Combined receipt and label roll having optimal adhesive patch patterns and a method of manufacturing thereof

A combined receipt and label roll, comprising:

• a core;
• a web wound on the core, wherein the web has first and second longitudinally-extending edges, and wherein the web comprising:
• i) a substrate having a front side and a back side opposite the front side, wherein the front side includes a thermally-sensitive coating disposed on the front side;
• ii) an adhesive disposed on the back side of the substrate as at least four adhesive patches, wherein the adhesive is a water-based microsphere adhesive, and wherein each adhesive patch is positioned relative to each other on the back side of the substrate in a selected pattern, the selected pattern selected from one of ten predefined patterns, each pattern including at least one adhesive patch situated in one or more of four quadrants defined on the back side, and each patch for each pattern including a predefined size and position within at least one of the four quadrants, wherein the ten predefined patterns include:
• 1) a first pattern comprising 7 adhesive patches arranged in a sideways U shape with the base of the U directed towards the first longitudinally-extending edge, wherein the 7 adhesive patches are of the same size;
• 2) a second pattern comprising two pairs of adhesive patches with a first pair having a first adhesive patch size and a second pair having a second pair adhesive patch size each of the two pairs aligned relative to each other in a diagonal relationship on the back side of the substrate, wherein the two pairs of adhesive patches comprising 4 adhesive patches, wherein the first adhesive patch size is 1.8 times smaller than the second pair adhesive patch size;
• 3) a third pattern comprising 7 patches arranged in a sideways U shape with the base of the U directed toward the second longitudinally-extending edge, wherein the 7 patches are of the same size, wherein each adhesive patch size of the 7 patches is 1.11 times larger than other patches associated with a seventh pattern and an eighth pattern;
• 4) a fourth pattern comprising 6 adhesive patches arranged in a C shape with the side of the C directed toward the first longitudinally-extending edge, wherein two of the 6 adhesive patches are a first size and four of the 6 adhesive patches are a second size, wherein the second size is smaller than the first size, and wherein the 6 adhesive patches are in a substantially C-Shape arrangement, wherein 4 of the 6 adhesive patches are 1.8 times smaller in size than the remaining 2 of the 6 adhesive patches;
• 5) a fifth pattern comprising 4 adhesive patches, wherein the 4 adhesive patches are arranged to form a substantial I-shaped arrangement that longitudinally extends along a the first-longitudinally-extending edge of the substrate, wherein 2 of the 4 adhesive patches form a first pair of patches that is 1.8 time smaller that the remaining 2 of the 4 adhesive patches that form a second pair of patches;
• 6) a sixth pattern comprising 9 adhesive patches arranged in a X shape, wherein the 9 adhesive patches are of the same size and are of a same size as that which is associated with patches of a ninth pattern, and wherein each of the 9 adhesive patterns are 1.8 times smaller in size than other patches associated with a seventh pattern and the eighth pattern;
• 7) the seventh pattern comprising 5 adhesive patches arranged in a sideways V shape with a base of the sideways V shape directed toward the first longitudinally-extending, edge, wherein the 5 adhesive patches are of the same size, wherein each of the 5 adhesive patches are 1.8 times larger than patches associated with the sixth pattern and the ninth pattern;
• 8) the eighth pattern comprising 5 adhesive patches arranged in a sideways V shape with a base of the sideways V shape directed toward the second longitudinally-extending;
• edge, wherein the 5 adhesive patches are of the same size, wherein each of the 5 adhesive patches are 1.8 times larger than patches associated with the sixth pattern and the ninth pattern;
• 9) the ninth pattern comprising 5 adhesive patches arranged as a diagonal line, wherein the 5 adhesive patches are of the same size, wherein each of the 5 adhesive patches are of a same size as patches associated with the sixth pattern;
• and
• 10) the tenth pattern comprising 4 adhesive patches, wherein each adhesive patch pair of the 4 adhesive patches arranged diagonally to its corresponding adhesive patch, wherein a first adhesive patch pair comprising 2 of the 4 adhesive patches is 1.8 time larger in size than a second adhesive patch pair comprising the remaining 2 of the 4 adhesive patches;
• wherein each pattern comprises a tack that may be obtained by measuring the peel force in pounds of force, wherein the tack associated with any given pattern is between 4.7 and 0.7 pounds of force without increasing a coat weight associated with the water-based microsphere adhesive;
• wherein an optimal configuration of the adhesive patches is selected from the patterns to achieve higher peel force of labels removed or separated from the combined receipt and label roll;
• wherein any given patch size of any given pattern is calculated based on a select patch size, with the given patch size being 1.8 times larger than the select patch size, being equal to the select patch size, being twice as large as the select patch size, or being 3.6 times larger than the select patch size, wherein the select patch size is a predefined smallest patch of a value of 1, wherein each given patch size in each given pattern is a multiple of the predefined smallest patch of the value of 1.