Abstract:
Self-supporting signs and methods of manufacturing are provided. One self-supporting sign includes a generally planar base portion and a generally planar upper portion extending from the base. The upper portion is foldable relative to the base about a fold line for movement between a storage configuration in which the base and upper portions are generally coplanar and a use configuration in which the base is generally horizontal and the upper portion is raised relative to the base. Only folding about the fold line is necessary to move from the storage configuration to the use configuration, and the base and upper portions are sufficiently rigid such that the upper portion remains at the use configuration after being moved to the use configuration. At least one of the base portion and the upper portion has a removable section independently usable for carrying data.

Description:
RELATED APPLICATIONS 
     This application is a continuation-in-part of U.S. patent application Ser. No. 12/984,419, filed Jan. 4, 2011 now U.S. Pat. No. 8,601,727, which claims priority to U.S. Provisional Patent Application Ser. No. 61/308,662, filed Feb. 26, 2010, and U.S. Provisional Patent Application Ser. No. 61/348,389, filed May 26, 2010. This application also claims priority to U.S. Provisional Patent Application 61/514,756, filed Aug. 3, 2011 and U.S. Provisional Patent Application 61/613,259, filed Mar. 20, 2012. Priority is claimed to each of those applications, and the contents of each are incorporated herein by reference. 
    
    
     BACKGROUND 
     The invention relates generally to the field of signs. More particularly, the invention relates to the field of self-supporting signs such as those used in retail and corporate environments. 
     The prior art includes, for example, signs  10 ,  20  such as those shown in  FIGS. 1 through 2   b . While presumably sufficient for their intended purpose, the prior art signs  10 ,  20  suffer from various shortcomings. For example, the sign  10  requires use of a support  12  coupled to a base  11 , and printed material  13  cannot stand on its own; it must be inserted in the support  12  (shown by arrow  15 ). The sign  20  can stand without having a separable base. However, to use the sign  20 , the sign must first be folded about fold lines  21 ,  22 ,  23 , and lower portions  24   a ,  24   b  must be coupled together (e.g., using adhesive, by mating tab  25   a  to slot  25   b , etc.). Further, because of its configuration, relatively large amounts of material may be required to construct the sign  20 . 
     SUMMARY 
     Self-supporting signs and methods of manufacturing same are provided herein. In one embodiment, a self-supporting sign comprises a unitary sheet having a base portion and an upper portion. The upper portion is foldable relative to the base portion about a fold line. The unitary sheet is sufficiently rigid such that when the upper portion is folded relative to the base portion about the fold line, the sign remains at a use configuration in which the base portion is generally horizontal and the upper portion is raised relative to the base portion. Only the single fold about the fold line is necessary to move the sign from a generally planar configuration to the use configuration. At least one of the base portion and the upper portion has a removable section independently usable for carrying data. 
     In another embodiment, a self-supporting sign comprises a unitary sheet having a base portion and an upper portion. The upper portion is foldable relative to the base portion about a fold line. The unitary sheet is sufficiently rigid such that when the upper portion is folded relative to the base portion about the fold line, the sign remains at a use configuration in which the base portion is generally horizontal and the upper portion is raised relative to the base portion. Only the single fold about the fold line is necessary to move the sign from a generally planar configuration to the use configuration. The upper portion having at least a section configured as a CR80 card. 
     In still another embodiment, a self-supporting sign comprises a unitary sheet having a base portion and an upper portion. The upper portion is foldable relative to the base portion about a fold line. The unitary sheet is sufficiently rigid such that when the upper portion is folded relative to the base portion about the fold line, the sign remains at a use configuration in which the base portion is generally horizontal and the upper portion is raised relative to the base portion. Only the single fold about the fold line is necessary to move the sign from a generally planar configuration to the use configuration. The base portion has a retaining member for supporting an item resting against the upper portion, and the base portion retaining member is defined by separation in the base portion. 
     In yet another embodiment, a self-supporting sign comprises a generally planar base portion and a generally planar upper portion extending from the base portion. The upper portion is foldable relative to the base portion about a fold line for movement between a storage configuration in which the base and upper portions are generally coplanar and a use configuration in which the base portion is generally horizontal and the upper portion is raised relative to the base portion. Only folding about the fold line is necessary to move from the storage configuration to the use configuration, and the base and upper portions are sufficiently rigid such that the upper portion remains at the use configuration after being moved to the use configuration. The base portion has a retaining member for supporting an item resting against the upper portion, and the base portion retaining member is defined by separation in the base portion. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows a perspective view of a PRIOR ART sign. 
         FIG. 2   a  shows a perspective view of another PRIOR ART sign. 
         FIG. 2   b  shows the PRIOR ART sign of  FIG. 2  before being folded and secured. 
         FIG. 3   a  shows a perspective view of a self-supporting sign according to an inventive embodiment, configured for use. 
         FIG. 3   b  shows another perspective view of the self-supporting sign of  FIG. 3   a.    
         FIG. 3   c  shows a side view of the self-supporting sign of  FIG. 3   a.    
         FIG. 4  shows a cross sectional view of a portion of the self-supporting sign of  FIG. 3   a.    
         FIG. 5  shows a front view of the self-supporting sign of  FIG. 3   a , before the upper portion is folded relative to the base. 
         FIG. 6  shows a schematic representation of a manufacturing process for the self-supporting sign of  FIG. 1 . 
         FIG. 7   a  shows a front view of a self-supporting sign according to another embodiment, before the upper portion is folded relative to the base. 
         FIG. 7   b  shows a rear view of the self-supporting sign of  FIG. 7   a , before the upper portion is folded relative to the base. 
         FIG. 8   a  shows a front view of a self-supporting sign according to still another embodiment, before the upper portion is folded relative to the base, in use with a card. 
         FIG. 8   b  shows a rear view of the self-supporting sign of  FIG. 8   a , before the upper portion is folded relative to the base, in use with a card. 
         FIG. 9  shows a front view of a self-supporting sign according to still yet another embodiment, before the upper portion is folded relative to the base. 
         FIG. 10  shows a front view of a self-supporting sign according to a further embodiment, before the upper portion is folded relative to the base. 
         FIG. 11  shows a front view of a self-supporting sign according to a still further embodiment, before the upper portion is folded relative to the base. 
         FIG. 12   a  shows 
         FIG. 12   b  shows 
         FIG. 13  shows a perspective view of a self-supporting sign according to an additional embodiment, configured for use. 
         FIG. 14  shows a perspective view of a self-supporting sign according to a still additional embodiment, configured for use. 
     
    
    
     DETAILED DESCRIPTION 
     Detailed descriptions of various embodiments are set forth herein, with reference to the accompanying drawings, to enable those skilled in the art to practice the current invention.  FIG. 3   a  through  5  show a self-supporting sign  100  according to one embodiment of the present invention. The self-supporting sign  100  has a unitary construction of sheet  110  foldable about a single line  105  to distinguish a base portion  120  from an upwardly-extending portion  130  (also referred to herein as the upper portion  130 ). 
     As shown in  FIG. 4 , the sheet  110  may include a primary layer  112 , a first laminate layer  114 , and a second laminate layer  116 , such that the primary layer  112  is located between the laminate layers  114 ,  116 . The primary layer  112  may be, for example, a synthetic printing substrate (e.g., the product marketed under the name Teslin® by PPG Industries of Monroeville, Pa.), a paper substrate, or any other appropriate foldable material. The laminate layer  114  and/or the laminate layer  116  may be, for example, 10 mil gloss laminate, or any other appropriate laminating material. Importantly, the primary layer  112  and the laminate layer(s)  114 ,  116  must collectively be sufficiently rigid such that the upper portion  130  remains in a raised position when the upper portion  130  is folded about the line  105  ( FIG. 5 ). Though not shown in the figures, it may also be acceptable for multiple laminate layers  114 ,  116  to be used on either or both sides of the primary layer  112  (e.g., such that the sheet includes two laminate layers  114  coupled atop one another), and for multiple primary layers  112  to be included (e.g., adhered to one another). Especially if laminate layers  114 ,  116  are included, it may be desirable for indicia to be placed on the primary layer  112  (e.g., using a digital press or any other appropriate method) before the laminate  114 ,  116  is adhered to the primary layer  112 . 
     While the base  120  may have various configurations (e.g., triangular, rectangular, etc.), it may be desirable for it to have a frusto-circular outer perimeter  122  with truncations  124  leading to internal lines  126 , which in turn lead to the fold line  105 , as shown in  FIGS. 3   a ,  3   b , and  5 . The fold line  105  may be generally centered in the base  120  (i.e., such that distance A is generally equal to distance B in  FIG. 5 ). 
     The upper portion  130  extends from the fold line  105  and may similarly have various configurations (e.g., rectangular, frusto-elliptical, or representative of a bird, animal, cross or other religious symbol, number, bell, or other object). The upper portion  130  shown in  FIG. 5  has a generally rectangular outer perimeter  132  with rounded corners  133 .  FIG. 5  also shows a front view of the sign  100  before the upper portion  130  is folded relative to the base  120  about the fold line  105 , and  FIG. 3   c  illustrates the relationship of the upper portion  130  relative to the base  120  when in use (i.e., after the upper portion  130  is folded relative to the base  120 ). 
       FIG. 6  shows a schematic representation of a manufacturing process  600  for the self-supporting sign  100 . At a first step  602 , the primary layer  112  is provided (e.g., as a sheet or roll). The process  600  proceeds from step  602  to step  604 . 
     At step  604 , indicia is added to the primary layer  112  (i.e., to one side or both sides of the primary layer  112 ), such as through a digital press or any other appropriate method. It may be particularly important for any desired indicia to be added before the primary layer  112  is coupled to the laminate layers  114 ,  116 , though indicia may be added in some embodiments after the primary layer  112  is coupled to the laminate layers  114 ,  116 . The process  600  proceeds from step  604  to step  606 . 
     At step  606 , the laminate layers  114 ,  116  are coupled to the opposite sides of the primary layer  112 , such as by pressure sensitive adhesive. The laminate layers  114 ,  116  may be obtained already having pressure sensitive adhesive, or pressure sensitive adhesive may otherwise be applied to the primary layer  112  and/or the laminate layers  114 ,  116 . Though the adhesive is not shown in the drawings (e.g., in  FIG. 4 ), those skilled in the art will appreciate that it is present nevertheless. The process  600  proceeds from step  606  to step  608 . 
     At step  608 , the primary layer  112  and the laminate layers  114 ,  116  are die cut, defining the self-supporting sign  100  (e.g., the perimeter  122 , the truncations  124 , the internal lines  126 , the perimeter  132 , and the corners  133 ). Simultaneously, or in a further step, the fold line  105  may be defined through pressure that does not cut through the sheet  110 . In some embodiments, the fold line  105  may not be defined through the manufacturing process. 
     To use the self-supporting sign  100 , then, the upper portion  130  is simply folded relative to the base  120  about the fold line  105  ( FIG. 5 ). Once folded ( FIGS. 3   a  through  3   c ), the upper portion  130  may remain generally stationary relative to the base  120 . In some embodiments, the upper portion  130  may be offset from about 50° to about 90° from the base  120  (i.e., angle C in  FIG. 3   c ), and more particularly from about 50° to about 65°. Unlike in the prior art, only a single fold is necessary, and there is no coupling of elements. And, before the upper portion  130  is folded relative to the base  120 , the flat configuration ( FIG. 5 ) may make the self-supporting sign  100  easy to store and/or ship. The upper portion  130  may also be re-folded to the flat configuration for storage when not in use. 
       FIGS. 7   a  and  7   b  show another self-supporting sign  700  that is substantially similar to the embodiment  100 , except as specifically noted and/or shown, or as would be inherent. Further, those skilled in the art will appreciate that the embodiment  100  (and thus the embodiment  700 ) may be modified in various ways, such as through incorporating all or part of any of the various described embodiments, for example. For uniformity and brevity, corresponding reference numbers may be used to indicate corresponding parts, though with any noted deviations. In both  FIG. 7   a  (front view) and  FIG. 7   b  (rear view), the upper portion  130  is not yet folded relative to the base  120 , as in  FIG. 5 . 
     In embodiment  700 , a pair of opposed retaining members  710  are formed in the upper portion  130  such that a business card, flyer, advertisement, coupon, invitation, memo, announcement, pad of paper, or other item may be coupled to the upper portion  130  by being held between one or both of the retaining members  710 . The retaining members  710  may for example be formed through a die cutting process (either at step  608  or another step) and may have a generally vertical portion  712  leading to angled portions  714  (as shown), or may be other shapes that allow the retaining function to be accomplished. While the retaining members  710  are shown to extend between one-fourth and one-third of the height of the upper portion  130 , other dimension may also be appropriate. 
       FIGS. 8   a  and  8   b  show another self-supporting sign  800  that is substantially similar to the embodiment  700 , except as specifically noted and/or shown, or as would be inherent. Further, those skilled in the art will appreciate that the embodiment  700  (and thus the embodiment  800 ) may be modified in various ways, such as through incorporating all or part of any of the various described embodiments, for example. For uniformity and brevity, corresponding reference numbers may be used to indicate corresponding parts, though with any noted deviations. In both  FIG. 8   a  (front view) and  FIG. 8   b  (rear view), the upper portion  130  is not yet folded relative to the base  120 , as in  FIGS. 5 ,  7   a , and  7   b.    
     In embodiment  800 , the pair of opposed retaining members  710  is replaced with a pair of retaining members  810  that are similarly formed in the upper portion  130  such that a business card, flyer, advertisement, coupon, invitation, memo, announcement, pad of paper, or other item may be coupled to the upper portion  130  by being held between one or both of the retaining members  810 . The retaining members  810  may for example be formed through a die cutting process (either at step  608  or another step) and may be generally rounded (as shown), or may be other shapes that allow the retaining function to be accomplished. The illustrated shapes are the primary difference between the retaining members  710  and the retaining members  810 . Embodiment  800  further includes a lower retaining member  820  for providing additional retaining support. A card  80  is shown coupled to the upper portion  130  by being restrained between the retaining members  810  and the lower retaining member  820 . 
       FIG. 9  shows another self-supporting sign  900  that is substantially similar to the embodiment  800 , except as specifically noted and/or shown, or as would be inherent. Further, those skilled in the art will appreciate that the embodiment  800  (and thus the embodiment  900 ) may be modified in various ways, such as through incorporating all or part of any of the various described embodiments, for example. For uniformity and brevity, corresponding reference numbers may be used to indicate corresponding parts, though with any noted deviations. In  FIG. 9 , the upper portion  130  is not yet folded relative to the base  120 , as in  FIGS. 5 ,  7   a ,  7   b ,  8   a , and  8   b.    
     Embodiment  900  primarily differs from the embodiment  800  by including multiple pairs of the retaining members  810 , multiple lower retaining members  820 , and also a pair of the retaining members  710 . The retaining members  710 ,  810 ,  820  are spaced along the upper portion  130  to provide various spacing for restraining objects of different sizes. 
       FIG. 10  shows another self-supporting sign  1000  that is substantially similar to the embodiment  900 , except as specifically noted and/or shown, or as would be inherent. Further, those skilled in the art will appreciate that the embodiment  900  (and thus the embodiment  1000 ) may be modified in various ways, such as through incorporating all or part of any of the various described embodiments, for example. For uniformity and brevity, corresponding reference numbers may be used to indicate corresponding parts, though with any noted deviations. In  FIG. 10 , the upper portion  130  is not yet folded relative to the base  120 , as in  FIGS. 5 ,  7   a ,  7   b ,  8   a ,  8   b , and  9 . 
     Embodiment  1000  primarily differs from the embodiment  900  by including at least one retaining member  1010  in the base  120  such that at least one business card, flyer, advertisement, coupon, invitation, memo, announcement, pad of paper, or other item may extend from the base  120  and be supported by the upper portion  130 . As shown in  FIG. 10 , the retaining members  1010  face in generally the same direction as the lower retaining member  820  when the sign  1000  is not yet folded relative to the base  120 . The retaining members  1010  may for example be formed through a die cutting process (either at step  608  or another step) and may have a generally horizontal portion leading to a pair of opposed generally perpendicular portions (as shown in  FIG. 10 ), or may be other shapes that allow the retaining function to be accomplished. 
     If multiple retaining members  1010  are included, a first number of items may initially be supported by one of the retaining members  1010  and the upper portion  130 . Some of those items may then be removed, and the remaining number of items may be supported by another of the retaining members  1010  (i.e., a retaining member  1010  closer to the fold line  105 ) and the upper portion  130 . For example, a certain number of business cards may initially be supported by one of the retaining members  1010  and the upper portion  130 . After some of the business cards are removed, the remaining business cards may be supported by another of the retaining members  1010  and the upper portion  130 . This may allow the remaining business cards to be positioned in a visually-appealing manner. 
       FIG. 11  shows another self-supporting sign  1100  that is substantially similar to the embodiment  100 , except as specifically noted and/or shown, or as would be inherent. Further, those skilled in the art will appreciate that the embodiment  100  (and thus the embodiment  1100 ) may be modified in various ways, such as through incorporating all or part of any of the various described embodiments, for example. For uniformity and brevity, corresponding reference numbers may be used to indicate corresponding parts, though with any noted deviations. In  FIG. 11 , as in  FIG. 5 , the upper portion  130  is not yet folded relative to the base  120 . 
     Embodiment  1100  primarily differs from the embodiment  100  shown in  FIG. 3   a  through  5  in four ways. First, the base  120  and the upper portion  130  have different configurations in the embodiment  1100 . Specifically, the upper portion  130  in the embodiment  1100  is shaped like a Christmas tree and the base  120  is configured to have a generally rectangular lower end  1120   a  and an upper end  1120   b  that is complementary to the upper portion  130 . As set forth above regarding embodiment  100 , the base  120  and the upper portion  130  may have various configurations. Additional exemplary configurations for the upper portion  130  include representations of landmarks, landscapes, holiday indicia. Also, the upper portion  130  may include user-generated content, such as pictures of a person, family, pet, artwork, et cetera. Such user-generated content may be particularly desirable if the embodiment  1100  is used as a holiday card. 
     Second, the base  120  in the embodiment  1100  includes a removable section  1125 . The removable section  1125  may be, for example, a prepaid or rechargeable card for use in purchasing goods or services, a coupon, a business card, or a membership card. The removable section  1125  may be secured (e.g., removably adhered or stapled) to the base  120  (e.g., to the laminate layer  114  or to the laminate layer  116 ), or may alternately be a section of the base  120  that may be removed from a remainder of the base  120  along perforations or a weakened break line. The removable section  1125  may include a magnetic stripe or other machine-readable indicia (e.g., a 2D bar code, a QR code, et cetera) if desired. 
     Third, the embodiment  1100  includes two-sided tape  1127  or pressure sensitive tape with a removable liner  1128  (shown partially peeled back in  FIG. 11 ) attached to the laminate layer  114 . The tape  1127  may alternately be coupled to the opposite (rear) side of the base  120 . 
     Fourth, the second laminate layer  116  may specifically be a material that can be written upon, or may be replaced or supplemented by such a material. The second laminate layer  116  (or its replacement or supplement) may include post card indicia, greeting card indicia, or other indicia which may be supplemented by an end user. 
     In use, the embodiment  1100  may (for example) be a greeting card or post card, and the user may write on the second laminate layer  116  and send the embodiment  1100  to a recipient (either with or without an envelope). Upon receipt, the recipient may remove the removable section  1125  and the liner  1128 , the upper portion  130  may be folded relative to the base  120  at fold line  105 , and the tape  1127  may be used to couple the base  120  to a countertop, shelf, or other environmental structure. 
       FIGS. 12   a  and  12   b  show another self-supporting sign  1200  that is substantially similar to the embodiment  1100 , except as specifically noted and/or shown, or as would be inherent. Further, those skilled in the art will appreciate that the embodiment  1100  (and thus the embodiment  1200 ) may be modified in various ways, such as through incorporating all or part of any of the various described embodiments, for example. For uniformity and brevity, corresponding reference numbers may be used to indicate corresponding parts, though with any noted deviations. In  FIG. 12   a , as in  FIG. 11 , the upper portion  130  is not yet folded relative to the base  120 . 
     Embodiment  1200  primarily differs from the embodiment  1100  shown in  FIG. 11  by including detachable perimeter sections  1250   a ,  1250   b . Particularly when the self supporting sign  1200  is intended for use as a post card, detachable perimeter sections  1250   a ,  1250   b  may be included to provide a generally rectangular perimeter. Such a generally rectangular perimeter may facilitate mailing without an envelope. Those skilled in the art will appreciate, however, that one or more detachable perimeter section may be included even when the sign  1200  is not intended for use as a post card, and that the detachable perimeter section(s) may provide perimeters of various shapes (not only generally rectangular). 
     The detachable perimeter sections  1250   a ,  1250   b  may be defined, for example, by die cutting.  FIG. 12   b  shows a detailed view of a die cut line  1255  bounding the perimeter section  1250   b  according to one embodiment. The die cut line  1255  includes voids  1255   a  to maintain the perimeter section  1250   b  coupled to the upper portion  130  until separation is desired. 
     In use, the detachable perimeter sections  1250   a ,  1250   b  may contribute to providing a first perimeter (e.g., a generally rectangular perimeter) for as long as desired. When the first perimeter is no longer desired, the detachable perimeter sections  1250   a ,  1250   b  may be separated from the upper portion  130 . The removable section  1125  and the liner  1128  may also be removed, the upper portion  130  may be folded relative to the base  120  at fold line  105 , and the tape  1127  may be used to couple the base  120  to a countertop, shelf, or other environmental structure. 
       FIG. 13  shows another self-supporting sign  1300  that is substantially similar to the embodiment  100 , except as specifically noted and/or shown, or as would be inherent. Further, those skilled in the art will appreciate that the embodiment  100  (and thus the embodiment  1300 ) may be modified in various ways, such as through incorporating all or part of any of the various described embodiments, for example. For uniformity and brevity, corresponding reference numbers may be used to indicate corresponding parts, though with any noted deviations. In  FIG. 13 , as in  FIG. 3   a , the upper portion  130  is folded relative to the base  120 . 
     Embodiment  1300  primarily differs from the embodiment  100  shown in  FIG. 3   a  through  6  in the configuration of the upper portion  130 . Specifically, the upper portion  130  in the embodiment  1300  is shaped like a business card, a prepaid or rechargeable card for use in purchasing goods or services, a coupon, or a membership card. For example, the upper portion  130  may generally have the shape and size of a CR80 card. As set forth above regarding embodiment  100 , the base  120  and the upper portion  130  may have various configurations. 
       FIG. 14  shows another self-supporting sign  1400  that is substantially similar to the embodiment  1300 , except as specifically noted and/or shown, or as would be inherent. Further, those skilled in the art will appreciate that the embodiment  1300  (and thus the embodiment  1400 ) may be modified in various ways, such as through incorporating all or part of any of the various described embodiments, for example. For uniformity and brevity, corresponding reference numbers may be used to indicate corresponding parts, though with any noted deviations. In  FIG. 14 , as in  FIG. 13 , the upper portion  130  is folded relative to the base  120 . 
     Embodiment  1400  primarily differs from the embodiment  1300  shown in  FIG. 12  in the configuration of the upper portion  130 . Specifically, the upper portion  130  in the embodiment  1400  includes perforations or a weakened break line  1407  to allow portion  130   a  to be separated from the remainder of the upper portion  130  and the base  120 . The portion  130   a  may then be used as a traditional business card, prepaid or rechargeable card for use in purchasing goods or services, coupon, membership card, et cetera. As set forth above regarding embodiment  1200 , the base  120  and the upper portion  130  may have various configurations. 
     Many different arrangements of the various components depicted, as well as components not shown, are possible without departing from the spirit and scope of the present invention. Embodiments of the present invention have been described with the intent to be illustrative rather than restrictive. Alternative embodiments will become apparent to those skilled in the art that do not depart from its scope. A skilled artisan may develop alternative means of implementing the aforementioned improvements without departing from the scope of the present invention. Further, it will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations and are contemplated within the scope of the claims. Further, various steps set forth herein may be carried out in orders that differ from those set forth herein without departing from the scope of the present methods. The description should not be restricted to the above embodiments, but should be measured by the following claims.