Apparatus and Process for Cutting Adhesive Labels

Abstract

A method and apparatus are provided for die cutting label stock comprising a facestock, an adhesive and optionally a liner to form labels where a liner of the linered pressure sensitive adhesive label stock may be a thin or ultrathin liner.

What is claimed is: 
     
         1 . A method of forming a cut adhesive backed label on a liner, comprising:
 providing a web of label stock comprising a facestock having a first side and a second side, an adhesive layer adhered to a first side of the facestock and, optionally, a release liner adhered an exposed surface of the adhesive layer;   when a liner is present, feeding the web of label stock to a separator station, wherein the separator separates the liner from the facestock and adhesive layer;   when a liner is not present or following separation of the liner from the facestock when present, feeding the facestock and adhesive layer to a cutting station to form a plurality of cut adhesive backed labels and a surrounding matrix, wherein the cutting station comprises a flexible rotary die and an anvil roller wherein the flexible rotary die comprises a die plate that is fastened to a mounting cylinder, wherein the adhesive is cooled by passing the facestock and adhesive layer through a chilling zone prior to entering the cutting station, wherein the chilling zone comprises a venture system and wherein the cooling is to such a degree so as to reduce the tack of the adhesive to the die;   when a release liner is present, relaminating the previously removed release liner to the cut adhesive backed labels and matrix or, optionally, laminating a new release liner to the cut adhesive backed labels;   wherein a solid material fills an air gap formed between the die plate and the mounting cylinder wherein the solid material has a greater thermal conductivity than air.   
     
     
         2 . The method of  claim 1  wherein the adhesive layer is cooled by passing the facestock and the adhesive layer through a chilling zone after the liner, if present, has been separated from the web of label stock and prior to feeding the facestock and the adhesive layer to the cutting station. 
     
     
         3 . A method of forming a cut adhesive backed label on a liner, comprising:
 providing a web of label stock comprising a facestock having a first side and a second side, an adhesive layer adhered to a first side of the facestock and, optionally, a release liner adhered an exposed surface of the adhesive layer, wherein the release liner has a thickness of less than or equal to 0.00626 mm;   when a liner is present, feeding the web of label stock to a separator station, wherein the separator separates the liner from the facestock and adhesive layer;   when a liner is not present or following separation of the liner from the facestock when present, feeding the facestock and adhesive layer to a cutting station comprising a die and an anvil in an orientation such that the adhesive of the adhesive layer contacts the die wherein a plurality of cut adhesive backed labels and a surrounding matrix is formed, wherein the die is a rotary die, wherein the cutting surface of the die is lubricated using a flexographic printing plate cylinder;   when a release liner is present, relaminating the previously removed release liner to the cut adhesive backed labels and matrix or, optionally, laminating a new release liner to the cut adhesive backed labels.   
     
     
         4 . The method of  claim 3  wherein the die is coated with a material which prevents the adhesive of the adhesive layer from adhering to the die. 
     
     
         5 . A method of forming a cut adhesive backed label on a liner, comprising:
 providing a web of label stock comprising a facestock having a first side and a second side, an adhesive layer adhered to a first side of the facestock and, optionally, a release liner adhered an exposed surface of the adhesive layer, wherein the release liner has a thickness less that 0.0254 mm;   when a liner is present, feeding the web of label stock to a separator station, wherein the separator separates the liner from the facestock and adhesive layer;   when a liner is not present or following separation of the liner from the facestock when present, feeding the facestock and adhesive layer to a cutting station to form a plurality of cut adhesive backed labels and a surrounding matrix, wherein the cutting station comprises a flexible rotary die and an anvil roller wherein the flexible rotary die comprises a die plate that is fastened to a mounting cylinder;   wherein the adhesive is cooled by passing the facestock and adhesive layer through a chilling zone prior to entering the cutting station;   wherein the chilling zone comprises a venture system;   wherein the cooling is to such a degree so as to reduce the tack of the adhesive to the die;   when a release liner is present, relaminating the previously removed release liner to the cut adhesive backed labels and matrix or, optionally, laminating a new release liner to the cut adhesive backed labels.   
     
     
         6 . The method of forming a cut adhesive backed label on a liner as claimed in  claim 5 , a lubricant is applied to the die or the anvil. 
     
     
         7 . The method of  claim 1 , wherein the chilling zone further comprises a dehumidifier. 
     
     
         8 . The method of  claim 1 , wherein the chilling zone further comprises an inert environment. 
     
     
         9 . The method of  claim 8 , wherein the inert environment comprises nitrogen. 
     
     
         10 . The method of  claim 5 , wherein the chilling zone further comprises a dehumidifier. 
     
     
         11 . The method of  claim 5 , wherein the chilling zone further comprises an inert environment. 
     
     
         12 . The method of  claim 11 , wherein the inert environment comprises nitrogen.