math..Math.S_i=\left(1S_4+1S_3\right)+\left(1S_3\right)+\left(1S_4+1S_3\right)+\left(1S_3\right)\\ =\left(13.6.Math..Math.S_1+12.Math..Math.S_1\right)+\left(12.Math..Math.S_1\right)+\left(13.6.Math..Math.S_1+12.Math..Math.S_1\right)+\left(12.Math..Math.S_1\right)\\ =\left(5.6+2+5.6+2=15.2\right).Math..Math.S_1\\ =15.2.Math..Math.S_1\end{array}$

[0051] The values for the size of the patches that go in each quadrant and for total patches are shown in Table 1 below.

TABLE-US-00001 TABLE 1 Calculation of adhesive volume in terms of S.sub.i per quadrant P.sub.i S.sub.i Total P.sub.1 S.sub.1 in P.sub.2 S.sub.2 in P.sub.3 S.sub.3 in Volume of Patch Quadrant Quadrant Quadrant P.sub.4 S.sub.4 in Patches in Pattern 1 2 3 Quadrant 4 Term of S1 A 2 3.6 3.6 2 11.2 B 4 3 4 3 14 C 3.6 2 2 3.6 11.2 D 3 4 3 4 14 E 5.6 2 5.6 2 15.2 F 5.6 0 5.6 0 11.2 G 2.25 2.25 2.25 2.25 9 H 1.8 2.7 1.8 2.7 9 I 2.7 1.8 2.7 1.8 9 J 0.25 2.25 2.25 0.25 5

[0052] Substituting values for CW.sub.Si, P.sub.iS.sub.i and (P.sub.iS.sub.i) to find A.sub.i in equation 1 we get the results are shown in the Table 2 below:

TABLE-US-00002 TABLE 2 Adhesive total coat weight (CW) and distribution per quadrant Patch Pattern CW A.sub.1 A.sub.2 A.sub.3 A.sub.4 Peel Force F 8.51 4.26 0 4.26 0 2.91 G 9.54 2.39 2.39 2.39 2.39 2.81 J 9.8 0.49 4.42 4.42 0.49 0.67 A 9.84 1.76 3.16 3.16 1.76 4.16 C 9.88 3.18 1.76 1.76 3.18 4.68 H 10.33 2.07 3.10 2.07 3.10 1.69 D 11.27 2.42 3.22 2.42 3.22 4.14 E 11.47 4.23 1.51 4.23 1.51 3.99 B 11.66 3.33 2.50 3.33 2.50 4.17 I 13.29 3.99 2.66 3.99 2.66 1.51

[0053] FIG. 9 illustrates adhesive volume and location in the quadrant affect peel force. In particular, FIG. 9 shows that at the same mass (coat weight) of 9.8 gsm, the peel force of the adhesive patch pattern shown in FIG. 6J is only 0.67 lbf, whilst the peel force for the one in FIG. 6C is 4.68 lbf. This significant increase in peel force is achieved by the size of patches used and the distribution of these patches in each of the four quadrants. Adhesive patch pattern J of FIG. 6J has a volume of only 0.25 S.sub.i on quadrants 3 and 4 and 2.25 S.sub.i in quadrants 1 and 2. That is, quadrants 3 and 4 had very little adhesive 0.25 S.sub.i. Adhesive patch pattern C of FIG. 6C has a volume of 3.6 S.sub.i in quadrants 1 and 3 and 2 S.sub.i in quadrants 2 and 4. The volume in each quadrant is fairly well distributed.

[0054] The above advantageous feature can be explained further with reference to the line graphs of FIGS. 10 and 11 in which a comparison is made among three different types of adhesives using four of the adhesive patterns shown in FIGS. 6A-6J. The three types of adhesive being compared in FIGS. 10 and 11 are the L7183A (standard tack) provided by Bostik, Inc located in Wauwatosa, Wis.; the L7259 (high tack) also provided by Bostik, Inc.; and the E5521 provided by Avery Products Corporation located in Mentor, Ohio. Adhesive patch patterns of A. C, E. F shown in FIGS. 6A, 6C, 6E, 6F, respectively, are the four adhesive patch patterns being compared in FIGS. 10 and 11.

[0055] More specifically, the line graph of FIG. 10 shows a comparison of coat weight of the three types of adhesives used in the four adhesive patch patterns of A, C, E, F. The line graph of FIG. 11 shows a comparison of the peel force associated with each of the three types of adhesives used in the four adhesive patch patterns of A, C, E, F.

[0056] It should be apparent from the line graphs of FIGS. 10 and 11 that an adhesive patch pattern may be selected to optimize peel force for a given coat weight of adhesive. As an example, even though the coat weight of the L7259 adhesive is pretty much constant for all four adhesive patch patterns (as shown in the line graph of FIG. 10), the adhesive patch pattern A may selected to provide the highest relative peel force (as shown in the line graph of FIG. 11). As another example, even though the coat weight of the E5521 adhesive is lower than the coat weight of the L7183A adhesive (as shown in the line graph of FIG. 10), the peel force associated with the E5521 adhesive is greater than the peel force associated with the L7183A adhesive (as shown in the line graph of FIG. 11). This was true for all four adhesive patch patterns A, C, E, and F.

[0057] Another advantage is that accumulation of adhesive on print heads of printers is reduced since viscosity associated with water-based microsphere adhesives is relatively low. Reducing accumulation of adhesive on print heads of printers helps to reduce chance of a jam occurring. Reducing accumulation of adhesive on print heads of printers also helps to improve print quality.

[0058] Still another advantage is that any regular thermal printer can be used to print linerless labels since adhesive tack associated with water-based microsphere adhesives is relatively low. Accordingly, printing of linerless labels can be performed without being restricted to use of special printers dedicated for purpose of printing linerless labels. As an example, printing of linerless labels using water-based microsphere adhesives need not be limited to using thermal printers designed for only thermal paper with adhesive on the opposite side of the thermal paper.

[0059] While the present invention has been illustrated by the description of example processes and system components, and while the various processes and components have been described in detail, applicant does not intend to restrict or in any way limit the scope of the appended claims to such detail. Additional modifications will also readily appear to those skilled in the art. The invention in its broadest aspects is therefore not limited to the specific details, implementations, or illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of applicant's general inventive concept.