Note: Descriptions are shown in the official language in which they were submitted.
j;; w. .t~ f II
CA 02390473 2002-06-12
LABEL PACKAGE CONSTRUCTION
BACKGROUND OF THE INVENTION
[0001] The present invention relates to sheets of printable labels and, in
particular,
to a self contained printable label packaging that can be displayed and sold.
[0002] Sheets of blank printable labels are sold in packages, so that the
customers
can print relevant information on the labels. Typically, in the prior art,
each sheet is
foldable as shown in FIG. 1, and such as is available from Avery Dennison
Corporation of Pasadena, California. The outer surface of this sheet has
marketing
or other information printed on it, and the inner surface has a layer of
adhesive for
affixing a die-cut face sheet having a predetermined style of labels. These
labels can
be hand printed, typed or computer printed.
[0003] FIG. 1 depicts a prior art package 1 comprising multiple panels 2 of
paper-
based sheet material that can be folded along the perforations 8. A series of
printable labels 4 reside on an inner face 22. The inner face is releasably
affixed by
means of adhesive to a backing sheet (not shown). Means for hanging the label
package 1 (comprising the sheet and labels) is achieved via an opening 6 in
the
sheet.
[0004] The outer face of the foldable sheet of FIG. 1 is shown in FIG. 2. The
backing sheet 26 contains marketing information 10. And FIG. 3 shows the cross-
sectional view of the foldable prior art sheet of FIG. 1 as viewed along line
3-3 of
FlG. 1. As shown, the backing sheet 26 is substantially thin and of
approximately
similar dimensions as the inner face sheet 22 of the foldable sheet 2. Means
for
bonding the inner face sheet 22 to the backing sheet 26 is provided by a
bonding
agent, such as adhesive 24.
SUMMARY OF THE INVENTION
[0005] There are a number of disadvantages in the prior art approach described
above. Firstly, the material for the foldable rectangular sheet is flimsy,
thereby
making the sheet easily susceptible to damage. Secondly, the material is of
fairly
poor print quality. This low print quality generally distorts the marketing
information
printed on the outer surface. Thirdly, the predetermined style of labels on
the inner
surface of the foldable rectangular sheet cannot be seen through the opaque
foldable sheet. This prevents the customer from accurately choosing the kind
of label
;i.i~~ ~~,~ ~~ ~~ ,
CA 02390473 2002-06-12
style based on hislher preference. Fourthly, the labels on the inner surface
cannot be
distinguished from the surrounding material (known as the matrix), making it
difficult
for the customer to peel the labels off the surface. Finally, the labels can
be either
permanent or removable.
[0006] Thus, what is needed for printable label applications is that the
foldable
sheet preferably is reasonably strong, has a good print quality, allows a
clear view of
the style of labels that are present on the inner surface of the foldable
sheet, or
providing adequate information on the outer surface of the foldable sheet
advising
the user of the style of label present on the inside surface, and allows a
clear and
distinguishing border between the labels and the surrounding strip on the
inner
surface.
[0007] In one embodiment of the present invention, the foldable sheet of
printable
labels comprises a face paper, a sturdy and high print quality backing sheet,
and an
adhesive layer between the backing sheet and the face paper. The face paper is
die
cut to introduce an area for labels. The outer surface of the foldable sheet
can
include marketing information.
[0008] in another embodiment of the present invention, the foldable sheet of
printable labels comprises a face paper, a high print quality backing sheet,
and an
adhesive layer between the backing sheet and the face paper. In addition, a
sturdy
insert card is placed inside the foldable sheet. The face paper is die cut to
introduce
an area for labels. The outer surface of the foldable sheet contains marketing
or
other information. The package comprising the foldable sheet of printable
labels and
the insert card is shrink wrapped so as to retain the insert card. The insert
card can
be disposed of by the customer after opening the shrink wrapped package.
[0009] In a further embodiment of the present invention, the foldable sheet of
printable labels comprises a face paper, a sturdy and high print quality
backing
sheet, an adhesive layer between the backing sheet and the face paper, a cut-
out
window on the foldable sheet, and a clear liner applied to the cut-out window.
The
face paper is die cut to introduce an area for labels. The outer surface of
the foldable
sheet preferably contains marketing information or other indicia.
[0010] In yet another embodiment of the present invention, the foldable sheet
of
printable labels comprises a face paper, a high print quality backing sheet,
an
2
',~ , ~ ~": I,I. ~ ~~ ( II
CA 02390473 2002-06-12
adhesive layer between the backing sheet and the face paper. In addition, a
sturdy
backing card is placed separate from the foldable sheet. The face paper is die
cut to
introduce an area for labels. The outer surface of the foldable sheet
preferably
contains marketing information or other indicia. The final package comprising
the
foldable sheet of printable labels and the backing card is shrink wrapped so
as to
retain the backing card in place. The backing card can be disposed of by the
customer after opening the shrink wrapped package.
[0011] In a still further embodiment of the present invention, the foldable
sheet of
printable labels comprises a face paper, a sturdy and high print quality
backing
sheet, an adhesive layer between the backing sheet and the face paper, a cut-
out
window on the foldable sheet, and a clear finer applied to the cut-out window.
The
face paper is die cut to introduce an area for labels. The matrix surrounding
the
labels is patterned differently so as to allow a clear differentiation between
the labels
and the surrounding matrix for easy label peel-off. The outer surface of the
foldable
sheet can include marketing, instructional or other information.
[0012] In another embodiment (or a variation of the above embodiments) a high
print quality backing sheet is provided. The sheet has a release coating
applied on
the side that is laminated to the face sheet with an adhesive layer on it.
BRIEF DESCRIPTION OF THE DRAWINGS
(0013] More particular description of the invention briefly summarized above
may
be had by reference to the specific embodiments thereof that are illustrated
in the
appended drawings. It is to be understood, however, that the appended drawings
illustrate only typical embodiments of the invention and are therefore not to
be
considered limiting of its scope, for the invention may admit to other equally
effective
embodiments.
[0014] In the drawings:
(0015] FIG. 1 is a top plan view of a prior art sheet depicting the inner face
of a
foldable sheet containing printable labels;
(0016] FIG. 2 is a top plan view of the prior art sheet of FIG. 1 depicting
the outer
surface of a foldable sheet containing marketing information;
3
. , J
CA 02390473 2002-06-12
[0017] FIG. 3 is an enlarged cross-sectional view taken along line 3-3 of FIG.
1;
[0018] FIG. 4 is a view similar to FIG. 3 but illustrating an embodiment of
the
present invention;
[0019] FIG. 5 is a perspective view of packaging comprising a foldable sheet
of the
present invention;
[0020] FIG. 6 is a perspective view of the embodiment of FIG. 5 showing an
unfolding step;
[0021] FIG. 7 is a perspective view of the embodiment of FIG. 5 showing the
sheet
unfolded;
[0022] FIG. 8 is a top plan view depicting an embodiment of the present
invention
comprising a window and a clear liner applied to the foldable sheet;
[0023] FIG. 9 depicts the front and outer surface of the embodiment shown in
FIG.
8;
[0024] FIG. 10 is a front view of another embodiment of the present invention
comprising a shrink-wrap and a sturdy insert card;
[0025] FIG. 11 is an enlarged cross-sectional view for the embodiment of FIG.
10
taken along line 11-11;
[0026] FIG. 12 depicts an embodiment of the invention showing a sturdy backing
card and a shrink-wrap;
[0027] FIG. 13 is an enlarged cross-sectional view of the embodiment of FIG.
12
taken on line 13-13;
[0028] FIG. 14 depicts an embodiment in the present invention where a window
emulation is applied or printed to the outer front side of the sheet;
[0029] FIG. 15 is a top plan view of an embodiment in the present invention,
where
the labels on the inner face are patterned differently from the surrounding
face
material;
[0030] FIG. 16 depicts a manufacturing process for an embodiment of the
present
invention; and
[0031] FIG. 17 depicts a manufacturing process for another embodiment of the
present invention.
4
~. 1l l ~ I ~I
CA 02390473 2002-06-12
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION
[0032] Referring to the drawings, FIG. 5 shows an embodiment of the present
invention. The label package 40 comprises a substantially sturdy and thick
backing
sheet. The first pair of outer surfaces of the backing sheet 42 and 44 contain
marketing or other information or indicia 10. The outgoing arrows 45a, 45b
indicate
the unfolding operation for accessing the labels 4.
[0033) Upon unfolding, a second pair of outer surfaces 46, 48 of the backing
sheet
are exposed as shown in FIG. 6. A glue bead 49 or the like can bond the second
pair
of outer surfaces 46 and 48 together. Another pair of outgoing arrows 49a and
49b
indicates another unfolding operation that is performed, in this embodiment,
so as to
access the printable labels.
(0034) Further unfolding exposes the inner face 50 along with the labels 4, as
shown in FIG. 7. The inner face 50 is laminated to the backing sheet by means
of a
permanent adhesive. Although the labels 4 are shown as being circular, they
may be
of any shape and of variable sizes. A groove 56 is formed in the foldable
sheet for
ease in the unfolding operation of FIG. 5.
[0035] FIG. 8 shows another embodiment in the present invention. The foldable
sheet 40 has a window 52 that is cut out as shown on the inner face 50. A
clear film
liner 54, such as a polyester or polypropylene, is affixed to the inner face
50 such as
by means of an adhesive. The window 52 provides an easy view for a customer of
the style of labels that are enclosed in the packaging.
[0036] As shown in FIG. 4 (which is similar to cross-sectional view along line
3-3 of
FIG. 1 ) for one embodiment in the present invention, the backing sheet 36 is
sturdy
and made of substantially thicker dimensions than the inner face 32. The
material
used for the backing sheet 36 is preferably a heavy paper #70 or #100 text, or
#50-
#60 cardstock. The material used for the inner face 32 is preferably 50# text.
The
inner face and the backing sheet are laminated together by means of a
permanent
adhesive, such as a waterbase acrylic emulsion adhesive.
(0037] FIG. 9 shows the label package 40 of FIG. 8, where all the panels are
appropriately folded and the label packaging is on display in a store.
I. I, ; I. I 6I
CA 02390473 2002-06-12
[0038] FIG. 10 depicts another embodiment of the present invention. In this
embodiment, the backing sheet need not be heavy. Instead, an insert card 58 is
placed inside the foldable sheet 40 to make the package substantially sturdy
and
thick. The insert card 58 can be 60# card or heavier, and a preferred example
of the
material is a heavy cardstock. This design again prevents the packaging from
being
easily damaged due to flexing. The package can be shrink-wrapped 56 by means
of
a material such as plastic to prevent the insert card 58 from separating from
the
foldable sheet. As an example, the single layer label thickness can be between
5.5
and 8.5 mils, a folded label sheet thickness can be at least twenty mils, and
an insert
card thickness can be between fifteen and thirty mils. More particularly, the
folded
label sheet thickness can be between twenty and thirty mils and the insert
card
thickness can be greater than twenty-one mils.
[0039] FIG. 11 shows the enveloping of the insert card 58 by the foldable
sheet 40.
The insert card 58 can also be positioned in slits 57 or 59, without
substantially
changing the nature of the design. A hang tab such as 58a in FIG. 10 can be
used
for generally any of the embodiments disclosed herein and particularly those
that are
shrink wrapped.
(0040] Another embodiment of the present invention is depicted in FIG. 12. In
this
embodiment, the backing sheet need not be heavy. Instead, a backing card 60 is
placed exterior to the foldable sheet 40 to make the package substantially
sturdy and
thick. The backing card can be a 60# card or heavier and a preferred example
of the
material is a heavy cardstock. This design again prevents the packaging from
being
easily damaged due to flexing. The package can be shrink-wrapped 56 by means
of
a material such as plastic to prevent the backing card 60 from separating from
the
foldable sheet. FIG. 13 shows the backing card 60 exterior to the foldable
sheet 40.
(0041) FIG. 14 depicts another embodiment in the present invention, where an
emulated or simulated window 62 is designed on the outer surface 42 of the
backing
sheet. In this design, the emulated window 62 performs the same function as a
real
window, without the need for cutting out a window in the manufacturing
process. The
style of labels in the packaging are projected on this emulated window 62 for
example via printing means in the manufacturing process. The window can have a
shape other than triangular and a size different than that depicted in the
drawings;
for example, it can be made larger where the labels themselves are larger.
6
,. :bf~le a l N r
CA 02390473 2002-06-12
[0042] The printable labels 4 of the embodiment of FIG. 15 are patterned
differently
from the surrounding inner face paper 66 (also called the matrix). In the
present
depiction, the labels are shown clear, whereas the surrounding matrix is
patterned or
tinted in color. This allows the customer to easily identify the labels 4 from
the
surrounding matrix 66 thereby resulting in an easy peel-off of the labels.
Other
differently patterned schemes as would be apparent to those skilled in the art
are
included in this disclosure.
[0043] Several stages of a manufacturing process are shown in FIG, 16. The raw
material (tape) in the form of a roll is constructed of dual face materials
that are
laminated together by a permanent adhesive. In this manufacturing embodiment,
the
first three print stations 102 are used to print the outside package graphics
on the
high gloss side of the material. The web is then turned over by a web turning
process
104 and the fourth printing station 106 is used to print on the inside or
label side of
the product. (Other methods aside from turning the web for printing on both
sides of
the paper, as would be apparent to those skilled in the art, can be employed.)
A first
die cutting station 112 cuts the labels using a flexible magnetic die. The
second die
cutting station 110 die cuts the hat and thumb holes as well as the vertical
perforations. The third die cutting station 108 sheets the material into
individual
sheets. The cut sheet travels along a short sandwich conveyor into folding
stations.
The first set of folding stations 114 folds the two outside panels (surfaces)
in towards
the center. Approximately half way through a second single folding station, a
glue
head 116 lays down a bead of releasable glue in a stitch pattern. The output
is sent
to a second folding station where it is folded in half and sealed by the glue.
The
output is sent to an ironing roller 118 and then drops onto a conveyor as a
final
package.
[0044] FIG. 17 shows an alternative embodiment in the manufacturing process,
where a tinting step is added at the beginning of the manufacturing process of
FIG.
16. The tinting step 202 applies a combination of four (preferably) colors to
the label
material. The tinted material then proceeds along the same manufacturing
process
as described in relation to FIG. 16. Stations 204, 206, 208, 210, 212, 214,
216, 218
and 220 in FIG. 17 correspond to stations 102, 104, 106, 108, 112, 114, 116
and 118
as depicted in FIG. 16 and as discussed above.
7
.. . . . ~ ~ i~i i~ ,~
CA 02390473 2002-06-12
(0045] While the specification describes particular embodiments of the present
invention, those of ordinary skill can devise variations of the present
invention
without departing from the inventive concept. For example, while the face
sheet has
been described herein as being made of paper, it can be made of other
materials,
such as film or foil. As another example, the processes shown in FIGS. 16 and
17
can be varied such as by adding printing and/or die cutting stations and/or by
varying
the order of the stations or process steps. Pursuant to a still further
example, the
matrix at the fold areas only can be removed to make the folding easier.
Folding can
be accomplished not only by adding perforations but also by other lines of
weakness.
Additionally, the backing sheet preferably has a release coating applied on
the inner
surface where it is laminated with the face. Also, the scope of the invention
includes
any combination of the elements from the different species, embodiments,
functions,
methods and/or subassemblies disclosed herein, as would be within the skill of
the
art.
s
