CA2028747A1 - Printing press process for making pattern silicone coated business form and product made thereby - Google Patents

Abstract

PRINTING PRESS PROCESS FOR MAKING PATTERN SILICONE
COATED BUSINESS FORM AND PRODUCT MADE THEREBY

Abstract of The Disclosure A process for producing a printed form containing a pattern (spot) coating of silicone release material on paper. The silicone pattern coating is printed with a lithographic printing tower, a letterpress tower, or a numbering unit of a printing press and is cured with ultraviolet (UV) lamps adjacent the printing station.

Description

- 1 - 20Z87~7 I PRINTING PRESS PROCESS FOR MAXING PATTERN SILICONE

I COATED BUSINESS FORM AND PRODUCT MADE THEREBY

Background of the Invention In the field of labels or like media of the I pressure-sensitive type, conventional manufacture 3 involves the use of a pressure-sensitive adhesive ¦ material appiied to a substrate or face stock, usually 3 paper, in the form of a continuous web and then the adhesive material is cured or dried. A release sheet or liner, usually provided as a continuous paper web 3 that is coated with a release agent, is applied to the exposed pressure-sensitive adhesive material surface to form a substrate-pressure-sensitive adhesive-release sheet label stock.
Representative documentation in the field of pressure-sensitive labels or the like includes U.S.
Gl Pat. No. 4,664,416, issued to D.J. Steidinger on May 5 ~l 12, 1987, which discloses a method of making a label-'d~' ~ equipped business form wherein a continuous web of ~g?` ~ business form material is advanced with a single ply `~
77 f ~,f~ label-providing web through an adhesive applying ~`
, station. -U.S. Pat. No. 4,854,610, issued to A. Kwiatek on August 8, 1989, discloses a method of making laminated articles and articles made therefrom by applying a layer of release coating material, followed by applying a layer of adhesive to the release coating material layer, and then applying a sheet component on top of the adhesive layer.
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~! Summary of the Invention `~
The present invention is directed to a business form and more specifically to a method or process for making the form. The invention involves a process for producing business paper forms and using a printing press for applying ultraviolet cured pattern '~``3 ``;3 .~

` - 2 - 20287~7 (spot) coatings of silicone release material on the paper forms. Silicone pattern coatings are applied onto a paper web by the printing press and the pattern coatings are cured by ultraviolet means in the form of lamps positioned in line with and adjacent the silicone printing station. The patterns or spots of coating material are placed at predetermined locations along the paper web and the coating patterns are printed by means of a lithography tower, a letterpress tower or a numbering unit of the printing press.
Labels are then applied onto the silicone release coatings by means of a label machine which may be either in line or off line.
In accordance with the above discussion, a principal object of the present invention is to provide a method or process for applying patterns of silicone release material onto a web of paper or like material.
Another object of the present invention is to provide a method or process for printing pattern silicone release coatings by use of either a lithography tower, a letterpress tower or a numbering unit.
An additional object of the present invention is to provide a method or process for printing pattern silicone release coatings onto a paper web and then curing the pattern coatings with ultraviolet energy positioned in line and adjacent the printing station.
A further object of the present invention is to provide a business form which is prepared by printing patterns of silicone release coatings at predetermined locations along a paper web, curing the release coatings with ultraviolet energy, and then applying labels onto the cured coatings.
Additional advantages and features of the present invention will become apparent and fully understood from a reading of the following description taken together with the annexed drawing.

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Brief Description of the Drawing Fig. 1 is a top or front plan view of a business form incorporating the subject matter of the present invention;
;l Fig. 2 is a top or front plan view of a paper web having patterns of silicone release coatings as applied at the printing station;
Fig. 3 is a sectional view taken along the line 3-3 of Fig. 2;
Fig. 4 is a perspective view of a prlnting station utilizing a lithography tower for applying the silicone coatings and showing ultraviolet means for curing the coatings;
Fig. 5 is a perspective view of a printing station utilizing a numbering unit or letterpress tower for applying the silicone coatings and showing ultraviolet means for curing the coatings;
Fig. 6 is a diagrammatic view showing the method or process of applying the patterns of silicone coating by means of the lithography tower;
Fig. 7 is a diagrammatic view showing the method or process of applying the patterns of silicone ~`
coating by means of the numbering unit or letterpress tower;
Fig. 8, on the sheet with Fig. 4, is a top or-plan view of a multiply business form showing a ~-silicone coating in different locations on the several plies; and ~-Fig. 9 is a perspective view similar to Fig.
4 and shows a modification of a printing station for applying the silicone coatings.

Description of the Preferred Embodiment Referring now to the drawing, Fig. 1 is a plan view of a portion of a continuous web 10 having spaced feed holes 12 along the right edge and spaced :
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, ~:0~37~L7 feed holes 14 along the left edge of the web 10. The web 1~ is made of paper stock material and is driven in a desired direction by appropriate pin feed means tnot shown) engaging in and operably associated with the feed holes 12 and 14. The web 10 is divided into sections or panels 16 separated by spaced horizontal lines of weakening in the manner of perforations 18.
A vertical line of perforations 17 is provided to the left of the feed holes 12 and a vertical line of perforations 19 is provided to the right of the feed holes 14 in the web 10. Printed matter 20 is provided in a lower right corner of each panel 16 and printed matter 22 is provided in spaced manner along the left side of each panel 16. The printed matter 20 and 22 may include spaces for names and addresses, instructions, and terms and conditions or the like which are normally included in the manufacture of business forms. The arrangement of the printed matter 20 and 22 on each panel 16 generally is determined by and dependent on the requirements of the user of the business form. The web 10 can be one of several plies in a multiply business form.
The web 10 in Fig. 1 is illustrated as a finished ply for use in business form construction and includes a silicone coating in the form of a pattern or block 24 positioned in the upper right corner of each panel 16. A preferred description of the pattern or block is a pattern coating 24 of silicone release material, however, other similar terms are used in the industry. A label 26 is applied onto the silicone pattern coating 24 by means of a label applicating machine. The label 26 includes a layer of face stock of paper, and a layer of adhesive on one surface of the face stock. The label 26 is applied onto the silicone release coating 24 with the adhesive surface of the label facing and on the surface of the silicone coating 24. Printed matter 28 is shown on the top surface of the label 26.

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Fig. 2 is a view similar to ~ig. 1 and shows the web 10 of panels 16 separated by the perforation lines 18. Each panel 16 includes the printed matter 20 and 22 along with the pattern silicone coating 24.
Fig. 2 illustrates the business form ply 10 as it appear~ after pas~ing the printing stations of the printing press and perfing anld hole punching operations prior to rewinding the web 10. Fig. 3 is a ~
sectional view in enlarged form of the panel 16 and - ;
the silicone coating 24.
Fig. 4 is a perspective view of the paper web 10 passing through a printing station of a lithography tower 30 for application of the pattern silicone coating 24 in dry offset manner. The web 10 with printed matter 20 and 22 in precise positions on the web is transported between rolls at the printing station of the tower 30.
The lithography tower 30 for providing dry offset application or printing of the silicone pattern coating 24 on the web 10 in¢ludes a plate roll 32, a blanket roll 34 and an impression roll 36. An ink train 38 for supplying silicone material includes multiple rolls of which only three are shown at the printing station of the tower 30. The ink train 38 may comprise additionàl rolls each of which i9 spaced a slight amount from the surface of the plate roll 32.
The plate roll 32 of the tower 30 has a pattern s~ coating plate 39 adhered thereto for the purpose o~
transferring silicone material as a pattern coating 40 from the ink train 38 onto the blanket roll 34. The rolls of the ink train 38 are positioned with respect ~;~ to the pattern coating plate 39 to deposit silicone ~` material on such plate 39 and not on the roll 32. The silicone pattern coating 24 is shown on the web 10 after transfer thereto from the pattern coating 40 on the blanket roIl 34. An ultraviolet light source 42 is positioned adjacent the tower 30 and in line with ~' ~i :

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the silicone pattern coating 24 for applying energy in curing the silicone material immediately after applying thereof by the tower 30 onto the surface of the web 10. The energy from the light source 42 is directed in a path to cover the width of the web 10.
Fig. 5 is a perspective view of the paper web 10 passing through a printing station of a numbering unit 44 or letterpress tower for application of the pattern silicone coating 24. The web 10 with printed matter 20 and 22 in precise positions on the web is transported between rolls at the printing station of the numbering unit 44. The numbering unit 44 for applying the silicone pattern coating 24 on each panel 16 includes a numbering unit shell 46 (or a plate cylinder in a letterpress tower) and an impression ;: roll 48. An ink train 50 for supplying silicone material includes multiple rolls of which only three are shown at the numbering unit 44. The numbering unit shell or plate cylinder 46 has a pattern coating plate 52 adhered thereto for the purpose of transferring silicone material as the pattern 24 onto the web 10. Again, the rolls of the ink train 50 are positioned with respect to the pattern coating plate 52 to deposit silicone material only on such plate 52.
The ultraviolet light source 42 is positioned adjacent the numbering unit 44 and in line with the silicone pattern coating 24 for applying energy in curing the silicone material immediately after applying thereof by the numbering unit or letterpress tower 44 onto the surface of the web 10. The energy from the light source 42 is directed to cover the width of the web ` 10.
Fig. 6 is a diagrammatic view of the path of the web 10 from an unwind roll 54 through one or more printed matter printing stations, as 56, and through a silicone printing station 58 of the lithography tower 30. The silicone material of the pattern coating 24 20287~7 is cured by the ultraviolet light source 42 and the web lO is then trained onto a rewind roll 60. A label applying machine 63 is provided near the end of the press line for applying the label 26 onto the silicone coating 24 by way of the in-line operation. The pin feed holes 12 and 14 are then punched in the web lO
and the perforation lines 17, 18 and 19 are also cut in the web by appropriate apparatus (not shown) just prior to rewinding the web on the roll 60. An alternative to rewinding the ~eb 10 onto the roll 60 is to fold the web by means of folding mechanism (not shown) installed in place of the rewinding mechanism.
Fig. 7 is a diagrammatic view of the path of the web lO from the unwind roll 54 through the printed matter printing station 56 of the lithography tower 30 and then through a silicone printing station 62 of the numbering unit 44. The arrangement of the light source 42 and the label applying machine 63 follows that of Fig. 6 and the web lO is then trained onto the rewind roll 60.
Fig. 8, on the sheet with Fig. 4, is a top or plan view of a multiply business form incorporating the process of the present invention. A multiply form 64 has plies 66, 68 and 70 along with a line of perforations 72 near the upper edge of the form for removing a desired ply or plies from the form 64. A
silicone coating pattern 24 can be printed at different locations, as shown on the respective plies.
The silicGne pattern 24 can be printed on a selected ply in one or more specified areas or on more than one ply of the business form 64.
Fig. 9 is a perspective view similar to Fig.
4 and shows the paper web 10 passing through a printing station of a lithography tower 30 for application of the pattern silicone coating 24.
Application of the silicone coating is letterpress type similar to the numbering unit 44. The web lO

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2~2:B74'7 with printed matter 20 and 22 in precise position on the web is transported between rolls at the printing station of the tower 30.
The lithography tower 30 for printing the silicone pattern coating 24 on the web 10 includes a plate roll 32, a blanket roll 34 and an impression roll 36. An ink train 38 for supplying silicone material includes multiple rolls of which only three are shown at the printing station of the tower 30.
The ink train 38 may comprise additional rolls each of which is spaced a slight amount from the surface of the plate roll 32. The plate roll 32 of the tower 30 has a printing plate 74 mounted thereon for the purpose of transferring silicone material from the ink train 38 onto the pattern plate 40 adhered to the blanket roll 34. The rolls of the ink train 38 are positioned with respect to the printing plate 74 to deposit silicone material on such plate 74. The ink train 38 inks the total surface of printing plate 74 with silicone material. The silicone pattern coating 24 is shown on the web 10 after transfer thereto from the pattern-shaped patch 40 which is adhered to the surface of the blanket roll 34. A plate can also be made to print off the blanket roll 34 by adhering the sticky-back plate to the blanket roll 34. An ultraviolet light source 42 is positioned adjacent the tower 30 and in line with the silicone pattern coating 24 for applying energy in curing the silicone material immediately after applying thereof by the tower 30 onto the surface of the web 10. The energy from the light source 42 is directed in a path to cover the width of the web 10.
The particular silicone materials used in the present invention are ultraviolet curable silicone epoxy systems or formulations supplied by General Electric Company. The curing of these materials is not oxygen inhibiting and therefore such materials are i 2C)28~7 , .:
appropriate to business form printing press operation ii and application because these materials do not require ;' nitrogen inerting in the ultraviolet curing zone. The 3 available silicone epoxy systems from G E are identified as W 9305 Tight Release Polymer, W 9300 Easy Release Polymer, and W 9310C Catalyst.
- Since the viscosity of the above three silicones is low (about 500 centipoises), a thickening of the material is required in order to apply the silicone by printing press operation. A dispersion of CAB-O-SIL fumed silica in a silicone formulation or system effectively thickens the formulation to a viscosity of about 5000-10,000 centipoises.
This higher viscosity dispersion enables the fountain of the printing press litho tower or of the numbering unit to hold the silicone formulation during the pattern printing operation. A thin silicone j formulation will tend to run out of the printing press fountains under standing conditions. The CAB-O-SIL
fumed silica does not absorb or reflect ultraviolet light or interfere with the curing proc~ss.
A preferred GE silicone epoxy formulation for use with various substrates that include bond paper, coated front (CF) paper, front of coated back (CB) paper, and self-contained carbonless paper, or substrates of coated paper stock that include carbonizing bond paper and Duncote ClS paper is as follows:
Parts By % Dry Material Weight Range UV 9305 67.5 60-70%
UV 9300 22.5 20-25%
W 931~C 3.0 2-4%
CAB-O-SIL EH-5 7.0 5-9~
The printing press application of the pattern i`~ silicone coating 24 is accomplished either with the lithography tower 30 or with the numbering unit or ~-~

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letterpress tower 44. Nhen using the lithography tower 30, a sticky-back rubber or photopolymer material, of ~ or 13 mil thickness and cut to the dimensions of the silicone pattern, is adhered to the plate roll 32 of the lithography tower 30 and performs as the plate 39 in a normal dry offset printing operation. The same rubber or photopolymer material of approximately 100 mil thickness and depending upon the printing press is adhered to the numbering unit shell or plate cylinder 46 when the numbering unit or lett~rpress tower 44 is used to print pattern silicone release coatings. Printing from the numbering unit 44 is letter-press type printing as compared to the offset printing of the lithography tower 30.
The press run speeds are limited according to the type and number of ultraviolet lamps used in the light source 42 at the curing station. The development program to produce the pattern silicone coated forms of the present invention included the use of a 14 inch Hamilton press which has at least one 6 inch UV lamp, rated at 300 watts per inch, and mounted approximately three feet from the printing station.
The lamp (or lamps) of the light source 42 are positioned in the lamp housing with the bottom or lower edge of the housing for the light source 42 being about two inches above the web 10 and the energy from the light source is directed to cover the width of the web, as illustrated in Figs. 4, 5 and 9. An ` additional UV lamp or light source 42 can be positioned in sidP-by-side relationship with the light source 42 shown in Figs. 4, S, and 9 to provide a plurality of lamps for covering the width of the web 10 or to cover a wider web. The run speed of the press was held constant for the different types of paper substrates at about 80 feet per minute.
Testing of the W cured pattern release coatings 2~ was performed with commercially available .

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2~2~t79,'7 pressure-sensitive labels of the rubber base adhesive type. Other adhesive labels such as acrylic type and hot melt based type were tested and yielded approximately the same label release properties. The labels 26 are applied either by an in-line operation wherein the labeling machine i5 adjacent the curing station or by an off-line operation wherein the labeling machine is located away from the printing press.
Regarding the off-line operationr the rewind roll 60 with the pattern silicone coatings 24 on the web 10 is mounted on the unwind stand of the label applying machine. In continuing normal operation of the press, the machine applies and registers the labels on the pattern silicone coatings 24. The labeled forms can then be rewound in roll form or folded in stacks.
Regarding off-line laboratory testing of silicone pattern coating~ prior to the label machine operation, one procedure is to apply the labels 26 to the pattern release coatings 24 at a time of 16 to 20 hours after the printing operation. The labeled release coatings 24 are then subjected to a pressure of approximately one pound per square inch for a period of 24 hours to approximately duplicate the pressure that the labels 26 are subjected to when stored in rolls or stacks. The labels 26 are then peeled off the pattern release coatings 24, measured as to peel strength and ~udged as to ease-of-release.
Any fiber tear, uncured silicone transfer to label adhesive, picking of the silicone layer or any other adverse properties are noted and recorded.
Regarding the in-line operation, the labels 24 are applied immediately after the silicone pattern printing and the W curing operations, as illustrated in Figs. 6 and 7. The finished product is a printed form that i.ncludes silicone pattern release coatings - 12 - 2~2~7~

24 and labels 26 on the coatings at desired locations.
Measuring the peel strength and other testing can be performed on the finished prodluct periodically. It was interesting to note during the testing program I that the labels 26 applied to the silicone coatings 24 immediately after printing ancl curing of the silicone coatings tested on a par with labels applied 16 to 20 hours after printing the silicone coatings. After peeling and release testing, the labels 26 are applied to corrugated cardboard to test adhesion properties.
It is thus seen that herein shown and described is a method for producing paper business forms containing ultraviolet light cured pattern coatings of silicone release material. Application of the silicone pattern coatings onto a paper web is performed by a printing press and curing of the pattern coatings is accomplished by ultraviolet lamps positioned in line with and adjacent the silicone printing station.
The present invention enables the accomplishment of the objects and advantages mentioned above and while a preferred embodiment has been disclosed herein, variations thereof ~ay occur to those skilled in the art. It is contemplated that all such variations and any modification not departing from the spirit and scope of the invention hereof are to be construed in accordance with the following claims.

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Claims (15)

1. A method of making a business form comprising the steps of advancing a web of business form material along a process line and past a printing station, printing a pattern coating of silicone material at predetermined areas on said web along the length thereof, advancing the web with the silicone printed pattern coating past a curing station positioned adjacent said printing station, curing the silicone printed pattern coating with ultraviolet energy, and applying label material on said silicone printed pattern coating.

2. The method of claim 1 wherein the ultraviolet energy for curing the silicone printed pattern coating is positioned in line with said printing station.

3. The method of claim 1 wherein the ultraviolet energy is provided by means of a plurality of ultraviolet lamps positioned in line with said printing station.

4. The method of claim 1 wherein the printing of said pattern coating of silicone material at said printing station is accomplished by means of a printing press lithography tower.

5. The method of claim 1 wherein the printing of said pattern coating of silicone material at said printing station is accomplished by means of a numbering unit.

6. The method of claim 1 including the step of providing spaced lines of weakening transversely positioned along the length of said web for forming sections thereof.

7. The method of claim 1 including the step of providing spaced lines of weakening longitudinally positioned along the length of said web for forming margins thereon and the step of providing pin feed holes in said margins for transporting said web.

8. The method of claim 1 wherein the printing of said pattern coating of silicone material at said printing station is accomplished by means of a letterpress tower.

9. A business form of the label type having a substrate, a pattern coating of silicone on said substrate, and an adhesive backed label on said pattern coating, the business form being made by advancing said substrate along a process line, printing said pattern coating of silicone on said substrate at predetermined areas along the length thereof, advancing the substrate with the silicone printed pattern coating past a curing station, curing the silicone printed pattern coating with ultraviolet energy, and applying said adhesive backed label on said coating of cured silicone.

10. The business form of claim 9 wherein the substrate is a web of continuous type having spaced lines of weakening transversely positioned along the length of said web.

11. The business form of claim 9 wherein the silicone used in said pattern coating has a viscosity of about 5,000-10,000 centipoises.

12. The business form of claim 11 wherein the silicone used in the preparation of said pattern coating is thickened with a dispersion of fumed silica.

13. The business form of claim 9 wherein the silicone used in said pattern coating is of the type material which is not oxygen inhibiting and which does not require nitrogen inerting when curing the silicone coating.

14. A business form of the label type having a paper substrate, a pattern coating of silicone on said substrate, and an adhesive backed label applied on said pattern coating of silicone, said silicone being a formulation containing as essential ingredients about 60 to 70% by weight of a tight release polymer, about 20 to 25% by weight of an easy release polymer, about 2 to 4% by weight catalyst, and about 5 to 9% by weight of fumed silica.

15. The business form of claim 14 wherein the viscosity of said silicone formulation is in the range of 5,000 to 10,000 centipoises.