CA2130273C - Peelable label and methods of manufacturing and recycling - Google Patents

Peelable label and methods of manufacturing and recycling Download PDF

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Publication number
CA2130273C
CA2130273C CA002130273A CA2130273A CA2130273C CA 2130273 C CA2130273 C CA 2130273C CA 002130273 A CA002130273 A CA 002130273A CA 2130273 A CA2130273 A CA 2130273A CA 2130273 C CA2130273 C CA 2130273C
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Canada
Prior art keywords
separation
interface
label
labels
substrates
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Expired - Fee Related
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CA002130273A
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French (fr)
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CA2130273A1 (en
Inventor
Melvin S. Freedman
Tim Parker
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Avery Dennison Corp
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Avery Dennison Corp
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Priority to CA002521070A priority Critical patent/CA2521070A1/en
Publication of CA2130273A1 publication Critical patent/CA2130273A1/en
Application granted granted Critical
Publication of CA2130273C publication Critical patent/CA2130273C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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Classifications

    • GPHYSICS
    • G09EDUCATION; CRYPTOGRAPHY; DISPLAY; ADVERTISING; SEALS
    • G09FDISPLAYING; ADVERTISING; SIGNS; LABELS OR NAME-PLATES; SEALS
    • G09F3/00Labels, tag tickets, or similar identification or indication means; Seals; Postage or like stamps
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D23/00Details of bottles or jars not otherwise provided for
    • B65D23/08Coverings or external coatings
    • B65D23/0842Sheets or tubes applied around the bottle with or without subsequent folding operations
    • B65D23/0864Applied in mould
    • GPHYSICS
    • G09EDUCATION; CRYPTOGRAPHY; DISPLAY; ADVERTISING; SEALS
    • G09FDISPLAYING; ADVERTISING; SIGNS; LABELS OR NAME-PLATES; SEALS
    • G09F3/00Labels, tag tickets, or similar identification or indication means; Seals; Postage or like stamps
    • G09F3/04Labels, tag tickets, or similar identification or indication means; Seals; Postage or like stamps to be fastened or secured by the material of the label itself, e.g. by thermo-adhesion
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2565/00Wrappers or flexible covers; Packaging materials of special type or form
    • B65D2565/38Packaging materials of special type or form
    • B65D2565/381Details of packaging materials of special type or form
    • B65D2565/385Details of packaging materials of special type or form especially suited for or with means facilitating recycling
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P20/00Technologies relating to chemical industry
    • Y02P20/50Improvements relating to the production of bulk chemicals
    • Y02P20/582Recycling of unreacted starting or intermediate materials
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/13Hollow or container type article [e.g., tube, vase, etc.]
    • Y10T428/1352Polymer or resin containing [i.e., natural or synthetic]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/13Hollow or container type article [e.g., tube, vase, etc.]
    • Y10T428/1352Polymer or resin containing [i.e., natural or synthetic]
    • Y10T428/139Open-ended, self-supporting conduit, cylinder, or tube-type article
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/13Hollow or container type article [e.g., tube, vase, etc.]
    • Y10T428/1352Polymer or resin containing [i.e., natural or synthetic]
    • Y10T428/139Open-ended, self-supporting conduit, cylinder, or tube-type article
    • Y10T428/1393Multilayer [continuous layer]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/13Hollow or container type article [e.g., tube, vase, etc.]
    • Y10T428/1352Polymer or resin containing [i.e., natural or synthetic]
    • Y10T428/1397Single layer [continuous layer]

Abstract

In-mold plastic labels (10) are provided with separation interfaces (5) whereby the printed surfaces (12) of the labels and the contaminating printing inks print associated with them can be removed so as to allow recycling of the bottle stock without contamination by printing inks.

Description

WO 93/17411 PC'1'/1US93/~1~62 PREELABLE LABEL AND METHODS OF MANUFACTURING AND RECSt'CLING
This invention relates to in-mold labelling, using die-cut ira--mold labels o~ the kind adapted to label blow-molded plastic bottles or other containers. Labelling methods and articles of this kind are referred to as °°in-mold°' because the labels are held in place within the mold wherein the bontainer is shaped dura.ng the container-forming step.
the invention particularly applies to in-mold labelling usingr pol~rraeric labels, rather than using natural cellulose pager labels: Polymeric labels offer'many aesthetic and functional advantages,over piper labels in the labelling of containers ~~ otl~.er a~cticles made by blow-molding plastic resins, such as high density pol~etl~ylene (~DPE). When a plastic container such as a ~tDPE
sque~e~e bottle is used,to package a product such as hair shampoo, a package using a polymeric label is generally more appealing to consumers than.a package using a piper labe2 that won't last in the shower and that does not have as'attractive an appearance.
In many applications, the use o~ polymeric labels is required fc~r teas~ns of aPpearan~ce, i~andling, pE'r~OZ'manCE, mOl~ture°°x'eSistanCE, C~nfCrmability, durability and cotnpa~ibility with the container to be labelled. For example, a low-modules plastic label is generally required fog a squ~e~e bottle so that the libel can fleas with the bottle without wrinkling or tearing. Pcalymeric labels also make p~ssible the manufacture of ~Zear or substantiall~r transparent- 3~bels having a °°nio-lalael look°°
with ~nly the indices on the label be~,ne~ readily visible t~ the c~nsumear . .
SU~~fi~TUTE SN~ET

Wi0 93/17411 PC1'/US93/0146~
y:
It is recognized that natural paper labels are incompatible in the recycling of molded plastic items. In many applications, in-mold labelling of natural or light colored plastic containers using polymeric labels also presents a recycling problem, both in respect to immediate use of scrap bottles created during production (particularly during start-up) and in respect to post consumer recycling.
During production, labels may be applied out of register with the bottles being formed, particularly - during start-up of the production line when ideal bottle-forming temperatures and other conditions may not yet be established and stabilized. The scrap bottles caused by prose s control drift or "start-up bottles°° thereby formed cannot be immediately recycled lby grinding or shredding them and re-ixacluding them in the resin supply for the blow-molding operation: To do so w~u1d contaminate the melt with the printing inky with which the polymeric labels are decorated: Instead, the mislabelled b~ttles or scrap bottles must be discarded, which wastes resin anal is a burden on landfill, or the labels with their contaminating inks must be removed from the start-up bottles before the bottles are x°egr~und for-recycling of the resin. Removal of the ~ontaminatinc~ inks often requgres cuttins~ out the entire labelled portion of each bottle, since it is usually 'insufficient to attempt to merely scrape and peel away the label ar the face ~f the la3~e1 to a sufficient degree to ~ce~ove the contaminating ink.
In aa~~ case, such services are laborgintensive and mar require c~nt~acta.nc~ out to emp3oyers of low-cost labor, withwattendant c~sts of handling, transport, and storage under very low d~r~sity packing.
suBST~T~a~rE s~E~~r '~~O 93/1741 I PCT/U~93/01462 ..'~.~~;:' rn respect to recycling following consumer use and return of bottles, a similar problem is presented. Consumers, or recycling facilities, have no ready way to remove the~contaminating inks, short of the inconvenient and labor--intensive steps previously mentioned. Recycling with printed plastic labels intact is restricted to dark colors or multilayer containers with the regrind buried in a central layer. This results in a thick container wall. Recycling of clear or thin-walled light color containers is thereby inhibited, and consumers sensitive to recycling capability are discouraged from using products sold in the bottles.
The present invention overcomes these problems. In~mold labelling is carried out in such a way as to g~rrva.de a controlled separation interface within each label between plies that make up the'label. This separation interface allows the printed face of~ the label to be readily separated from the remainder of the label and from the molded ~aottle. i~hen scrap battles are formed during start-up (the g~start--up be~ttles~~ previously referred to) , or a.f an occasiona3 scrap bottle is formed later in production, the printed facesof the labels can be immediately stripped and the scrap b~ttles imx~~diate~~.y ~~d int~ a hopper for grinding and re-inclusion in the resin supply without causing color contamination., Co~asumers can also readily remove the printed faces of the labels before returning the bottles, or they can ~e readily removed at recycling fadiliti.e~.
,~ concept ~f the present inven°ti~n is the provisi~n of in-mold label stock of 3ayered film materia3 conta~.ni.ng a separati~n interface. The film material comprises two polymeric film plies SUSSTITUTE SH~~T

WO 93/17411 PdCi'/1.J~93/()1462 each comprising one or more film layers. The two film plies are in contact with each other and present to each other surfaces of different camposition at a pair of contacting interior faces joined at the separation interface. ane of the film plies comprises printable in-mold label facestock.
the other film'ply comprises a label core and an adhesive, preferably a heat~activatable adhesive.
The film plies have controlled affinity for each other at the separat~.on interface end adhere to each -~ other to a sufficiently high degree to withstand the maximum separatign fore imposed on the stock at the separation interface as labels are printed, cut from the stock, and deployed for affixation on blown parisons in a bl~wing,mald or on other substrates.
However' the,fil~n plies adhere to each other to a Sufficiently low degree to allow them t~ cleanly and readily separate from each other at the separation interface under the imposition of stripping or separation forces greater than the maximum s~paratic>n forces to which they have been subjected during printing, die-cutting and deployment, although the 3atter forces have been generally ~:egax~ded by the art as serrere, see f ~r example the cliscuss~:on of stresses on in-mold label stock ~~terial in IT-S. Patent 4,gg3,697 to l~ornbusch et al. In other words, the separation farces imposed by stripping are greater than the maximum separation forces i~tposed by printing, da:e-cutting and deplo~rment, and the differea~ces between the two l~yels of separation forces can b~ sufficient to provide reliable ~arinting, da~~cutti~ng, positioning and ~cffi~ing ef labels on the one hand, and reliable striping of the outermost film ply of the label on the other.
SUSST~TUTE SHE~t W~p 93/17411 PC.'T/U593/Q1462 s" ;, the invention will be more fully understood from the following more detailed description and tie accompanying drawings, which are highly schematic or diagrammatic and in which FIG.
l illustrates a cdextruded in-mold~label film contemplated by tie invention; FIG lA,illustrates another in-mold label film contemplated by the invention; FIG: 2 is a representation of a printing, drying, sheeting and stacking line used in the method of the invention; FIG. 3 is an isometric - sketch il~oastrat3ng stacks of individual labels dae-cut from the Mack of label stock seen in FIG. 2;
FIG. 4 illustrates the use of the stacked individual libels in a molding operation, including a top view in schematic cross-section of the mold in open position eluting insertion of a label; FIG 5 is a side view in schematic cross~section of the same mold ~:n closed position, but ~hotan empty for simplidit~ of iliusta'ata.on; FIG: s is a top view in schematic cr~ss-section of an in~mold labelled bottle formed by the mold 44; and F7CGa 7 is a view sa~ilar to FIG 6 sh~wing the face of the label.
beginning to be peeled fr~m the remainder of the la~ael xn .a manner contemp~:ated by the invention FIG. ~ is'a szmilar view illustrating in an ~rtif~:cially regu~.ari~ed manner aa~oth~r aspect c~f the invention in which a similar labelled container i ground into pa~tiole~ for classification. FIG.
~A shows a' portion of 'FIG. 8 on ara enlarged scale.
The thicknesses of the films, labels and bottles seen'in the figures arm greatly exaggerated for Clarity of' illcxstgati~n.
The composite or layered label film ~y~ter~.al 10 shown in FIG. 1 is a d~extrusion including the layers 12 , 14 , ~.6 and ~.8 . Ir~y~r 12 is SU~ST~T~TE SHEET

a printable facestock layer and layer 14 is one of the layers defining a separation interface S, to be described below. The layers 12 and 14 together comprise a multilayer first or peelable film face ply 15. The layer 16 is a core or stiffening layer which contributes to the stiffness of labels cut from the composite label film.
Adequate stiffness is necessary to proper printing, sheeting, die-cutting, and undistorted deployment (transfer and insertion) of the label into the mold, as more fully discussed in copending Canadian application of common assignee Ser. No. 2,117,057, filed September 9, 1992, and issued April 27, 1999. The layer 18 comprises.a heat-activatable adhesive. The layers 16 and 18 together make up a multilayer second or non-peelable film ply 19. The plies 15 and 19 may also be referred to respectively as face ply and core ply. The coextruded label stock is preferably extruded, hot-stretched and annealed in the manner described in said Canadian Ser. No. 2,117,057, subject however to the significant difference that a distinct controlled separation interface is formed between coextruded plies.
That is, the coextrusion is carried out with such materials and in such a manner as to define the separation interface S between layers 14 and 16. This separation interface is similar in character to the "peelable interface 17" of Freedman U.S. Patent 4,925,714 to common assignee. The intimately contacting layers 14 and 16 are of different composition, and the contacting surfaces of layers 14 and 16, that is to say, the pair of contacting interior faces of the first and second W~ X3/17411 P~/US~3/01462 7 . ~ y .; ~ , ~~ r;:. r.
. .
film plies 15 and 19, present to each other surfaces of different composition with a contro3led degree of incompatibility at a pair of contacting interior faces joined at the separation interface S.
Consistently with the teaching of the foregoing copending application, a preferable total thickness of the hot coextrudate is about 20 mils, making a total thickness of about 4 mils following hot stretching at a five to one stretch ratio.
Qbdiously, the thicknesses of the hot coextrudate, - the degree of stretch, and the thicknesses in the stretched film may all be varied. Tn a presently preferred construction, the approximate thicknesses of layers 12, 14, i6 and 18 following stretching are respectively 0.5, 1, 2, and 0.5 mils, while the co~~posit~.ons of tlae layers by weight percentages are Y
Layer 12 polypropylene homopolymer ethylene--vinyl aeetate copolymer Layer 14 pollrpr~pylene homopolymer 10-~
Layer ~.~ pt~lye~hyiene blend (see below)100 Layer 18 heat-aetivatable adhesive p~lypropylene homopolymer ethylene-vinylacetate copolymer hntistat The polyethylene blend referred to in the foregoing com~ositioh is a blend of low and higher d~rasity pol~ethylenes, the exact proportion of which ~epehds ~n the laest trade-of f laetween f actors such a~ flexibi.7.ity, release, layer thicknesses and produc~a.onspeed for a particular application.
Generally; a higher proportion of low density s~~~r~~-~r~ s~~~~
__ . ._ ~ ~ . ~ .,r_= , . .. .. .... _. . .. . . .r. .. .:.~ . .. . . . . ~ ..

~V~ 93/17411 PCT/US93/01462 y.t.: I;A'... ,.
~: . . $
polyethylene favors easier release at the separation interface, and a higher proportion of higher density polyethylenes favors stiffness and enables thinner stock to be suce~ssfully die-cut and deployed and/or production speeds to increase. Preferred proportions of polyethylenes of different densi°ties have not been determined as of the date of this application. However, as reflected in the formulation above, indications are that low density polyethylene i~ to be included and that higher density polyethylene (m~di~nm and/or ha.gh density) is to be blended therewith. The preferred proportion or proportions will be determined by routine testing. Nucleation by addition of fine particulate to the layer 16 nay be used to enhance the degree of polymer c~ys~allinity arid increase the stiffness of the layer: Ixa this manner, overall label thickness may be reduced and/or a label may be provided having first and second film pBes of similar thicknesses, or even a relativel:y~thinner ply 19, with ~lne ply 19 being /relatively ~tif~er.
The heat-ac~ivatable'adhesive is a proprietary product sold by H-B: Fuller of Blue Ash, Ohio .under product number ~i'72'7 , and co~aprises a lalend' of ethylene-vinyl acetate copolymer ('°HVA,~° ) , polyethylene waxes and a ~ackzfier effective to accomplish adhesion to HOPE. The adhesive by itself would bo far too'~owa~ery~s or low in viscosity to be successfully extruded, but it melt blends well with the OVA. The EVA stiffens up the ~xtrudate, bud is Sao sticky to process fol~.o~ihg extrusion, because It .bonds ~o slick go proce~s~.ng rolls~with which it comes into -contac°t while i~ is w~r~n so as to da~agc th;~ adhesive layer or 3.aminate, The add~.tio~r of polypropylene provides ~ skeletal backbone structure ~l~~S'tiTUTE S~EET

'~VVO 93f 1'741 i PCT/US93/0146~
.,..,~,., ~~~
.a;s;
to give the extrudate excellent heat stability for hot~°stretching and other processing.
The antistat is incorporated in the adhesive-containing charge (the charge for layer 1.8) and uniformly blended therewith. The amount of antistat used may be varied for particular formulations and processing conditions, the 5~
amount used h~~ein being typical. The antistat is efficiently used, since it may be added to the adhesive charge only: Thus, addition of antistat on~.y to the adttesiv~-containing change provides specificity and efficiency of use without the disadvantages of a topically applied antistat. In certain appla:catior~s, it may be advantageous to also include the antistat in the central layer charge as well as the base layer charge,-or in the central layer charge only.
Tn,the particular adhesive layer composition described, the antistat used is sold by H~echst Celanese under product number E2956 and is of the type that when added in bulk blooms to the surface and dissipates electrostatic charges by .~ydraphi~:ic action which attracts extremely minute amouhts of ambient ~noa.sture: Collection of moistoare at the face layer, which may interfere with the label printing pr~c~ss, is avoided by addihg the ~ntistat to the adhesive layer ~nly. Moisture collected at the adhesive layer surface does not interfere w~.th adhesi~n ~f he label to the doh~ainer in the in~mc~~.d 7,aballing process. It is believed that the moisture i.s vaporised or dissipated by the elevated molding service temperata~res, but in such small ~uanta~ties as to not integfer~ with adhesion.
S~J~ST~'~TE SHEET

W(? 93/174t 1 fCT/lJS93/01462 s,,; ...,, , ..,., In the above-described construction, the layer 12 fundtions essentially to render the label stock printable: In some instances, an acceptable alternative may be to omit the 3ayer 12, as in the construction of FIG. lA. In this construction, the layer 14a is directly exposed as the print-receiving surface which is rendered printable by corona treatment or the like in a known manner prior to the actual printing step. In such a donstruction, the first or peelable film ply may be the monolayer face ply 15a consisting c~f the single layer 14a, and the composition of the layers 14a, 16a and 18a may be as described above for the layers 14, 16 and 18, but thicknesses may be 0:5, 2.5, and 0.5 for layers 14a, lfaa and 18a respectively: The layers 16a and 18a together make-up the multilayer second or non-peelable film ply 19a.
As described above, the presently pre~erx~ed compositions of the ~.ayers of the face and core: plies which ~efirie the se~aaration interface comprise different polyolefins in: amounts sufficient to yield the desired ~~paratior~ characteristics, the ~os~ preferred pnlyolefi~ns pr~sently.being polyethya.ene end polypropylene hom~polymers. These may be reversed from the order described above, far example with layer 14 cc~mprasing ~ ~~lyethylene Mend and layer 1:6 polypropylene homopolymer, but ghis is less greferable when labelling polyethylene battles. It is n~tal~le that even with such reversal, ' sui, able gaerf~rm~r~ce of the overall label canstruc~ion, and''partidularly ~uiteble compatibility with tie ink-receptive layer and the adhesive layer, is achieved. The presently pref erred csr~posi;tion ' of the grixatabl.e f acestock layer and the adhesive layer ~ompr~se blends of S~P~S E SHEET' VV~O 93/1?411 PCT/US93/01462 11 . ' __ olefin polymers and copolymers of olefin monomers with ethylenically unsaturated carboxylic acid or ethylenically unsaturated carboxylic acid ester comonomers such as the ethylene-vinyl acetate copolymer. Thus, the multilayer face and core plies each include a layer of olefin polymers and a layer comprising a blend of olefin polymers and copolymers of olefin monomers with ethylenically unsaturated carboxylic acid or ethylenically unsaturated carboxylic acid ester comonomers such as the -- - ethylene-vinyl acetate copolymer.
As schematically illustrated in FIG. 2, the coextruded, hot-stretched stock, which may be supplied in ,the fo~mm of the self-wound roll ~4, may be printed or decorated in a printing press z6, and dried by heat, W radiation, or the like. The printing or decoration may be covered with a proteetiVe laccyuer if desired.
Foll~wing printing and drying, the stock may be sheeted and stacked in a manner similar to that known for the sheeting o~ paper-backed label stock. The cutting station is inda.cated by arrow C
in FIG.-2. The severed rectangular sheets are collected to fe~rm the stack 3~: the stack may contain 100, 200 ~r more sheets. For clarity of illustration, in tlae drawing the thickness of the sheets is greatly exaggerated and the stack 30 is therefore shown as being made up of only a re~.ati,vely small number ~~' sheets . Each sheet in the stack is intended ts~ provide material for sweral indiv~:dual labels to be die-cut from the sheeted material.
Individual labels are formed in a known mahner b~ hollo~t,p~nches or cutting dies gnat shown) which punch out stacks 32 of individual labels from SI~SST~T~3TE SHEET

Wfl 93/ 17411 PCT/ U593/01 G62 ~. 2 the stack 30 of label stock. For example, the array ' of nine stacks 32 of individual labels seen in FIG.
3 may be simultaneously punched out of the rectangular stack 30. Alternatively, the labels may be die cut by rotary or reciprocating means from a web without sheeting and then gathered into stacks.
In either case, a matrix (not shown) of waste material is left behind. The stacks 32 of individual labels are stabilized by suitable wrapping or packaging (not shown) in a manner similar to that previously used with paper~backed labels. The stabilized stacks 32 are then moved or transported to the site where the blow--molded bottles a~~ being manufactured, which often is a different place than the site of label manufacture,.
At the site of bottle manufacture, stacks 32 of inda:widual labals are loaded in a dispensing magazine of a known ~.ypeP schemat~.c~lly illustrated by maga~~ne 34'in FTG. 4. f~r example, the labels may be advanced to the front of the magazine by Spring means 36;,~nd may ba la.~htly retained for pick-off by spranc~y or mechanically retracting retainer fa.ngers or detents 38: A robotic label feed head 40 carries vacuum cups 4z adapted to be advanced by means (nd~ shown) internal to the head ~~ tQ hick off the front label presented by the magazine'3~, retracted for translating movement of the heacl~ and the single picked-off Label 32a into the Qpen~d.bl~w mold ~4 by actuation of the translating cylinder 41; and advanced again to apply the picked-off label 32a to the proper location on the interaor surface of the mold and release it.
The label may then be held ~ccur~tely in position within the m~ld by vacuum applied to the mold wall through ananifolded vacuum: line 46 while the label ~~3~STtTt~TE S~~ET

1~~ 93J17~t1 t PCTlCJS93lOt4~2 13 ~~.~rP~~a~
feed head 4~ is retracted. The vacuum line outlets to the interior of the mold may be flush with the interior surface of the mold, as shown, so that the label occupies part of the~mold cavity proper. Tn other words, preferably there is no recess on the interior surface of the mold to accommodate the thickness of the label, or any portion of the label thickness.
A hot workpiece or parison (not shown in FAGS. 4 or 5) ~f HDPB or similar thermoplastic -- - resin, the material for which has been supplied in known manner from a reservoir (not shown of molten resin, is fed into the mold, the mold is closed, and the parison i~ expanded in a known manner to complete the formation of tae molded container. As the hot parison contacts the adhesiveacontaining lager 18 of the label, activation o~ the adhesive is triggered. If'as described above the entire thi~kn~ss of the label is on, not in, the interior surface of the mold, the label becomes embedded in the workpiecs t~ which it is adhered, thus providing a fully inset lalbel that is flush with the container surface amd that replaces araci therefore saves a partion ~f the charge for the bottle without diminish~,ng the s~xuct~ral iaategrity of the bottle ~p any c~~te~ted ignificant degree.
FIB: ~ illustrates a cross~section of a f~rmed bottle B which has been in-mold labelled as jest desdribed. A label L has been inlaid in the wall of he b~ttl~. The label has first and second film plied 1~- arad 1~ which are f~.rmly joined at the sep~rati~n interfade S. ~Th~ interply adhesion b~tw~en first and secoa~d film plies 1.5 and, 19 is sufficiently high to withstand the maximum process separati.~n force imposed on the atcrck at the SU~ST~TVTE SHEET

~1'O 93/17411 fC'~'1U593/0146~
separation interface S during sheeting, die-cutting, feeding and in-mold application of the labels to bottles as the latter are formed. .However, these film plies adhere to each other to a sufficiently low degree to allow them to cleanly and readily separate from each other at the interface S under the imposition of a separation force greater than the aforesaid maximum process separation force encountered in label processing.
As pointed out in previously cited U.S.
Patent 4;925,714, the interface peel strength at an interface such as the separation interface S is a function of several parameters, including among others, the identities of' the two dissimilar polymeric layers, the presence and~ty~es of additives in one or both of the coextruded layers defining the interface, the presence or absence of pigments in one or both layers, the pressure exerted bY. and the temperature of, the nip rollers, and thermal agia~g of the layers. while several factors can playa role in providing a desired peel strength, that d~a fired peel strength can be achieved through'routine trial. arid exror adjustments.
Strengths which presently are believed most desireable are specified below.
g~~ara~t.ion can be achieved by unitary peeling bn the one hand, or by grinding, shredding or chopping: In both cases the object is to separate contaminated ~esxn from other resins, nit t~
separate different resin mate~ia~s. By unitary peeling is meant the kind of peeling that may be accomplished ~a~ball~ by liberally peeli.n~ back the peehble fih p~:y 15, as been in ~°IG. 7. Even though the l~be1 ~.s inset int~ the bottle; the peeling acts:~n can be started by prying the edge of su~s~~~us~t~~r W~ 93117~i11 PCTlUS93l01462 the label or pushing a blunt knife or similar tool in the inboard direction over the label edge with a smearing action while bearing down on the label.
After the peelinr~ is started, 'the ply 15 is grasped and manually pulled. The peeling action proceeds continuously and progressively over the interface between the peelable film ply or face ply ~.5 and the remaining non-peelable film ply or core ply 19. 1'he multilayer film plies 2.5 and 19 on each side of the interface remain integral films during the peeling.
-. - Separation of peelable face plies from bottles in this manner fully accomplishes the desired separation of'printing inks from the bulk of the bott~.e st~ck fear recyGlinc~ purposes, leaving the bottle stack uncontaminated by the inky. Separation by unitary peeling will generally be relied on when consumers are expected to do the peeling when returningor delivering used containers for recycling: This process may be autbmated in commercial o~ industrial ~ecyc~:ing operations by sazita~le means'such as mechanically replicating the ~nanu~~ removal described above, or using powered axially-rotating cylindrical arrays of stiffly flexing rubber pusher fingers or the Tike knot shown) which are brought to bear on the label surface in: an action sami~:ar t~ that of will-known "chicken picker" apparatus for defeathering fowl.
Separation by grinding, shredding or chopping involves both separata:onat he peeling interface ~uria~g gr~.nding iaself, and subsequent particle c2aseifa.cation. The c~.assific~tion step separates particles resulting from the g~ind~.ng into two classes t ( 1 j partidles con~~.ining conta~a~.nan~t sink) and (2) particles free of contami~aant. The ~bje~t is to isolate contaminated resin frs~m the SU~S'~tTUTE SHEET
. _.... _ ,--a ss v . :Ti,raYVT:F: P..fW' ....~-pr . .:.:4, . r _____ _______________._._.._~..,.~~".,.~..~.~,~. . . ,r....~ A,.n<..»,,>",-.T., n.,~..,.. .. , , ,_ ........_, .. . . :r . _ . .F .~t -r.~... .. . , W~ 93/ 1741 i PLT/US93/0 i 4b~
~~.a~~~~
W ~ ~ " . °' '' 16 bulk of the resinous material, not to separate ' resins of different kinds. A grinding operation is represented for clarity in a highly schematic and artificially regularized fashion in FIGS. 8 and 8~
which show a labelled bottle B being passed through a grinder 50. Grinding subjects the film material to high mechanical stresses, so that the separation interface S experiences separation farces sufficient to cause the particles being formed by the grinding to split at this interface. The result is two -- classes of particles, hs seen on opposite sides of the dividing ~.ine lD-D in FIG. 8A. One class of particles (to the right of dividing line D-D) cansists entirely of the bottle'material, or consists entirely of the material of core ply ~.9, or consists partly of both. The other class of particles consists entirely of the material of face ply 15. These classes of particles are then separated using any well-known particle classifi~cati.on technique, such as centrifuging or flotati~n, which exploits a difference in density or specific gr~~rity between the classes of particles in ~rder to c~mplet~ separatian.
In som~.circums~ances, it may be most efficient or economical to recycle by only partially ~~.i~~ing the bottles in tho label area. Thus, the lahelled side ~f the bottle may be ~ngag~d with grinding means to the extent necessary to wholly or p~r~ially remove the label wh3:le leaving the remainder of the bottle whcal~ for remelting. Such removal could be followedby particle classification a.f the amOUnt of removed material otfieer than from thec~ntam~n~tedf~~eep~y~ma~e~.twOrthwhiles In some cases, very'precise ad~ustm~nt of grinding conditions may even allow the peelable film ply S~B~T~TUTE S~~ET

WC~ 93/17411 fCTI~,~S93/01462 17 ;> ~ ~";~dtaa ~mf.
alone to be removed by shredding or grinding of such ply alone to an extent sufficient to cause separation at the separation interface. There would then be no need or purpose for a subsequent reclassification step. Such a process might be an alternative for unitary peeling by hand or by automated means, and might in some circumstances be more efficient than unitary peeling while, as in unitary peeling, avoiding the need for particle classification .
When grinda.n~ is to be used followed by partic2e classification based on density, materials for the bottle stock and for the non-peelable film ply or core ply on the one hand, and for the peelable film ply car ~ac~ ply on the other hand, mist be sufficiently different to allow successful classifi~atiorr. The specific gravity of polyester bottles in common use is generally relatively high, say shout 1. z5, and,that of vinyl bottles is about 1:3 or 1.4., so generally ~ater,ials chosen for the peelable film ply or face ply will be lower density materials, such as'un~i~.~.ed polyethylene or pQlyp~bpyler~e of say about : ~ specif is gravity .
Materials for the n~n-peelable film ply or core ply may be given higher densities, say up to about ~..2 t~ ~.4,,by use,of filler, pravided the filler is not such as t~ unacceptably degrade the material mix that is recycled for container manufacture. In general, use of filler in the non-peelable film ply or core ply, may be matdhed to filler use in the bottle mat~ri.al for desired results. .For low density p~lyethylen~ and gaolypropylene containers, the p~el~bl~ film ply or face ply may employ (fillers and pigments to iaaer~ase density for centrifugal separation after ~rind~.ng:
SUSS'~~TE13E SHEET

dV0 93/741 i P~'/LJS93/01462 . 18 .,," ~n:~s:: f;~.
~t ,. . ..
In many circumstances, the constraints as to relative specific gravities may be looser than indicated above, due to the fact that the label material in its entirety constitutes only a minor part of the total bottle construction. Therefore, if some of the core ply is separated along with the face~ply, the loss to recycling may be minor and acceptable. The major consideration is the accomplishment of complete removal of the material of the face ply, containing the contaminating inks.
-- If that is accomplished, removal of some additional material may be inconsequential. Thus, for example, when subjected to centrifuging or flotation, if the core ply has a specific gravity as low as that of the face ply, ground particles consisting entirely of the core ply will separate along with the face ply, and particles consisting of both the bottle st~ck and the core ply will also tend to separate along with the face ply.; Such tendency will be g~:~atest for those individual particles of the latter type where the ma°t~rial of the relatively Sight core ply makes up mast of the particle.
~ndividua~. particles where th~.opgaosite is true will tend to remazn with the bottle stack. This loosening of constraints as to required density , relations provides more opta:ons thin would otherwise be the case as to use or aeon-~us~ o~ fillers, or as to the degree of filler use, when matching the core pli~ to the'bottle material as mend~ned above.
Whether separation is acc~mplished blr unitary peeling or by grindincj, the non~peelable ~or~ ply 1~ remains with~the bottle stock, but is of such ~ nature that contaminati~m c~f the bottle stock does not occur, ~r is mi.nimi2ed ~~ Such an extent ti~at he stock is acceptable'for remelting and SUSS ~ ITUTE SHEET

Wfl 93717411 PCT/US93/01452 reuse, either in the same application as in its ' virgin use, or in ,.her applications which are less demanding as to stock specifications. In particular, in many applications, the non-peelable core ply 19 is Buff ici~ntly compatible with reuse of the bovtle stock that if a defect such as incorrect label orientation occurs during bottle manufacture (particularly a risk during startup), the peelable face ply can be removed by direct peeling, or by regrinding combined ?pith centrifuging or flotation, and the bottle material, including the material of the core ply ~.9, can be directly cycled back to the bottle-maker's own resin inventory for the blow-molding lines and can be ian~mediately remelted for reuss on 'the bottle ine.
When separation is to be accomplished by unitary peeling, peel strengths in the range of about 3U~-20C1 grams per two-inch w~.dth at 90 degrees peel have been found effective. Peel strengths in the range of about 5(3-150 are preferred, and most desireable are interfacial peel strengths in the 'range of about 55-?5. Desired values for peel strengths when 'separation is t~ be by griming fal.lowed ~y centrifuging'or flotation have not been confirmed but are believed to.approximat~ those given above for unitary peeling.
In some app~.ications, during bottle ~,anufac~.ure when the face ply of a misaligned label . has been peeled off anc~ the b~~tle proper is xnot defective, it may be acceptable to reapply a fresh ~~b~l over the structure that rel~ains after removal of the face ply, even tM~ugh such yew label will not b~ completely ~'~.nlaid" in the labelled face of the bottle. Such a defectively labelled bottle would not be remelted, but could simply receive a new ~~~STI?lJTE SH~~T

label in an off-line post-molding operation. Application of the new label might be accomplished by known out-of-mold applicator devices such as a hot-stamping machine or a "Therimage" type applicator or "decorator."
Subsequently, such a bottle could be recycled like any other, since the peelable film ply of the new label could be removed in the same manner as other labels, whether by unitary peeling or by grinding and subsequent particle classification.
Whenever consistent with the present description of invention, in connection with the various stages of label stock manufacture and labelling referred to herein, it is presently believed generally desirable to also observe the practices and criteria disclosed in foregoing Canadian Ser. No. 2,117,057.
As used in the foregoing description of the invention and in the following claims, "bottles" refers to all forms of blow-molded containers, and generally to all similar blown products suitable for labelling. The terms "grinding," "shredding," and "chopping" are used interchangeably.
It should be evident that this disclosure is by way of example and that various changes may be made by adding, modifying or eliminating details without departing from the fair scope of the teaching contained in this disclosure. As an example of the many possible variations in the practice of the invention, die-cutting of labels may be done directly by rotary or reciprocating means and such labels may then be gathered into individual stacks of labels, thus substituting a gathering step for the step of forming the stack 30.

WO 93/ 17~ 11 P(:T/ US93/O i 462 21 : ~ .a~'.
Alternatively, die cutting of labels may be done in-°
line with, the molding operation or other workpiece forming operation, with the labels then being picked off one by one by the label inserting mechanism.
Or, rolls of labels aright be delivered into a slot in the mold half and die-cut by the action of the mold closing.
Indeed, while the invention has been described in connection with in-mold labelling and presently appeaz~s t~ be particularly advantageous -~ for that application, the same concepts also have utility for praviding graphics or decoration for polymeric substrates thermally formed as by thermofcirming, injection molding, reaction injection molding, rbtational molding, and forming of sheet molding G~m~ound: Die-cut labels of the present invention can also be applied by hot stamping or ironing or rall'application, either those provided with continuous c~r.~cier or th~se whose backing is die-cut to the same shape. If pressure-sensitive adhesive is applied o~ tramsfer-boated ontp the multaply extr~adate after printing to form an adhesive layer an place of the layer 1~~ application can be by'pressuro a~.oneo Application of labels might be acco~nplishedl by 'known out-of-mold applicator devises such a~ a hot~stamp~.ng machine or a ilTh~'r7l.mf'lgell t~ app,l,l.cator or IldeC°.rorato~s 11 the i~avention therefore should not be limited to particular details of thus disci~sure except to the ~xt~nt that the f~llowinc~ claims aye necessarily s~
limited.
SU~S~I'~UT~ ~H~ET'

Claims (35)

WHAT IS CLAIMED IS:
1. In-mold label stock comprising a roll of layered film material containing within itself a separation interface, said layered film material comprising two polymeric film plies each comprising one or more film layers, said film plies being in contact with each other and presenting to each other surfaces of different composition at a pair of contacting interior faces joined at said separation interface, one of said film plies comprising printable in-mold label facestock, the other of said film plies comprising an adhesive, said film plies adhering to each other at said separation interface to a sufficiently high degree to withstand the maximum process separation force imposed on said stock at said separation interface as said stock is printed and as labels are cut from said stock and are deployed for affixation on substrates, said film plies adhering to each other at said separation interface to a sufficiently low degree to allow them to cleanly and readily separate from each other at said separation interface under the imposition of a separation force greater than said maximum process separation force.
2. Label stock as in claim 1, the peel strength at said separation interface being in the range of about 30 to 200 grams per two-inch width at 90 degrees peel.
3. Label stock as in claim 1, the peel strength at said separation interface being in the range of about 50 to 150 grams per two-inch width at 90 degrees peel.
4. Label stock as in claim 1, the peel strength at said separation interface being in the range of about 55 to 75 grams per two-inch width at 90 degrees peel.
5. Label stock as in claim 1, said other of said film plies further comprising a stiffening core layer.
6. Label stock as in claim 1, the peel strength at said separation interface being in the range of about 30 to 200 grams per two-inch width at 90 degrees peel.
7. Label stock as in claim 1, the peel strength at said separation interface being in the range of about 50 to 150 grams per two-inch width at 90 degrees peel.
8. Label stock as in claim 1, the peel strength at said separation interface being in the range of about 55 to 75 grams per two-inch width at 90 degrees peel.
9. A labelled plastic bottle or other substrate comprising a substrate body, a label formed of layered film material and containing within itself a separation interface, said label being applied to the substrate body, said layered film material comprising two polymeric film plies each comprising one or more film layers, said film plies being in contact with each other and presenting to each other surfaces of different composition at a pair of contacting interior faces joined at said separation interface, one of said film plies comprising printable label facestock, the other of said film plies comprising an adhesive, said film plies adhering to each other at said separation interface to a sufficiently high degree to withstand the maximum process separation force imposed at said separation interface as said layered film material is printed and as labels cut therefrom are deployed for affixation on said substrate, said film plies adhering to each other at said separation interface to a sufficiently low degree to allow them to cleanly and readily separate from each other at said separation interface under the imposition of a separation force greater than said maximum process separation force.
10. Label stock as in claim 9, the peel strength at said separation interface being in the range of about 30 to 200 grams per two-inch width at 90 degrees peel.
11. Label stock as in claim 9, the peel strength at said separation interface being in the range of about 50 to 150 grams per two-inch width at 90 degrees peel.
12. Label stock as in claim 9, the peel strength at said separation interface being in the range of about 55 to 75 grams per two-inch width at 90 degrees peel.
13. Label stock as in claim 9, said other of said film plies further comprising a stiffening core. layer.
14. Label stock as in claim 13, the peel strength at said separation interface being in the range of about 30 to 200 grams per two-inch width at 90 degrees peel.
15. Label stock as in claim 13, the peel strength at said separation interface being in the range of about 50 to 150 grams per two-inch width at 90 degrees peel.
16. Label stock as in claim 13, the peel strength at said separation interface being in the range of about 55 to 75 grams per two-inch width at 90 degrees peel.
17. Labelling method including the steps of:

forming layered film material containing within itself a separation interface and comprising two polymeric film plies each comprising one or more film layers, said film plies being separably adhered to each other at said separation interface and one of them comprising printable label facestock and the other comprising an adhesive layer, printing the facestock with an ink or inks to decorate the same, die-cutting the film material to form individual labels, sequentially deploying the labels for bonding onto successive substrates as said substrates and labels are brought into contact and said labels are bonded to said substrates, said printing, die-cutting, deploying, and bonding being carried out in the absence of forces at said separation interface sufficient to cause separation.
18. A method as in claim 17 further including, subsequent to said bonding of said labels to said substrates, imposing separation forces at said interface of said layered film material sufficient to cause interply separation whereby said printed facestock is separated for recycling of said substrate stock uncontaminated by said ink or inks.
19. A method as in claim 18, said step of imposing separation forces including the step of peeling said interface apart with a peeling action which proceeds continuously and progressively over said interface.
20. A method as in claim 18, said step of imposing separation forces including the step of shredding at least some of said layered film material on at least one side of said interface.
21. A method as in claim 18, said step of imposing separation forces including the step of shredding at least some of said layered film material on each side of said interface.
22. A method as in claim 21, including the step of classifying by differences in specific gravity and separating the shredded material from one side of said interface from the shredded material from the other side of said interface.
23. A method as in claim 22, said classifying and separating step including a flotation step.
24. A method as in claim 22, said classifying and separating step including a centrifuging step.
25. A method as in claim 18, further including, subsequent to said bonding of said labels to said substrates, selecting substrates which are not properly formed or whose labels are misformed or misregistered, and imposing separation forces at said interface of said layered film material of said selected substrates, said forces being sufficient to cause separation whereby said printed facestock is separated, and recycling said selected substrates uncontaminated by said ink or inks to thereby contribute to the replinishment of the supply of substrate stock while eliminating waste.
26. A method as in claim 25, said recycling of said selected substrates being directly to the supply of substrate extrudate at the input end of a substrate-forming line.
27. A method as in claim 18, further including, subsequent to said bonding of said labels to said substrates, selecting substrates whose labels are misformed or misregistered, and imposing separation forces at said interface of said layered film material of said selected substrates, said forces being sufficient to cause separation whereby said printed facestock is separated from said selected substrates, and applying undamaged labels to said substrates to thereby include said selected substrates in the product of the substrate labeling operation.
28. A method including the steps of farming layered film material containing within itself a separation interface and comprising two polymeric film plies each comprising one or more film layers, said film plies being separably adhered to each other at said separation interface and one of them comprising printable label facestock and the other comprising an adhesive layer, printing the facestock with an ink or inks to decorate the same, die-cutting the film material to form individual labels, sequentially deploying the labels for bonding onto successive plastic substrates, and bonding them thereto, said printing, die-cutting, and deploying being carried out in the absence of forces at said separation interface sufficient to cause separation.
29. A method as in claim 28 further including, subsequent to said bonding of said labels to said substrates, imposing separation forces at said interface of said layered film material sufficient to cause separation whereby said printed facestock is separated from said ply comprising an adhesive layer for recycling of said substrates uncontaminated by said ink or inks.
30. Label stock as in claim 1, wherein said surfaces of said contacting faces are formed of different polyolefins.
31. Label stock as in claim 1, wherein said surfaces of said contacting faces are formed of either polyethylene homopolymer or polypropylene homopolymer.
32. Label stock as in claim 1, wherein at least one of said film plies includes a plurality of said film layers, said film layers including a layer of olefin polymer and a layer comprising a blend of olefin polymers and copolymers of olefin monomers with ethylenically unsaturated carboxylic acid or ethylenically unsaturated carboxylic acid ester comonomers such as the ethylene-vinyl acetate copolymer.
33. Label stock as in claim 9, wherein said surfaces of said contacting faces are formed of different polyolefins.
34. Label stock as in claim 33, wherein said surfaces of said contacting faces are formed of either polyethylene homopolymer or polypropylene homopolymer.
35. Label stock as in claim 9, wherein at least one of said film plies includes a plurality of said film layers, said film layers including a layer of olefin polymer and a layer comprising a blend of olefin polymers and copolymers of olefin monomers with ethylenically unsaturated carboxylic acid or ethylenically unsaturated carboxylic acid ester comonomers such as the ethylene-vinyl acetate copolymer.
CA002130273A 1992-02-21 1993-02-10 Peelable label and methods of manufacturing and recycling Expired - Fee Related CA2130273C (en)

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US839,369 1992-02-21
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AU3774493A (en) 1993-09-13
AU668382B2 (en) 1996-05-02
KR950701111A (en) 1995-02-20
JP3514757B2 (en) 2004-03-31
EP0627109B1 (en) 2000-04-26
CA2521070A1 (en) 1993-09-02
EP0627109A1 (en) 1994-12-07
ATE192254T1 (en) 2000-05-15
TW446667B (en) 2001-07-21
JPH07507397A (en) 1995-08-10
WO1993017411A1 (en) 1993-09-02
US6165576A (en) 2000-12-26
EP0627109A4 (en) 1997-05-07
DE69328475T2 (en) 2001-01-25
TW397768B (en) 2000-07-11
DE69328475D1 (en) 2000-05-31
US6159568A (en) 2000-12-12
CA2130273A1 (en) 1993-09-02
DK0627109T3 (en) 2000-08-07

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