EP1656654B1

EP1656654B1 - Adhesive label and booklet blanks

Info

Publication number: EP1656654B1
Application number: EP04768072.3A
Authority: EP
Inventors: Barry Denny; Andrew Newman House DENNY
Original assignee: Denny Bros Ltd
Current assignee: Denny Bros Ltd
Priority date: 2003-08-22
Filing date: 2004-08-13
Publication date: 2013-07-03
Anticipated expiration: 2024-08-13
Also published as: HK1091021A1; EP1656654A2; ES2428029T3; DK1656654T3; PL1656654T3; WO2005020195A2; WO2005020195A3

Description

The present invention relates to adhesive labels and a method of their manufacture. In particular, the present invention is concerned with adhesive labels in the form of an adhesive label blank that may be printed by the label user, using for example a conventional desktop printer, and then folded and adhered to a surface. The present invention also separately relates to booklets and in particular to a booklet blank that may be printed by the user, again using a conventional desktop printer, and then folded and adhered to create a booklet.
Adhesive labels having a pre-printed leaflet portion, referred to hereafter as leaflet-labels and described, for example, in GB 1596306 and EP0304242 , provide efficient means for attaching large amounts of information to a product. Product manufacturers that use leaflet-labels generally require large quantities of leaflet-labels that can be quickly and easily transferred to their products preferably in an in-line process. Accordingly, recent developments in the manufacture of leaflet-labels have focused on providing leaflet-labels on reels, typically with hundreds of leaflet-labels on each reel, and which are manufactured using in-line assembly processes.
In the pharmaceutical industry, leaflet-labels have been adopted as a particularly convenient means for securing instructions and other vital information to drugs containers. The leaflet-labels generally contain information on safe dosage levels and contraindications etc. However, conventional leaflet-labels such as those described above are inappropriate for clinical trials where only a small number of patients participate in a trial of an experimental drug.
EP 0973141 describes a label sheet having an integral paper form, whereby information can be printed by a user on the form and on the labels and the labels subsequently removed individually for attaching to other objects.
US 5,129,682 describes a business form having removable labels associated with it so that information can be printed on the form and the labels and the labels then removed individually and applied as required.
Whilst in-line leaflet-label assembly methods provide an efficient and cost-effective means for producing a large quantity (>100) of leaflet-labels, the method becomes particularly cost-ineffective for small quantities (<50). The printing stations, folding presses, die-cutting stations etc. of an assembly line must all be reprogrammed for each new design of leaflet-label. As a result, in-line assembly is inconvenient and inappropriate for the manufacture of a small numbers of leaflet-labels.
A leaflet-label blank under the name of LaserInfold^™ is currently available which is provided unprinted and is designed to be printed and manually folded by those using the leaflet-label rather than by the leaflet-label manufacturer.
The blank comprises two sheets of paper: a leaflet sheet 1 and a support sheet 10. Referring to Figure 1, the leaflet sheet I has a perimeter cut 2 separating a leaflet-label portion 3 from a waste portion 4. The leaflet sheet 1 has a plurality of perforated fold lines 5 defining within the label-leaflet portion 3 a front panel 6, a back panel 7, a tab 8 and six other panels 9. Adhesive is provided between the leaflet sheet 1 and the support sheet 10 such that the two are held together. However, the strength of the adhesive and the sheet to which the adhesive preferentially adheres varies across the area of the support sheet. Thus, the rear surface of the leaflet sheet, i.e. the surface of the leaflet sheet facing towards the adhesive support sheet, coinciding with the waste portion 4 of the leaflet sheet is firmly adhered to the support sheet. On the other hand, other regions of the rear surface of the leaflet sheet are coated in a release material so that the adhesive does not adhere to those regions. The regions correspond on the leaflet sheet 1 to the position of the tab 8, the other panels 9 and a portion of the front panel 6 remote from the tab 8 and generally corresponding in size to the tab 8.
Referring now to Figure 2, the support sheet 10 corresponds in size and shape to the leaflet sheet 3 and has a series of cuts 11 through the support sheet 10 which describe the perimeter of first and second separated support regions 12 and 13 surrounded by waste material 14. The front surface of the second separate region 13, i.e. the surface facing towards the leaflet sheet, is also coated with a release material. The first support region 12 coincidences with the position of the front panel 6 of the leaflet portion 3 and the second support region 13 coincidences with the position of the back panel 7.
To use the blank as a leaflet-label, the user first prints the leaflet portion of the blank using for example a conventional inkjet or laser printer. Owing to the presence of the support sheet 10, only the top surface of the leaflet portion 3 can be printed. The leaflet portion 3 is then separated from the waste portion 4 and from the support sheet 10 by peeling the leaflet portion 3 away from the support sheet 10. Owing to the cuts 11 in the support sheet 10, the first support region 12 remains adhered to the front panel 6 and the second support region 13 remains adhered to back panel 7. The second support region 13, having release material on its front surface, is releasably adhered to the back panel 7 whereas the first support region 12, having no such release material, is permanently adhered to the front panel 6 (other than where release material is provided on the front panel).
Once all of the waste 4, 14 has been removed, the leaflet portion 3 is folded up following the perforated fold lines so that the other panels 9 are positioned between the front 6 and back 7 panels. Finally the tab 8 is folded away from the back panel 7, round the open edge of the leaflet-label, and is positioned over that portion of the front panel 6 which includes release material and under the first support region 12. The adhesive on the first support region 12 releasably adheres to the tab 8 thereby holding the leaflet-label closed. Finally, the second support region 13 is removed exposing a patch of adhesive on the rear panel 7 that is used to adhere the now printed leaflet-label to a product/container surface.
Whilst the leaflet-label blank described above enables a user to create leaflet-labels quickly in-house, the blank suffers from several significant disadvantages. First, there is a substantial amount of waste, both in terms of paper and adhesive. In particular, almost all the support sheet 10 is discarded with only the first support region 12 actually forming part of the final leaflet-label. Second, only the front surface of the leaflet sheet can be printed upon. The rear surfaces of the other panels 9, which are visible when the leaflet-label is opened, cannot be printed. Third, the manufacture of the blank is far from straightforward, requiring patches of release material to be defined on both the leaflet sheet and the support sheet prior to coating with adhesive.
It is an object of the present invention to provide a leaflet-label blank that overcomes in part one or more of the aforementioned disadvantages of the prior art. An additional object of the present invention is to provide a method of manufacture for the leaflet-label blank.
Accordingly, in a first aspect the present invention provides an adhesive label blank according to claim 1. The adhesive label comprises a printable main sheet having a front surface and a rear surface and a fold line about which the main sheet is foldable with the front surface innermost, the fold line thereby defining a front panel and a rear panel; a release sheet; and adhesive provided between the main sheet and the release sheet characterised in that the adhesive is provided between the release sheet and at least part of that portion of the rear surface of the main sheet forming the rear panel whereby the rear surface of the main sheet includes an exposed region not covered by the release sheet.
With the present invention only that portion of the rear surface of the label blank which is adhered to the release sheet is excluded from being printed upon. This in turn significantly reduces the amount of wastage arising from use of the label blanks as the release sheet does not extend the whole surface area of the main sheet. Indeed in a preferred embodiment the surface area of the release sheet is equal to or less than the area of the rear panel only.
In addition to the front and rear panels, the main sheet preferably has one or more additional fold lines defining one or more further panels in the main sheet, which are arranged to be positioned between the front and rear panels of the folded leaflet-label.
It will be understood that reference herein to fold line is to be understood as referring to an imaginary line along which the main sheet is folded. The position of the fold lines may be indicated by printed lines (pre-printed or printed as part of the printing of the label blank), perforations and/or by scored lines in the main sheet.
Ideally, the adhesive label blank further comprises a support sheet and additional adhesive which adheres a first surface of the support sheet to the rear surface of the main sheet, the release sheet being adhered to an opposed second surface of the support sheet by means of the adhesive wherein the support sheet bearing the additional adhesive extends beyond an edge of the rear panel of the main sheet with a cover strip overlying the additional adhesive. Similarly, a tab may be provided which extends beyond an edge of the front panel, the tab being arranged to cooperate with the support sheet to hold the adhesive label blank closed, when folded. The support sheet may extend either beyond a fold line defining an edge of the rear panel or beyond a free edge of the rear panel. In a second aspect, the present invention provides a method of manufacturing an adhesive label blank comprising the steps of: providing a printable main sheet having a front surface, a rear surface, and a fold line about which the main sheet is foldable with the front surface innermost, the fold line thereby defining a front panel and a rear panel; providing a laminate comprising a first release sheet and a first layer of adhesive; and adhering the laminate to the rear surface of the main sheet such that the rear surface of the main sheet has an exposed region not covered by the laminate.
The method may include the step of printing pre-printed information onto the main sheet. For example, the position of the fold lines may be indicated by print lines.
Preferably, the laminate further includes a support sheet, a second layer of adhesive and a second release sheet, wherein the first layer of adhesive is disposed on a first surface of the support sheet and is covered by the first release sheet, and the second layer of adhesive is disposed on an opposing second surface of the support sheet and is partially covered by the second release sheet. The laminate is then adhered to the main sheet by a region of the second layer of adhesive not covered by the second release sheet such that a portion of the support sheet covered by the second release sheet extends beyond an edge of the rear panel.
The step of providing the laminate preferably involves: providing a laminar material comprising a first web of release material, a first layer of adhesive, a central layer of support material, a second layer of adhesive and a second web of release material; removing the second web of release material to expose the second layer of adhesive; applying to the second layer of adhesive a ribbon of double-sided adhesive tape having a release liner over one of its two oppose layers of adhesive, the double-sided adhesive tape being arranged with the release liner facing away from the second layer of adhesive of the laminar material; re-applying the second web of release material over the second layer of adhesive of the laminar material and over the ribbon of double-sided adhesive tape; cutting the first web of release material, the central layer and the double-sided adhesive tape to define a patch; removing that portion of the first web of release material, central layer and double-sided adhesive tape surrounding the patch from the second web of release material to define the first release sheet, the support sheet and the second release sheet carried on the second web of release material; and removing the laminate of first release sheet, support sheet and second release sheet from the second web of release material.
The main sheet ideally includes a tab that extends beyond an edge of the front panel, and the laminate is adhered to the main sheet such that the main sheet can be folded so as to cause the tab to overlie that portion of the support sheet that extends beyond the edge of the rear panel.
The tab, which preferably forms part of and is continuous with the front panel, may be formed by cutting the main sheet. Alternatively, a tear-away strip may be provided in the main sheet along an edge that includes the front panel, the tear-away strip extending across all panels along the edge with the exception of the front panel.
A tear-away strip may also be provided along that edge of the main sheet that includes the rear panel. The laminate is then adhered to the main sheet such that the portion of the support sheet covered by the second release sheet does not extend beyond the tear away strip but does extend beyond that edge of the rear panel adjacent by the tear-away strip. This arrangement has the particular benefit that the support sheet does not protrude beyond the edge of the label blank, which might otherwise create problems during printing of the label blank. After the label blank has been printed by the end user, the tear-away strip is removed to expose that part of the support sheet that extends beyond the edge of the rear panel.
As mentioned earlier, the present invention is separately concerned with booklets and in particular a booklet blank that may be printed by the end user.
A variety of methods are known for manufacturing booklets in which the pages of the booklet are held together along a common spine. US patent 6,273,411 describes a method of manufacturing a booklet from a single pre-printed sheet, in which a central line of adhesive is first applied along the length of the printed sheet. The sheet is then folded several times about fold-lines perpendicular to the line of adhesive. The edges of the folded sheet perpendicular to the line of adhesive are then trimmed so as to create a number of individual leaves held together by the adhesive. Finally, the trimmed sheet is folded in half about the glue line to create the booklet.
Known methods of manufacturing such booklets generally employ in-line processing. For example, in US patent 6,273,411 booklets are manufactured by an apparatus that includes a sheet feeder, a gluing station, a first folding station, a cutter, and a second folding station. Whilst in-line processing is generally an efficient method of manufacturing booklets in large quantities (both in terms of time and cost), the method is inefficient in manufacturing small quantities of booklets and does not lend itself to the situation in which an individual wishes to print and create his own booklet. Again, referring to the example of clinical trials, a physician may wish to provide a patient with a booklet, which may be conveniently carried by the patient, containing information specific to the trial drug. There is therefore a perceived need for a booklet blank which can be printed using, for example, a desktop printer and then easily constructed by an individual to form a booklet.
It is therefore a further object of the present invention to provide a booklet blank that overcomes in part one or more of the aforementioned disadvantages of the prior art.
Accordingly, in a third aspect, the present invention provides a booklet blank comprising a first panel having a fold line, a strip of release material, adhesive provided between the strip of release material and a region of the first panel on or adjacent the fold line, and a second panel attached to the first panel and configured such that the second panel may be folded over the first panel so as to overlie the strip of release material and adhesive.
With the booklet blank of the present invention, an individual may conveniently print and create his own booklets. In order to construct the booklet after the booklet blank has been printed (e.g. using a desktop printer), the strip of release material is first removed to expose the adhesive. Thereafter, the second panel is folded over the first panel and adhered to the exposed adhesive. The second panel is then separated from the first panel such that the second panel is held to the first panel only by the adhesive. Finally, the first panel is folded about its fold line to create the booklet.
The first and second panels may form part of a single sheet, with the panels defined by a fold line in the single sheet. When constructing the booklet, the first and second panels are separated by tearing or cutting the single sheet along the fold line. The fold line of the single sheet may be perforated or scored with a half-depth cut to aid the separation of the two panels. Alternatively, the first and second panels may form separate sheets that are releasably adhered, e.g. by means of an adhesive tape adhered to both panels. The two panels are then separated during the construction of the booklet by removing the adhesive tape.
The second panel may be configured such that upon folding it over the first panel, the second panel extends across the fold line in the first panel. Accordingly, when the first panel is folded about its fold line, the second panel is also folded to create a booklet having four leaves (two from the folded first panel and two from the folded second panel). Alternatively, the second panel may be configured such that it does not extend across the fold line of the first panel upon folding. Consequently, the finished booklet has only three leaves (two from the folded first panel and one from the second panel).
The booklet blank may be provided with an additional strip of release material and adhesive on the opposite surface of the first panel to that of the strip of release material. When the booklet is created, the additional strip of release material may be removed to expose a region of adhesive proximate the spine of the booklet. Accordingly, one booklet may be inserted and adhered to another booklet.
Embodiments of the present invention will now be described by way of example only with reference to the accompanying drawings, in which:

Figure 1 is a top plan view of a leaflet-label blank in accordance with the prior art;
Figure 2 is a bottom plan view of the leaflet-label blank of Figure 1;
Figure 3 is a top plan view of a leaflet-label blank in accordance with the present invention;
Figure 4 is a bottom plan view of the leaflet-label blank of Figure 3;
Figure 5 is an enlarged sectional view of the base portion of the leaflet-label blank of Figure 3;
Figure 6 is an enlarged section view of a base portion of an alternative leaflet-label blank in accordance with the present invention;
Figure 7 is a top plan view of a second alternative embodiment of leaflet-label blank in accordance with the present invention;
Figure 8 is a top plan view of a third alternative embodiment of leaflet-label blank in accordance with the present invention;
Figure 9 is a top plan view of a fourth alternative embodiment of leaflet-label blank in accordance with the present invention;
Figure 10 is an enlarged section view of the leaflet-label of Figure 9 in a folded configuration;
Figure 11 is a top plan view of a fifth alternative embodiment of leaflet-label blank in accordance with the present invention;
Figure 12 is a top plan view of a sixth alternative embodiment of leaflet-label blank in accordance with the present invention;
Figure 13 is an enlarged sectional view of the base portion of the leaflet-label blank of Figure 12;
Figure 14 is a top plan view of a seventh alternative embodiment of leaflet-label blank in accordance with the present invention;
Figure 15 is an enlarged sectional view of an alternative base portion of a leaflet-label blank in accordance with the present invention;
Figure 16 is a top plan view of a plurality of base portions carried on a backing of release material manufactured in accordance with the present invention;
Figure 17 is a sectional view of one of the base portions carried on a backing of release material illustrated in Figure 16;
Figure 18 is a top plan view of a booklet blank in accordance with the present invention;
Figure 19 is a bottom plan view of the booklet blank of Figure 18;
Figure 20 is an enlarged section view of the booklet blank of Figure 18;
Figure 21 illustrates an intermediate step in the construction of a booklet from the booklet blank of Figure 18;
Figure 22 is a view of a booklet created by the booklet blank of Figure 18;
Figure 23 is an enlarged section view of an alternative embodiment of booklet blank in accordance the present invention.
Figure 24 is a top plan view of a third embodiment of booklet blank in accordance with the present invention; and
Figure 25 is a top plan view of a fourth embodiment of booklet blank in accordance with the present invention.

The leaflet-label blank 20 illustrated in Figure 3 comprises a printable main sheet 21 and a base portion 22 releasably adhered to the main sheet 21.
The main sheet 21 is preferably made of paper or thin card, although other materials having printable surfaces (i.e. surfaces upon which an image can be printed using, for example, conventional desktop printers) may alternatively be employed including, but not limited to, glossy paper or plastic film such as that used for transparencies. The main sheet 21, as illustrated, is rectangular in shape but alternative shapes for the main sheet are envisaged. Also, the main sheet 21 has a size preferably no greater than that which can be accommodated by most conventional desktop printers. More preferably, the size of the main sheet 21 is similar to that of standard document sizes such as European A4 (297 x 210 mm) or US Letter (279.4 x 215.9 mm).
The thickness of the main sheet 21 and the base portion 22 is limited by the physical capabilities of the printer used to print the leaflet-label blank 20. In particular, conventional desktop printers are known to jam when attempting to print upon documents having weights greater than about 150 g/m² or 0.2 mm thickness. Additionally, some printers are known to jam upon a sudden and significant change in the thickness of the document. For these reasons the total thickness of the main sheet 21 and base portion 22 is preferably less than 0.25 mm. Naturally, where the printer is capable of accommodating thicker documents, a thicker main sheet 21 and/or base portion 22 may be employed.
The main sheet 21 has a first fold line 23 describing a boundary between a front panel 24 and a rear panel 25. Preferably, the main sheet 21 has at least one further fold line 26, transverse to the first fold line 23, defining one or more further panels 27. In the particular embodiment illustrated in Figure 3, four fold lines 23,26 serve to define a front panel 24, a rear panel 25 and six further panels 27. The position of the fold lines 23,26 may be indicated by means of pre-printed lines on the main sheet 21. Alternatively, or additionally, one or more of the fold lines 23,26 (or parts of the fold lines) may be formed of lines of perforations or scores in the main sheet 21 so as to aid the eventual folding of the main sheet 21 or so as to enable one or more of the panels 27 of the main sheet 21 to be removed.
With the leaflet-label blank 20 illustrated in Figures 3 and 4, the front 24 and rear panels 25 are immediately adjacent one another and disposed at one end of the main sheet 21. However, depending upon the manner in which the main sheet 21 is to be folded, almost any configuration is possible. For example, Figure 8 illustrates an alternative embodiment in which the front panel 24, rear panel 25 and further panels 27 are configured differently with the front 24 and rear 25 panels remote from one another.
The front panel 24 has a tab 28 extending beyond an edge of the front panel. The tab 28 preferably forms part of and is continuous with the main sheet 21. However, the tab 28 may alternatively be formed of a separate element adhered to the front panel 24. Where the tab 28 is formed of a separate element, the tab 28 may extend beyond a free edge of the front panel 24 or an edge of the front panel 24 defined by a fold line. The tab 28 may alternatively comprise a portion of a further panel 27 adjoining the front panel 24, an example of which is described below and illustrated in Figures 9 to 11.
The tab 28 preferably has a length corresponding to that of the edge of the front panel 24 beyond which the tab 28 extends. Additionally, the tab is preferably rectangular in shape, as illustrated in Figure 3, having a length normal to the free edge of the front panel of at least 3 mm. Nevertheless, alternative shapes and sizes of tab may equally be employed such as a semi-circle.
Referring now to Figure 5, the base portion 22 comprises a support sheet 29; a first layer of adhesive 30 between the support sheet and the rear surface of the main sheet 21; a second layer of adhesive 31 on the opposite surface of the support sheet 29 to the first layer of adhesive 30; a backing cover 32 of release material over the second layer of adhesive 31; and a separate protective cover strip 33 of release material. It should be noted that Figure 5 is not drawn to scale but is intended only to clearly illustrate the individual elements of the base portion 22.
The support sheet 29 is preferably made of plastic. However, suitable alternatives include but are not limited to paper, card and metal film. In the illustrated embodiment a first surface of the support sheet 29 is substantially covered by the first layer of adhesive 30 and the opposing second surface of the support sheet 29 is substantially covered by the second layer of adhesive 31. Alternatively, the layers of adhesive 30 and 31 may be formed by a plurality of lines of adhesive or a pattern of separate adhesive regions or spots.
The backing cover 32 completely covers and is releasably adhered to the second layer of adhesive 31. The backing cover 32 therefore preferably comprises a thin sheet of paper having a coating of a release material such as silicone on the surface of the backing strip 32 in contact with the adhesive 31.
The cover strip 33 covers and is releaseably adhered to an end region of the first layer of adhesive 30 which end region of the layer of adhesive 30 preferably corresponds in size and shape to the tab 28 of the main sheet 21, although alternative smaller sizes and shapes may also be used; in particular the end region may be smaller than the tab 28. The cover strip 33 preferably extends beyond at least one edge of the support sheet 29. The portion of the cover strip 33 that extends beyond the support sheet 29, and thus beyond the first layer of adhesive 30, may be used to facilitate the subsequent removal of the cover strip 33 from the base portion 22. As with the backing cover 32, the cover strip 33 is preferably a thin sheet of paper having a coating of a release material disposed over the surface of the cover strip in contact with the adhesive.
The base portion 22 may therefore be regarded as having two sections, a first section 35 corresponding to the region of the first layer of adhesive 30 covered by the main sheet 21 and a second section 34 corresponding to a region of the first layer of adhesive covered by the cover strip 33. The size and orientation of the base portion 22 is such that the first section 35 of the base portion 22 is directly adhered only to the rear panel 25 of the main sheet 21 with the second section 34 extending beyond an edge of the rear panel 25. As illustrated in Figures 3 through 5 the second section 34 extends beyond a free edge 36 of the rear panel 25. However, as illustrated in Figure 6, alternatively the second section 34 may extend beyond an edge of the rear panel 25 defined by a fold line 23.
The first section 35 of the base portion 22 is preferably substantially the same size as the rear panel 25 of the main sheet 21. However, the first section 35 may alternatively be smaller or indeed larger than the rear panel 25. Where the first section 35 is larger than the rear panel 25, the first layer of adhesive 30 covers only an area of the first surface of the support sheet 29 having a size no greater than the size of the rear panel 25. This in turn means that not all of the first surface of the support sheet 29 is coated with adhesive.
As mentioned above, the leaflet-label blank 20 is provided as a substantially flat sheet suitable for use with most convention desktop printers. Since the base portion 22 preferably only extends over the rear panel 25, the majority of the total surface of the main sheet 21 remains available for printing. In particular, both the front and rear sides of the main sheet 21 may be printed upon with the exception of that area covered by the base portion 22. The main sheet 21 may be completely blank or may include pre-printed information, but should nevertheless have at least one printable region.
In use, the leaflet-label blank 20 is intended to be fed into a printer, typically a desktop printer, connected to a computer. The layout of the information to be printed on the leaflet-label blank 20 can therefore be designed using conventional word processing/desktop publishing software packages. At the same time as the information is printed on the leaflet-label blank 20, one or more lines corresponding to the positions where the main sheet 21 is to be folded, i.e. the position of the fold lines 23, 26 may additionally be printed. After the leaflet-label blank 20 has been printed, the main sheet 21 is then folded manually along its fold lines 23, 26 such that the further panels 27 are positioned between the front panel 24 and the rear panel 25. The cover strip 33 is then removed from the second section 34 of the base portion 22 to expose a strip of adhesive. The tab 28 is then adhered to the exposed strip of adhesive so that the printed leaflet-label is held closed. Thereafter, the backing cover 32 may be removed thereby exposing the second layer of adhesive 31 and the printed leaflet-label can then be adhered to the surface of a product or container.
The base portion 22 may have one of more cuts 22a through at least the backing cover 32 to facilitate removal of the backing cover 32 from the base portion 22. In particular, by having a half-depth cut along the centre of the base portion 22 parallel to the cover strip 33, the backing cover 32 may be more easily accessed and removed by bending the finally constructed label about the cut in the backing cover 32.
Appropriate selection of the material used for the tab 28 and the choice of first layer of adhesive 30 determines the type of closure that is required. For example, a permanent closure is achieved by having a tab 28 made of paper and a first layer of Fasson^® S660 adhesive 30 or a similar adhesive that bonds permanently to paper. Where the tab 28 is adhered permanently, the tab 28 may be provided with a line of perforations or a similar tear line to assist in opening the printed leaflet-label. A resealable closure may be achieved by coating part or all surface of the tab 28 which adheres to the exposed strip of adhesive with a release material such as silicone varnish.
The tab 28 is preferably larger than the second section 34 of the base portion 22 (i.e. larger than the exposed strip of adhesive) so that the tab 28 includes an unadhered portion which can be grasped to open the printed leaflet-label. An unadhered portion may also be formed by coating a portion 28' of the exposed surface of the tab 28 with a suitable release material. Alternatively, or indeed additionally, the first surface of the support sheet 29 may not be completely covered by the first layer of adhesive 30. Instead, a region of the support sheet 29 forming part of the second section 34 (e.g. a corner) may be free from adhesive. Accordingly, the tab 28 is not completely adhered to the exposed strip of adhesive but has an unadhered portion which again may be grasped to open the printed leaflet-label.
Figure 7 shows an alternative embodiment of a leaflet-label blank 20 in which the front panel 24 of the main sheet 21 initially includes no tab 28. Instead, one or more line of perforations 40 are provided along an edge 41 of the main sheet 21 which includes the front panel 24. The lines of perforations 40 are continuous and extend across the further panels 27 so as to form a tear-away strip 42 in the main sheet 21. The lines of perforations 40 do not extend across the front panel 24. This particular embodiment has the advantage that the main sheet 21 has no protruding elements which might interfere with the paper feed of a printer. After printing the leaflet-label blank 20, the tab 28 is defined by tearing the main sheet 21 along the perforations and removing the tear-away strip 42 as waste. As illustrated, the line of perforations 40 may extend at an angle to the edge 41 to thereby define a cut-away portion 28a at a corner of the tab 28 which is intended to assist in the opening of the leaflet-label once it has been printed, folded and sealed.
Additionally, the main sheet 21 may comprise a line of perforations 43 provided along an edge 44 of the main sheet 21 which includes the rear panel 25. The line of perforations extends across the rear panel 25 and all further panels 27 to create a tear-away strip 45. The second section 34 of the base portion 22 extends beyond the edge of the rear panel 25 defined by the line of perforations 43 but does not extend beyond the free edge 44 of the tear-away strip 45. This arrangement has the advantage that the base portion 22 does not extend or protrude beyond the edges of the main sheet 21 during printing, which might otherwise create problems. After printing the leaflet-label blank 20, the tear-away strip 45 is removed by tearing the main sheet 21 along the line of perforations 43 so as to define a free edge of the rear panel 25 and thereby reveal the second section 34 which extends beyond the free edge.
Figure 8 illustrates a further embodiment in which the tab 28 of the front panel 24 and the second section 34 of the base portion 22 are disposed along the same edge 46 of the main sheet 21. A single line of perforations 47 may then be used to define the tab 28 and the free edge of the rear panel 25 beyond which the second section 34 extends.
The leaflet-label blank 20 preferably has no elements protruding beyond the edges of the main sheet 21, i.e. the tab 28 and the base portion 22 (in particular the second section 34) remain within the footprint of the main sheet 21. This may be achieved by having a tab 28 and second section 34 which extend beyond fold lines rather than free edges of the main sheet 21. Alternatively, this may be achieved by means of one or more tear-away strips in the main sheet 21 which when removed define the tab and/or reveal the second section 34. With these embodiments the perimeter of the leaflet-label blank 20 is thus defined by the main sheet 21. Accordingly, where the main sheet 21 is of a standard document size, e.g. A4 or US letter, the leaflet-label blank 20 may be conveniently printed using conventional printers and document handlers/feeders.
Figure 9 illustrates an embodiment of a leaflet-label blank 20 in which the tab 28 extends beyond an edge of the front panel 24 defined by a fold line 26 and the tab 28 comprises a portion of the further panel 27 adjacent the fold line 26. The size of the front panel 24 is larger than that of the rear panel 25 such that when the main sheet 21 of the leaflet-label blank 20 is folded, as illustrated in Figure 10, the tab 28 extends beyond the rear panel 25 and overlies the base portion 22. This particular embodiment has the advantage that the tab 28 at no time forms a protruding element.
Figure 11 illustrates a further development of the leaflet-label blank 20 illustrated in Figure 9. The section of the base portion 22 which extends beyond the free edge 36 of the rear panel 25 has a width (parallel to the free edge 36) substantially the same as that of the rear panel 25. Additionally, each further panel 27 sharing the same edge of the main sheet 21 as that beyond which the base portion 22 extends, has an adjoining panel 48 corresponding in size to the extending section of the base portion 22. Accordingly, the leaflet-label blank 20, like those illustrated in Figures 7 and 8, has a substantially rectangular perimeter with no protruding elements. After printing, the adjoining panel(s) 48 may be folded about the fold line 49 and held between the front 24 and rear 25 panels along with the further panels 27. Alternatively, the fold line 49 may be perforated such that the adjoining panel(s) 48 may be easily removed (e.g. by tearing) after the main sheet 21 has been printed.
With the leaflet-label blanks 20 thus far described and illustrated in Figures 3 through 11, the second section 34 of the base portion 22, to which the tab 28 adheres, extends beyond an edge of the rear panel 25 of the main sheet 21. Figures 12 through 14, however, illustrate an alternative design of leaflet-label blank 20 in which the second section 34 of the base portion 22 does not extend beyond an edge of the rear panel 25 but instead remains covered by the rear panel 25. The folded leaflet-label is then held closed by tucking the tab 28 in between the rear panel 25 and the second section 34.
As illustrated in Figure 12, the base portion 22 of the leaflet-label blank 20 is adhered to the rear surface of the main sheet 21 such that the base portion 22 preferably remains within the footprint of the main sheet 21. The first section 35 of the base portion 22 is directly adhered to the rear panel 25 only of the main sheet 21 and the second section 34 of the base portion 22 lies adjacent, but does not extend beyond, an edge of the rear panel 25. The edge of the rear panel 25 may be a free edge 36, as illustrated in Figure 13, or an edge defined by a fold line 23.
The base portion 22 is preferably substantially the same size as the rear panel 25 of the main sheet 21. However, where the size of the base portion 22 is larger than that of the rear panel 25, the first layer of adhesive 30 preferably covers an area of the support sheet 29 having a size no greater than the size of the rear panel 25. This then ensures that the base portion 22 is directly adhered to the rear panel 25 only of the main sheet 21.
The tab 28 is configured such that it can be folded relative to the front panel 24. Where the tab 28 forms part of and is continuous with the main sheet 21, the main sheet 21 comprises a tab fold line 37 between the tab 28 and the front panel 24.
To construct the leaflet-label, the main sheet 21 is folded about its fold lines 23, 26 such that the further panels 27 are positioned between the front panel 24 and the rear panel 25. The tab 28 is then folded (e.g. about the tab fold line 37) over the rear panel 25 and tucked in between the rear panel 25 and the base portion 22. The cover strip 33 is then removed from the second section 34 of the base portion 22 to expose a strip of adhesive. Finally, the tab 28 is adhered to the base portion 22 by the exposed strip of adhesive so as to hold the leaflet-label closed. Thereafter, the backing cover 32 may be removed so as to expose the second layer of adhesive 31 for adhering the leaflet-label to the surface of a product or container.
As has been noted above, the material used for the tab 28 and the choice of first layer of adhesive 30 will determine the type of closure that is obtained. Where the tab 28 is permanently adhered to the first layer of adhesive 30, the tab 28 may be provided with a line of perforations or a similar tear line (e.g. along the tab fold line 37) to assist in opening the leaflet-label. A resealable closure can be achieved by coating that surface of the tab 28 which adheres to the exposed strip of adhesive with a release material such as silicone varnish. Where the tab 28 is releasably adhered to the base portion 22, a strip of first layer of adhesive 30 will be exposed by the tab 28 when the leaflet-label is opened. In order to prevent the exposed strip of adhesive from permanently adhering to the rear panel 25, which would consequently prevent the leaflet-label from being resealed, the surface region of the rear panel 25 which adheres to the exposed strip of adhesive is preferably coated with a release material such as silicon varnish.
Where the surface of the rear panel 25 has a region of release material, the cover strip 33 of the base portion 22 may be omitted from the leaflet-label blank 20. Accordingly, the first section 35 of the base portion 22 is permanently adhered to the rear panel 25 by the first layer of adhesive 30 and the second section 34 of the base portion 22 is releasably adhered to the rear panel 25 by the first layer of adhesive 30. Where the cover strip 33 is omitted, the rear panel 25 preferably extends beyond the second section 34 of the base portion 22 such that the rear panel 25 includes an unadhered portion which can be grasped to separate the rear panel 25 from the second section 34. Alternatively, the upper surface of the support sheet 29 may comprise an unadhesive portion (e.g. free from adhesive) at an edge or corner of the second section 34 so that the rear panel 25 is not entirely adhered to the second section 34.
Figure 14 illustrates an embodiment of a leaflet-label blank 20 similar to that of Figure 12. However, the tab 28, which forms part of the main sheet 21, extends along an entire edge 41 of the main sheet 21, i.e. the tab 28 is not only attached to the front panel 24 but also to the other panels 27 along that edge 41 of the main sheet 21. When the main sheet 21 is folded about the further 26 fold lines, the tab 28 is similarly folded about these fold lines. Since the tab 28 is folded (e.g. about the tab fold line 37) over the rear panel 25 and tucked in between the rear panel 25 and the base portion 22, the portion of the tab 28 which directly adheres to the base portion 22 is that which is attached to the front panel 24. Accordingly, all panels of the main sheet 21 are held closed. This particular embodiment has the advantage that the leaflet-label blank 20 has no protruding elements which might otherwise interfere with the paper feed of a printer. Moreover, there are no tear-away strips to be removed from the leaflet-label blank 20 after printing.
Rather than tucking the tab 28 between the rear panel 25 and the base portion 22, a series of holes may be formed in the rear panel 25 such that the second section 34 of the base portion 22 lies directly beneath and is exposed by the series of holes. By removing the cover strip 33 of the base portion 22, regions of the first layer of adhesive 31 are exposed by the holes in the rear panel 25. The folded main sheet 21 may then be held closed by adhering the tab 28 to the regions of first layer of adhesive 30 exposed by the holes. Since the leaflet-label may be held closed without the tab 28 extending beyond or wrapping around an edge of the rear panel 25, this embodiment is particularly well-suited to leaflet-label blanks 20 in which the tab 28 forms part of an adjoining panel 27.
When the main sheet 21 is folded, the holes in the rear panel 25 may be covered by one or more further panels 27 thus preventing the tab 28 from directly adhering to the first layer of adhesive 30. Accordingly, corresponding holes may be formed in one or more of the further panels 27 such that, when the main sheet 21 is folded, the holes in the rear 25 and further 27 panels align enabling the tab 28 to be directly adhere to the regions of first layer of adhesive 30 exposed by the holes.
Although reference has been made up to now to the provision of a cover strip 33 comprising release material such as silicone coated paper, preferably the cover strip 33 comprises a strip of double-sided adhesive tape with its release liner as illustrated in Figure 15. Thus, the cover strip 33 includes a strip of tape 29a preferably coated to make it resealable. A first layer of adhesive 30a is provided on a first surface of the tape 29a facing towards the layer of adhesive 30 of the base portion 22. A second layer of adhesive 31a is provided on a second side of the tape 29a facing away from the base portion 22 and finally a release liner 32a in the form of silicone coated paper is provided over the outwardly facing surface of the second layer of adhesive 31 a. This arrangement has the advantage that different types of adhesive can be selected for adhering the base portion 22 to the main sheet and for holding the leaflet-label closed once printed and folded. Thus, the layer of adhesive 30 of the base portion 22 can be chosen to be a permanent adhesive whilst the second layer of adhesive 31a of the cover strip 33 is chosen to be resealable. This additionally avoids the need for printing varnish on the contacting surfaces of the tab 28 for the version of the base portion illustrated in Figure 6 when the first layer of adhesive 30 of the base portion is a permanent adhesive.
In a further alternative, the cover strip 33 may be omitted from the base portion 22 such that the second section 34 of the base portion 22 is permanently adhered to the rear panel 25 and regions of first layer of adhesive 30 are continuously exposed by the holes in the rear panel 25. However, in omitting the cover strip 33 there is a danger that the regions of first layer of adhesive 30 exposed by the holes may create problems during printing, e.g. by sticking to the printing drum or rollers. Accordingly, the first layer of adhesive, or at least the regions of adhesive exposed by the holes, may comprise a water-activated adhesive. Alternatively, the adhesive may be a self-sealing adhesive and the tab 28 may be provided with corresponding spots of self-sealing adhesive.
In all embodiments of leaflet-label blank 20 thus far described, the tab 28 adheres to the first layer of adhesive 30 of the base portion 22 so as to close the folded leaflet-label. However, in an alternative embodiment of leaflet-label blank 20 (not illustrated in the accompanying Figures) the tab 28 is adhered to the second layer of adhesive 31 so as to close the folded leaflet-label. As with the embodiments illustrated in Figures 12 through 14, the base portion 22 is adhered to the rear panel 25 of the main sheet 21 such that the second section 34 lies adjacent, but does not extend beyond, an edge (e.g. free edge of fold line) of the rear panel 25. The base portion 22, however, does not comprise a cover strip 33. Consequently, both the first section 35 and the second section 34 of the base portion 22 are directly adhered to the rear panel 25 by the first layer of adhesive 30. The tab 28 is again configured (e.g. by means of a fold line) so as to be foldable about the edge of the front panel 24 beyond which the tab 28 extends.
In order to construct the leaflet-label 20, the main sheet 21 is folded about its fold lines 23, 26 such that the further panels 27 are positioned between the front panel 24 and the rear panel 25. The backing cover 32 is then removed so as to expose the second layer of adhesive 31. The tab 28 is then folded over both the rear panel 25 and the base portion 22 and adhered to the second layer of adhesive 31. Finally, the leaflet-label is adhered to the surface of a product or container by the region of second layer of adhesive 31 not covered by the tab 28.
Rather than a single backing cover 32, the base portion 22 may comprise a first backing cover which covers the first section 35 of the second layer of adhesive 31 and a second backing cover which covers the second section 34 of the second layer of adhesive 31. Accordingly, when constructing the leaflet-label, the second backing cover is initially removed so as to expose a strip of second layer of adhesive 31. The tab 28 is then adhered to the exposed strip of adhesive so as to close the leaflet-label. When the leaflet-label is ready to be adhered to a product or container, the first backing cover is removed so as to expose the remainder of the second layer of adhesive 31.
It will be appreciated that in this particular embodiment of leaflet-label blank 20, the support sheet 29 and the first layer of adhesive 30 are redundant and may therefore be omitted from the base portion 22. The base portion 22 is then adhered to the rear panel 25 of the main sheet 21 by the second layer of adhesive 31.
Whilst reference has been made to the specific embodiments illustrated in Figures 3 through 15, it should be borne in mind that these embodiments are provided by way of example only and that the leaflet-label blank 20 may be of any design in which the main sheet 21 can be folded and held closed by the base portion 22. For example, the tab 28 and base portion 22 have been described above as extending respectively beyond a single edge only of the front panel 24 and rear panel 25. However, the tab 28 and base portion 22 may equally extend beyond more than one edge. For example, the tab 28 and second section 34 of the base portion 22 may be L-shaped, extending beyond two free edges of the front panel 24 and rear panel 25 respectively. The front panel 24 may alternatively have more than one tab 28 extending beyond different edges of the front panel 24. Similarly, the base portion 22 may have more than one second section 34, or the leaflet-label blank 20 may have more than one base portion 22 adhered to the rear panel 25. Moreover, in all of the embodiments described above, the tab 28 is described as extending beyond an edge of the front panel 25. Whilst this generally ensures that all panels 25,27 are held tightly closed, the tab 28 need not extend beyond an edge of the front panel 24 but may instead extend beyond an edge of a further panel 27. Although all panels are not therefore necessarily held tightly closed, the leaflet-label is nevertheless held closed such that the main sheet 21 cannot be fully opened.
The manufacture of the leaflet-label blank 20 will now be described with reference to Figures 16 and 17. The leaflet-label blanks 20 are manufactured using conventional in-line processes employed in label manufacturing according to the following three-stage process: (1) a plurality of main sheets 21 are prepared, (2) a plurality of self-adhesive base portions 22 supported on a backing of release material are formed, and (3) the self-adhesive base portions 22 are removed from the backing of release material and adhered to a respective main sheet 21 to create a plurality of leaflet-label blanks 20.
The main sheets 21 may be formed from a reel of blank paper or alternatively from a stack of individual sheets of paper or thin card. Each main sheet 21 is first printed, if necessary, with pre-printed information as required. For example, each main sheet 21 may be printed with a plurality of lines to indicate the position of the fold lines 23,26,37 in the sheet 21. In the embodiments illustrated in Figures 7 and 8, the tear-away strips 42,45 are preferably shaded and include text reminding the user to remove the tear-away strips 42,45 after printing. Each main sheet 21 may also be printed with other pre-printed information such as logos, questionnaires etc. so as to personalise the leaflet-label blank 20 or identify a company. Any release material (e.g. silicone) to be applied to the tab portion 28 and/or the rear panel 25 of each main sheet 21 is then applied, preferably by printing.
After printing, any perforations or scores that are to be formed in the main sheet 21 are then added using, for example, rotary drum or flat bed cutters. For example, in the embodiments illustrated in Figures 7 and 8, the lines of perforations 40,43,47 are formed at this point. Additionally, one or more of the fold lines 23,26,37 (or parts of the fold lines) may be defined by perforations or scores formed in the main sheet 21.
Each main sheet 21 is then cut or trimmed (where necessary) to the appropriate shape and size. When the main sheets 21 are constructed from a reel of paper, the printed and perforated reel of paper may be cut to create a plurality of main sheets 21. However, the reel of paper is preferably cut only after the self-adhesive base portions 22 have been applied to the reel of paper. Cutting of the reel at this stage then serves to create a plurality of leaflet-label blanks 20.
The plurality of self-adhesive base portions 22 disposed on a backing of release material are prepared from a reel of conventional three-layer label stock; the label stock comprising a central support sheet (e.g. paper) having adhesive on both sides and covered by a top backing cover and a bottom backing cover (e.g. paper) having a release material (e.g. silicone) on those surfaces adjacent the adhesive.
The top backing cover, which ultimately forms the backing cover 32 of the finished leaflet-label blank 20, is first printed with a series of images, if desired. Each image corresponds to a single leaflet-label and may comprise, for example, a company logo and/or instructions on how to construct the leaflet-label.
Next the bottom backing cover is temporarily removed from the web of base portions and a continuous ribbon of double-sided adhesive tape is applied at or adjacent a longitudinal edge of the web. The double-sided tape is adhered by one of its adhesive surfaces to the web of base portions but with the opposite adhesive surface of the tape, still protected by its release liner, uppermost facing away from the web of base portions. The bottom backing cover is then re-applied to the web of base portions and over the ribbon of double-sided adhesive tape so that the release liner of the double-sided adhesive tape is in contact with the silicone coated surface of the bottom backing cover.
A series of rectangular cuts are then made preferably by die-cutting in the top backing cover and through the support sheet of the three-layer label stock as well as the ribbon of double-sided adhesive tape. However, the cuts do not extend through the bottom backing cover. Each rectangular cut is aligned so as to encompass an image printed onto the top backing cover. As the base portions 22 are eventually adhered to the rear panel 25 of the main sheet 21, the size and shape of the cuts made in the label stock will naturally depend upon the design of the leaflet-label and in particular the size and shape of the rear panel 25 of the main sheet 21.
The waste around the outside of these cuts is then removes to thus produce a plurality of self-adhesive base portions 22 having a generally rectangular shape and an image printed on the top cover. Each base portion 22 is temporarily adhered to a web of the bottom backing cover but with an edge region of each base portion separated from contact with the bottom backing cover by a strip of the double-sided tape.
In the same or preferably a subsequent die-cutting operation, one or more lines are cut into the top backing cover of each base portion. The cut lines extend on through the top backing cover and are provided to make manual removal of the top backing cover easier. In particular, by bending the folded leaflet-label about the line-cuts, the backing cover 32 may be more easily accessed and removed.
In the alternative where only a release liner is required for the cover strip, after the top backing cover has been printed a plurality of rectangular cuts are then made in the top backing cover and support sheet of the three-layer label stock by die-cutting. Again no cutting of the bottom cover sheet occurs. Each rectangular cut is aligned so as to encompass an image printed onto the top backing cover. The result is a plurality of self-adhesive base portions 22 carried on the bottom backing cover, each base portion 22 having a generally rectangular shape and an image printed on the top cover.
In the same or a subsequent die-cutting operation, one or more lines are preferably cut in the top backing cover of each base portion 22. More preferably, the top backing cover is cut with a single line along the centre of each base portion 22. The same line-cuts may also be made in the support sheet, but again no cutting of the bottom backing cover occurs.
The waste material surrounding the base portions 22 and consisting of the top backing cover and the support sheet is removed from the label stock to leave, as illustrated in Figure 16, a plurality of self-adhesive base portions 22 spaced apart on the bottom backing cover 50.
The bottom backing cover 50 is then die-cut through with a plurality of rectangular cuts 51 to create a plurality of individual cover strips 33. Each cover strip 33 is cut so as to overlie an end region of a respective base portion 22. Preferably, each cover strip 33 completely covers that region of the base portion 22 that is not eventually adhered to the rear panel 25 of the main sheet 21, i.e. each cover strip 33 covers that part of the base portion 22 which is intended to extend beyond the edge of the rear panel 25 of the main sheet 21. In this way, no areas of adhesive are exposed when the base portion 22 is eventually adhered to the rear panel 25 of the main sheet 21. Owing to manufacturing tolerances, each cover strip 33 preferably covers a slightly larger area of the base portion 22 than is required such that when the base portion 22 is adhered to the to rear panel 25, the rear panel 25 partially overlies the cover strip 33. More preferably, each cover strip 33 extends beyond at least one edge of the base portion 22. The portion of the cover strip 33 that extends beyond the base portion 22 provides a flap which the end user can more easily grasp to remove the cover strip 33 from the base portion 22.
Whilst reference has been made to cover strips 33 having a rectangular shape, it will be appreciated that the cuts made in the bottom backing cover 50 may be of alternative shapes and sizes according to the design of the leaflet-label.
It will, of course, be appreciated that in the embodiment of leaflet-label blank 20 described above in which the cover strip 33 is omitted, the step of die-cutting the bottom backing cover 50 with a plurality of rectangular cuts 51 is excluded.
As illustrated in Figure 17, the result is a plurality of self-adhesive base portions 22 supported on a web of release material 50. Each self-adhesive base portion 22 is then removed from the web of release material 50 by passing the web of release material over a beak or similar surface having a tight curvature. In removing the base portions 22, the respective cover strips 33 are removed from the web of release material 50 as well. Each base portion 22 is then aligned with and adhered to the rear panel 25 of a main sheet 21 by the layer of adhesive 30 that is exposed when the base portion 22 is removed from the web of release material 50. The alignment of the base portion 22 with the rear panel 25 will naturally depend upon the particular design of leaflet-label blank 20. For example, in the embodiments illustrated in Figures 3-6, the base portion 22 is adhered to the rear panel 25 such that the region of the base portion 22 covered by the cover strip 33 extends beyond an edge (preferably a free edge) of the rear panel 25. In the embodiments illustrated in Figure 12-15, however, the base portion 22 is adhered to the rear panel 25 such that the region of the base portion 22 covered by the cover strip 33 is adjacent, but does not extend beyond, an edge of the rear panel 25. The process of removing each base portion 22 from the web of release material 50 and adhering it to the rear panel 25 of the main sheet 21 may be performed using a conventional label applicator.
The labels of the present invention are intended to be used with conventional desktop printers and document handlers. Accordingly, small numbers of leaflet-labels may be generated from the blanks by the end user quickly, conveniently and cheaply. The availability of both surfaces of the main sheet for printing has the particular benefit that all visible surfaces of the eventual leaflet-label may be printed with information. Moreover, resealable labels are achievable with a relatively small degree of waste.
The booklet blank 100 illustrated in Figures 18-20 comprises a cover sheet 101, an inner sheet 102, a strip of adhesive tape 103 holding the cover 101 and inner 102 sheets together, and a line of adhesive 104 disposed on a surface of the cover sheet 101 and covered by a strip of release material 105.
The cover sheet 101 and inner sheet 102 are preferably made of paper or thin card, though other materials having printable surfaces may alternatively be employed, e.g. glossy paper. Additionally, the surfaces of the cover sheet 101 and inner sheet 102 are preferably substantially blank so as to maximise the amount of space available to the user for printing. Nevertheless, either or both sheets 101,102 may carry pre-printed information, such as a company logo, an advertisement or product information. Moreover, it is not necessary that both sheets 101,102 have printable surfaces or that both sheets 101,102 are made of the same material. For example, the cover sheet 101 may consist of pre-printed card, laminated paper or plastic, which is not intended to be printed by the end user. However, at least one of the cover sheet 101 and inner sheet 102 has a printable region.
The cover sheet 101 and inner sheet 102 are preferably of the same size, though this is not essential. Indeed, as the inner sheet 102 forms the two inner leaves of the eventual booklet 110 (see Figure 22), it may be preferable to have an inner sheet 102 that is slightly smaller in length than that of the cover sheet 101.
The size of the booklet blank 100, when the cover sheet 101 and inner sheet 102 are held together, is preferably no greater than that which can be accommodated by most conventional desktop printers. More preferably, the booklet blank 100 is of a size similar to that of standard document sizes such as European A5 (210 x 148 mm), A4 (297 x 210 mm) and US Letter (279.4 x 215.9 mm).
The cover sheet 101 and inner sheet 102 are held together by a strip of adhesive tape 103 adhered to an edge region of the cover sheet 101 and an edge region of the inner sheet 102. The adhesive tape 103 serves to temporary hold the two sheets 101,102 together during printing of the booklet blank 100 and is removed thereafter. In order to minimise the risk of a paper jam occurring during printing of the booklet blank 100, the strip of adhesive tape 103 preferably extends along substantially the full length of the edges 108,109 of the two sheets 101,102.
The adhesive tape 103 is releasably adhered to both the cover 101 and inner 102 sheets so that the adhesive tape 103 may be later removed without damage to either sheet 101,102. For a booklet blank 100 of approximately A4 in size, the width of the adhesive tape 103 is preferably about 1 cm. This ensures that the cover sheet 101 and inner sheet 102 are held together relatively securely whilst leaving a substantial fraction of each sheet 101,102 free for printing. It will of course be appreciated that the width of the adhesive tape 103 may be tailored to suit. In particular, a larger or smaller booklet blank 100 may demand a larger or smaller width of adhesive tape 103.
As illustrated in Figure 20, the adhesive tape 103 adheres to a first surface 115 of the cover sheet 101 whilst the line of adhesive 104 is disposed on the opposing second surface 116 of the cover sheet 101. The line of adhesive 104 extends substantially normal to that edge 108 of the cover sheet 101 adjacent the inner sheet 102. The line of adhesive 104 is responsible for securing the cover sheet 101 to the inner sheet 102 after the booklet blank 100 has been printed and folded. Accordingly, in order to provide a secure bond between the cover 101 and inner 102 sheets, the line of adhesive 104 preferably extends across more than 50% of the width of the cover sheet 101. For a booklet blank 100 of approximately A4 in size, the width of the line of adhesive 104 (i.e. parallel to the edge 108 of the cover sheet 101 adjacent the inner sheet 102) is preferably about 5 mm. Again, the width of the line of adhesive 104 may be tailored to suit.
The line of adhesive 104 is positioned approximately halfway along the length of the cover sheet 101. When the booklet 110 is finally constructed (Figure 22), the cover sheet 101 and inner sheet 102 are folded in half about the line X-X indicated in Figure 19. This fold line in the cover 101 and inner 102 sheets serves as the spine 111 of the eventual booklet 110 (Figure 22). Ideally, therefore, the line of adhesive 104 should be positioned as close as possible to this fold line such that sheets 101,102 of the booklet 110 are adhered along the spine 111. When the finished booklet 110 is opened and closed, the spine 111 of the booklet 110 is stressed. If the width of the line of adhesive 104 is limited to the width of the fold line in the cover sheet 101, the adhesive bond between the two sheets 101,102 may weaken with continued opening and closing of the booklet 110. This in turn may eventually result in the sheets 101,102 becoming detached. Accordingly, the line of adhesive 104, if bridging the fold line in the cover sheet 101, preferably extends either side of the fold line by at least a couple of millimetres. Alternatively, rather than positioning the line of adhesive 104 directly along the fold line in the cover sheet 101, the line of adhesive 104 may be positioned just off the fold line. The bond between the sheets 101,102 would not therefore be unduly stressed by opening and closing the booklet 110.
Whilst reference has thus far been to a line of adhesive, it will of course be appreciated that one or more spots of glue generally positioned along a line may achieve the same result.
The strip of release material 105 completely covers and is releasably adhered to the line of adhesive 104. Suitable release materials include wax or silicone coated paper, though the actual choice of release material 105 will depend upon the choice of adhesive for the line of adhesive 104. Indeed, if a water-activated adhesive is used for the line of adhesive 104, the strip of release material 105 may actually be omitted from the booklet blank 100.
The strip of release material 105 is preferably larger than the line of adhesive 104 such that a portion of the release material 105 is unadhered so as to provide a tab which the user can more easily grip to remove the release material 105 from the line of adhesive 104.
The line of adhesive 104 and strip of release material 105 may be formed from a strip of self-adhesive laminate adhered to the cover sheet 101, the laminate comprising a base layer (e.g. paper of plastic), a layer of adhesive and a release layer (e.g. silicone paper). The base layer of the laminate is adhered to the cover sheet 101 by a separate line or spots of adhesive. The adhesive layer and release layer of the laminate then serve respectively as the line of adhesive 104 and strip of release material 105. Owing to the presence of a base layer, which will exhibit some rigidity, the self-adhesive laminate is preferably adhered to the cover sheet 101 such that it does not overlie but is immediately adjacent the fold line in the cover sheet 101. In using a self-adhesive laminate, the manufacture of the booklet blank 100 is generally made easier. In particular, adhering a base layer of paper or plastic to the cover sheet 101 is generally easier than adhering a strip of release material directly to the cover sheet 101. Moreover, the strip of self-adhesive laminate may be easily adhered to the cover sheet 101 using conventional three-layer label stock. The three-layer label stock comprises a central sheet (e.g. paper or plastic) having adhesive on both sides and covered by a top release sheet and a bottom release sheet (e.g. silicone paper). The bottom release sheet is removed to expose a strip of adhesive and the laminate is adhered to the cover sheet 101 by the exposed strip of adhesive.
In the embodiment illustrated in Figures 18-20, the line of adhesive 104 is disposed on the cover sheet 101. However, the line of adhesive 104 may equally be disposed on the inner sheet 102, again along a line normal to the edge 109 of the inner sheet 102 adjacent the cover sheet 101 and approximately halfway along the length of the inner sheet 102. Moreover, the line of adhesive may extend across both the cover sheet 101 and the inner sheet 102. More than one line of adhesive may also be employed. For example, a pair of adhesive lines may be disposed on the cover sheet of 101, each line positioned on opposite sides of the fold line in the cover sheet 101.
Some printers are known to jam upon a sudden and significant change in the thickness of a document. Accordingly, the thickness of the adhesive tape 103 and the combined thickness of the line of adhesive 104 and the release material 105 is preferably no greater than about 0.2 mm, and more preferably no greater than about 0.05 mm.
In use, the booklet blank 100 is intended to be fed into a printer, typically a desktop printer, connected to a computer. The layout of the information to be printed on the booklet blank 100 can therefore be designed using conventional word processing/desktop publishing software packages. After the booklet blank 100 has been printed, the strip of release material 105 covering the line of adhesive 104 is removed. Alternatively, if the line of adhesive 104 consists of a water-activated adhesive and the booklet blank 100 is devoid of the strip of release material 105, the adhesive 104 is wetted. The cover sheet 101 and inner sheet 102 are then folded lengthwise about their join such that the two sheets 101,102 are adhered to one another by the line of adhesive 104. The adhesive tape 103 is the removed, as shown in Figure 21, and the cover sheet 101 and inner sheet 102 are folded in half about the strip of adhesive 104 to create a booklet 110, Figure 22. The booklet 110 has four leaves: two outer leaves formed by the cover sheet 101 and two inner leaves formed by the inner sheet 102.
In the embodiment described above, the cover sheet 101 and inner sheet 102 are held together by a strip of adhesive tape 103. In an alternative embodiment, the cover sheet 101 and inner sheet 102 are formed from a single sheet of material, e.g. a single sheet of paper. One or both of the sheets 101,102 may subsequently be pre-printed and/or laminated as required. The cover sheet 101 and inner sheet 102 are then defined by a fold line along the length of the single sheet. When constructing the booklet, the strip of release material 105 is removed to expose the line of adhesive 104 and the single-sheet booklet blank is folded about the lengthwise fold line so as to adhere the cover sheet 101 to the inner sheet 102. The user is then required to tear or cut along the fold line to separate the cover sheet 101 from the inner sheet 102. This may be performed, for example, using a conventional letter opener or similar implement. The single sheet may be perforated along the lengthwise fold line to assist the user in separating the two sheets 101,102. Alternatively, the single sheet may be scored with a half-depth cut along the lengthwise fold line. The half-depth cut is preferably formed in that surface of the single sheet having the strip of adhesive 104. Consequently, folding the single-sheet booklet blank about the half-depth cut may cause the single sheet to simply split in two. Whilst tearing of the fold line, even when perforated, may result in an untidy finish to the edges 108,109 of the sheets 101,102, a half-depth cut has the advantage of providing a tidy finish to both edges 108,109.
In the embodiments described above, the finished booklet 110 comprises only four leaves. However, as will now be described, a second booklet or portion of the second booklet may be inserted into a first booklet to create a booklet 110 having more than four leaves.
Once the first booklet 110 has been created, a second booklet blank 100 is printed as required. The inner sheet 102 of the booklet blank 100 is then discarded to leave only the cover sheet 101. The cover sheet 101 is then folded in half about its length (i.e. parallel to the line of adhesive). The direction of the fold (i.e. whether the line of adhesive is on the inner or outer surface of the folded cover sheet 101) will depend upon whether the cover sheet 101 is to be inserted into the booklet 110, or form the new cover of the booklet 110. Once folded, the strip of release material 105 is removed and the cover sheet 101 is adhered to the booklet 110, either by inserting the cover sheet 101 into the booklet (when the line of adhesive is on the outer surface of the folded cover sheet 101) or by inserting the booklet 110 into the cover sheet 101 (when the line of adhesive is on the inner surface of the cover sheet 101).
In the above example, the inner sheet 102 of the second booklet blank 100 was discarded. However, by having a booklet blank 100 in which the line of adhesive 104 extends across both the cover sheet 101 and the inner sheet 102, both sheets 101,102 can be used.
Figure 23 illustrates an alternative embodiment of the booklet blank 100 which includes an additional line of adhesive 113 and strip of release material 114 on the first surface 115 of the cover sheet 101. As with the line of adhesive 104 formed on the second surface 116 of the cover sheet 101, the additional line of adhesive 113 preferably extends along a line normal to the edge 108 of the cover sheet 101 and is positioned approximately halfway along the length of the cover sheet 101. The additional line of adhesive 113 may alternatively or additionally be disposed on the inner sheet 102. The booklet blank 100 is then printed and folded in the manner described above to create a booklet. However, the finished booklet now has a line of adhesive 113 covered by a strip of release material 114 on the outer surface of the booklet along or near the spine of the booklet. If the additional line of adhesive 113 is disposed on the inner sheet 102 of the booklet blank 100, rather than the cover sheet 101, the finished booklet will have a line of adhesive 113 covered by a strip of release material 114 on the inner surface of the booklet. Moreover, by having additional lines of adhesive 113 on both the cover sheet 101 and inner sheet 102 of the booklet blank 100, the finished booklet will have a line of adhesive 113 covered by a strip of release material 114 on both the outer and inner surfaces of the booklet. The strip of release material 114 is then removed and the booklet adhered to another booklet by inserting one of the booklets into the other.
In the embodiments described above, the booklet blank 100 is folded to create a booklet 110 having four leaves (i.e. two cover leaves and two inner leaves). Figures 24 and 25, however, illustrate embodiments of the booklet blank 100 which when folded create booklets having only three leaves.
The inner sheet 102 of the booklet blanks 100 of Figures 24 and 25 is preferably half the size of the cover sheet 101 and is attached to the cover sheet 101 such that, when the strip of release material 105 is removed and the cover and inner sheets 101,102 are folded about their join, the inner sheet 102 is adhered to the line of adhesive 104 along a free edge 112. In Figure 24, the cover and inner sheets 101,102 are attached along edges 108,109 that are normal to the line of adhesive 104, whilst in Figure 25, the sheets 101,102 are attached along edges 108,109 that are parallel to the line of adhesive 104. The arrows indicate the direction in which the inner sheet 102 is folded relative to the cover sheet 101 to adhere the free edge 112 of the inner sheet to the line of adhesive 104.
Although in the embodiments illustrated in Figure 24 and 25 the line of adhesive 104 is disposed along the cover sheet 101, the adhesive 104 may equally be disposed along the inner sheet 102 adjacent the free edge 112. As with previous the embodiments, the booklet blanks 100 of Figure 24 and 25 may include additional lines of adhesive 113 for adhering the finished booklet to other booklets to create a booklet having any number of leaves from three and upwards.
The booklet blanks of the present invention are intended to be used with conventional desktop printers and document handlers. Accordingly, an end user is able create his own design of booklet having any number of leaves quickly, conveniently and cheaply.
It will, of course, be appreciated that the present invention encompasses variations and changes in shape and the disposition of adhesive, for example, other than those described in detail above and the scope of the invention is limited only to the features of the accompanying claims.

Claims

An adhesive label blank (20) adapted to form a leaflet-label in use, said label blank comprising
a printable main sheet (21) having a front surface and a rear surface;
a backing cover (32); and
adhesive (31) provided between the main sheet (21) and the release sheet backing cover (32)
characterised in that the printable main sheet (21) further includes a fold line (23) about which the main sheet (21) is foldable with the front surface innermost, the fold line (23) dividing the main sheet (21) into at least a first panel (24) and a second panel (25);
the backing cover (32) is a removable release sheet releasably adhered to the adhesive (31) and the adhesive (31) is provided between the release sheet (32) and at least part of that portion of the rear surface of the main sheet (21) forming the second panel (25) whereby the rear surface of the main sheet (21) includes an exposed region not covered by the release sheet (32).
An adhesive label blank as claimed in claim 1, wherein at least a portion of both the front surface of the main sheet (21) and the exposed region of the rear surface of the main sheet (21) is printable.
An adhesive label blank as claimed in either of claims I or 2, wherein the adhesive (31) is provided between the second panel (25) of the main sheet (21) and the release sheet (32) and the region of the rear surface of the main sheet (21) covered by the release sheet (32) is substantially equal to the surface area of the second panel (25).
An adhesive label blank as claimed in any one of the preceding claims, further comprising a support sheet (29) and additional adhesive (30) which adheres a first surface of the support sheet (29) to the rear surface of the main sheet (21), the release sheet (32) being adhered to an opposed second surface of the support sheet (29) by means of the adhesive (31) wherein the support sheet (29) bearing the additional adhesive (30) extends beyond an edge of the second panel (25) of the main sheet (21) with a cover strip (33) overlying a second section (34) of the additional adhesive (30).
An adhesive label blank as claimed in claim 4, further comprising a tab (28) extending beyond an edge of the first panel (24), the tab (28) being arranged to cooperate with the support sheet (29) to hold the adhesive label blank (20) closed, when folded.
An adhesive label blank as claimed in claim 5, wherein the tab (28) is a continuation of the first panel (24).
An adhesive label blank as claimed in either one of claims 5 or 6, wherein the tab (28) is larger in size than that portion of the support sheet (29) that extends beyond the edge of the rear panel (25).
An adhesive label blank as claimed in any one of claims 4 to 7, wherein the support sheet (29) extends beyond a fold line (23) defining an edge of the second panel (25).
An adhesive label blank as claimed in any one of the preceding claims, wherein the main sheet (21) comprises one or more additional fold lines (26) defining one or more further panels (27) for folding between the first (24) and second (25) panels.
An adhesive label blank as claimed in any one of claims 4 to 9, wherein the cover strip (33) extends beyond an edge of the support sheet (29).
A method of manufacturing an adhesive label blank comprising the steps of:
providing a printable main sheet (21) having a front surface, a rear surface, and a fold line (23) about which the main sheet (21) is foldable with the front surface innermost, the fold line (23) dividing the main sheet (21) into at least a first panel (24) and a second panel (25);

providing a first layer of adhesive (31) on at least a part of that portion of the rear surface of the main sheet (21) forming the second panel (25); and

releaseably adhering a laminate comprising a removable release sheet (32) to the first layer of adhesive (31) such that the rear surface of the main sheet (21) has an exposed region not covered by the release sheet (32).
The method as claimed in claim 11, wherein the main sheet (21) comprises one or more additional fold lines (26) defining one or more further panels (27).
The method as claimed in either claim 11 or 12, wherein the laminate further comprises a support sheet (29), a second layer of adhesive (30) and a second release sheet (33), and the first layer of adhesive (31) is disposed on a first surface of the support sheet (29) and is covered by the first release sheet (32), the second layer of adhesive (30) is disposed on an opposing second surface of the support sheet (29) and is partially covered by the second release sheet (33), and the laminate is adhered to the main sheet (21) by a region of the second layer of adhesive (30) not covered by the second release sheet (33) such that a portion of the support sheet (29) covered by the second release sheet (33) extends beyond an edge of the second panel (25).
The method as claimed in claim 13, wherein the step of providing the laminate includes the steps of:
providing a laminar material comprising a first web of release material, a first layer of adhesive, a central layer of support material, a second layer of adhesive and a second web of release material (50);

cutting the first web of release material and central layer to define a patch (22);

removing that portion of the first web of release material and central layer surrounding the patch from the second web of release material to define the first release sheet (32) and the support sheet (29) carried on the second web of release material (50);

cutting the second web of release material (50) to define the second release sheet (33), the second web (50) being cut such that the second release sheet (33) partially covers the support sheet (29); and

removing the laminate of first release sheet (32), support sheet (29) and second release sheet (33) from the second web of release material (50).
The method of claim 13, wherein the second release sheet (33) comprises double-sided adhesive tape with a release liner (32a) on the adhesive surface (31a) facing away from the support sheet.
The method of claim 15, wherein the step of providing the laminate includes the steps of:
providing a laminar material comprising a first web of release material, a first layer of adhesive, a central layer of support material, a second layer of adhesive and a second web of release material (50);

removing the second web of release material (50) to expose the second layer of adhesive;

applying to the second layer of adhesive a ribbon of double-sided adhesive tape (29a) having a release liner (32a) over one of its two opposed layers of adhesive, the double-sided adhesive tape (29a) being arranged with the release liner (32a) facing away from the second layer of adhesive of the laminar material;

re-applying the second web of release material over the second layer of adhesive of the laminar material and over the ribbon of double-sided adhesive tape (29a);

cutting the first web of release material, the central layer and the double-sided adhesive tape to define a patch (22);

removing that portion of the first web of release material, central layer and double-sided adhesive tape surrounding the patch (22) from the second web of release material to define the first release sheet (32), the support sheet (29) and the second release sheet (33) carried on the second web of release material; and

removing the laminate of first release sheet (32), support sheet (29) and second release sheet (33) from the second web of release material (50).
The method as claimed in any one of claims 13 to 16, wherein the second release sheet (33) extends beyond an edge of the support sheet (29).
The method as claimed in any one of claims 13 to 17, wherein the main sheet (21) includes a tab (28) extending beyond an edge of the first panel (24), and the laminate is adhered to the main sheet (21) such that the main sheet (21) can be folded so as to cause the tab (28) to overlie that portion of the support sheet (29) that extends beyond the edge of the second panel (25).
The method as claimed in claim 18, wherein the tab (28) is provided along an edge of the first panel (24) by cutting the main sheet (21).
The method as claimed in claim 18, further comprising the step of providing a tear-away strip (42) in the main sheet (21) along an edge that includes the first panel (24) such that the tear-away strip (42) extends across all panels along that edge with the exception of the first panel (24).
The method as claimed in any one of claims 13 to 20, further comprising the step of providing a tear-away strip (45) in the main sheet (21) along an edge that includes the second panel (25), and the laminate is adhered to the main sheet (21) such that the portion of the support sheet (29) covered by the second release sheet (33) does not extend beyond the tear away strip (45) but does extend beyond that edge of the second panel (25) adjacent by the tear-away strip (45).