FORM COMPRISING A PRINTABLE MATERIAL AND A MAGNETIC LAYER AND LAMINATES FOR CREATING SUCH A FORM

Abstract: The invention refers to a form (1) comprising a form layer (2) with at least a section of printable material, an adhesive layer (3), a separating layer (5), an intermediate layer (4) between the adhesive layer (3) and the separating layer (5), and a magnet (7), said adhesive layer (3), separating layer (5) and intermediate layer (4) are arranged between the form layer (2) and a cover layer (6). In order to avoid the drawbacks of known forms comprising a magnet, it is suggested that the magnet is a magnetic layer (7) integrated in the intermediate layer (4).

Description: Description FORM COMPRISING A PRINTABLE MATERIAL AND A MAGNETIC LAYER AND LAMINATES FOR CREATING SUCH A FORM The present invention refers to a form comprising a form layer with at least a section of printable material, an adhesive layer, a separating layer, an intermediate layer between the adhesive layer and the separating layer, and a magnet, said adhesive layer, separating layer and intermediate layer are arranged between the form layer and a cover layer, and also refers to a laminate for creating a form. Forms of the aforementioned kind are generally known in the industry and are referred to as multilayer forms. The different layers can extend over the entire form, or can be provided by way of patches, such that only a section of the form is multilayered. The multilayered sections can be provided with a cut-out in order to provide a removable portion that forms a shape, usually a card. Numerous applications for such forms, such as business forms, exist. The magnet is usually glued to the back side of the form for the multilayered section and allows attachment of the form or a card removed from the form to a magnetic surface. There is a great need for such forms or cards comprising magnets. Such forms or cards can be used for a magnetic message, a tag or the like and easy attachment to magnetic surfaces. However, magnetic forms tend to be rather thick and are also heat sensitive. They tend to melt when used in today's printers. Also, the requirement of fixing or gluing the magnet to a top of a business form requires additional steps when manufacturing the form. Due to the heat sensitivity, the magnet can only be attached to the form after printing the form. Manufacturing of such forms therefore becomes very complex. Also, the thickness requirements of printers prohibited the use of magnetic forms. It is the object of the present invention to overcome the drawbacks of the forms of the aforementioned kind and to provide a form and a laminate comprising a magnetic section, which are easier to manufacture and which are printer compatible. The object of the invention is achieved by a magnetic form of the aforementioned kind, wherein the magnetic section is a magnetic layer integrated in the intermediate layer of the form. This way, the magnetic layer or magnetic section is removed from the surface of the form into the form and covered by the form layer or the cover layer which protects the magnetic layer from the heat generated by today's printers. This avoids melting or shrinkage of the magnetic layer and creates an overall thinner form. Depending on the thickness of the cover layer or form layer or addition layers integrated into the form, the distance of the magnetic layer from the surface of the form can be very accurately adjusted such that the magnetic layer does not melt or soften when printing the form and also provides sufficient magnetic strength in order to securely attach the form or a card peeled off the form to a magnetic surface. The location of the magnetic layer between other layers is particularly advantageous, as in laser printers heat is generated from the top and bottom. As the invention allows the manufacturing of very thin magnetic forms, feeding to printers is possible or enhanced and stacking of the forms is improved, as the forms tend to stick together less than conventional magnetic forms due to the location of the magnetic layer. This also improves feeding of the forms from stacks of forms to printers. In a preferred embodiment of the invention, the intermediate layer can comprise a support layer. This allows a thinning of the magnetic layer as the magnetic layer can be strengthened by the support layer. According to an alternative embodiment, the support layer can be formed by the cover layer. This way the overall thickness of the form can be reduced. It may be advantageous if the support layer is adjacent to the magnetic layer. This allows to prefabricate the intermediate layer while manufacturing the form. If the support layer and the magnetic layer form a single layer, the magnetic layer can be very thin compared to previously known forms as the magnetic layer is sufficiently strong due to the support layer. If they are formed as a single layer, this layer can be prefabricated such that manufacturing of the laminate itself becomes less complex. Also, the reduced thickness of the magnetic layer allows for the provision of a more flexible form compared to previously known forms having a magnet. The magnetic layer can be permanently attached to the support layer to avoid inadvertent separation between the support layer and the magnetic layer. A very thin magnetic layer can be provided, if the magnetic layer is laminated to the support layer. In a preferred embodiment, the separating layer can be arranged between the form layer and the intermediate layer. This allows to peel the form layer off the intermediate layer such that the intermediate layer stays with the cover layer. ]n a different embodiment of the invention, the separating layer can be arranged between the intermediate layer and the cover layer. This allows to peel off the cover layer from the intermediate layer such that the intermediate layer with the magnetic layer stays on the form layer. If the magnetic layer is arranged between the adhesive layer and the support layer, it is possible to move the magnetic layer closer to the layer adjacent to the adhesive layer depending on the embodiment of the invention, the magnetic layer can be located closer to the form layer or the cover layer. In a different embodiment, the magnetic layer can be arranged between the separating layer and the support layer. This allows to locate the magnetic layer closer to the surface of the form or a card removed from the form, when the layer adjacent to the separating layer is removed. Another embodiment can comprise a second adhesive layer adjacent to the separating layer to securely attach the separating layer to the intermediate layer or the form layer or the cover layer. For forming a card integrated in the form; a cut-out can be provided through the form layer, the adhesive layer and the intermediate layer. The card then comprises the form layer, the adhesive layer and the intermediate layer. The cover layer stays with the form layer. In a preferred embodiment, the die cut can extend at least into the separating layer. This eases separation of the card from the cover layer. In a different embodiment, a cut-out can be provided through the cover layer, the adhesive layer and the intermediate layer in order to form a removable card. This card would then comprise the cover layer, the adhesive layer and the intermediate layer with the magnetic layer. In order to facilitate the removing of the card, the die cut may extend at least into the separating layer adjacent to the form layer. In order to further strengthen the card removed from the form, a film layer can be provided between the adhesive layer and the intermediate layer. Of course, this film layer would also be cut with the cut-out if the cut-out is provided. In an advantageous embodiment of the invention, the separating layer can comprise two films that separate during separation of the card from the cover layer such that one of the films remains on the layers adjacent to the separating layer respectively. Such films are known as dry peel layers. During separation of card, a dry peel layer between the films breaks apart such that the films remain on each of the adjacent layers respectively. The advantage of the dry peel layer is that the remains of the separating layer do not stick, after removing the card from the form. Alternatively, an additional dry peel layer between the films is not required. Instead the two films are bonded chemically while being coated on top of each other during manufacturing. In order to create a form, it may be advantageous if the form layer extends beyond the adhesive layer, separating layer, intermediate and cover layers. This way only a section of the form is multilayered. In order to avoid melting of the magnetic layer, the magnetic layer is completely covered on the top and bottom. Coverage can be achieved by the form layer, support layer or cover layer depending on the embodiment of the invention. An alternative embodiment of the separating layer could comprise third adhesive layer and a varnish film coating, which covers the third adhesive layer after removing the card such that there is no stickiness to the card or the cover layer, depending on which layer the film is located. Upon separating the varnish coating film has a greater affinity to the third adhesive layer than to the layer adjacent to the varnish coating film. in alternative embodiments the separating layer can comprise a peelable glue or a release substance such as silicone. The objects of the invention are also achieved by a laminate for creating a form for comprising an adhesive layer, a separating layer, an intermediate layer between the adhesive layer and the separating layer and a cover layer, characterised in that the intermediate layer comprises a magnetic layer. Such a laminate can be attached to a form in order to form the patches, to create removable sections such as business cards and the like. In an advantageous embodiment of the invention, separating layer can be arranged between the intermediate layer and the cover layer. This way, the adhesive layer is the outermost layer of the laminate. For the purpose of delivering the laminate, the adhesive layer can be covered with an additional layer, that may be removed before attaching the laminate to a form. It can generally be advantageous if the laminate is attachable to the form through the adhesive layer. This allows a secure attachment of the laminate to a form and simple manufacturing. The invention also refers to a form comprising a form layer with at least a section of printable material, a magnet and at least a support layer which is characterised in that the magnet is a magnetic layer laminated to the support layer to form an integrated magnetic layer, said magnet being located between the support layer and the form layer. This allows to cover the magnet with fewer layers than the previously described embodiment. It allows to manufacture even thinner forms. Of course, additional cover layers or separating layers can be provided in order to strengthen the form or the card. It can be advantageous if an adhesive layer between the form layer and the magnetic layer is provided. It allows easy attachment of the magnetic layer to the form layer. Alternatively, a separating layer could be provided between the magnetic layer and the form layer. This allows easy removal of the magnetic layer from the form layer. Of course, it is possible to provide cut-outs as in the previous embodiments also in combination with a cover layer and a separating layer. In a preferred embodiment, a perforation can be provided, which extends at least through the form layer, magnetic layer and the support layer to form a removable card. This allows to break a card of desired shape out of the form instead of peeling it off a cover layer or a form layer. A separating layer can then be omitted. The invention will be explained with reference to the figures of which Figure 1 is schematic sectional view of a first embodiment of the invention; Figure 2 is a schematic sectional view of a second embodiment of the invention; and Figure 3 is a schematic sectional view of a third embodiment of the invention. Figure 4 is a schematic sectional view of a fourth embodiment of the invention. Figure 1 shows a first embodiment of the form 1 according to the invention. The form 1 comprises a form layer 2 of paper or cardboard, preferably paper, an adhesive layer 3 and an intermediate layer 4, a separating layer 5 and a cover layer 6. The intermediate layer 4 is comprised of a magnetic layer 7 which is laminated to a support layer 8, such that magnetic layer 7 and support layer 8 form a single intermediate layer. The magnetic layer is preferably between 100- 300 microns thick. The support layer 8 is made of a paper or film like material. This combination of magnetic layer and support layer is sold as sheets. The side having the magnetic layer is facing the form, whereas the side forming the support layer faces the cover layer 6. Between the intermediate layer 4 and the adhesive layer 3, an optional film layer 9 is provided in order to strengthen the form. The film layer is located adjacent to the magnetic layer 7 of the intermediate layer 4 and can for example be comprised of a polyester film or paper. Where the extra stiffness provided by film 9 is not needed, film 9 is omitted. The adhesive layer 3 can be comprised of a pressure sensitive or permanent adhesive. The separating layer is comprised of dry peel laminate which forms the separating layer 5 and consists of two films. As layer 5 is a separating layer, it is possible to peel away the cover layer 6 off the intermediate layer 4, whereby the films of separating layer break apart such that films of the former separating layer will stay on the intermediate layer 4 and the cover layer 6 respectively. The cover layer 6 itself is made of a filmic material such as polyester but could also be made of paper like material. The separating layer 5 mostly comprises cast acrylic coating. It is also possible to use a dry peel layer as a separating layer which completely detaches from the cover layer or completely stays with the cover layer. The form layer 2 of paper or cardboard material is usually A4 format. Of course, other formats are possible. The other layers, adhesive layer 3, intermediate layer 4, separating layer 5, cover layer 6 and film layer 9 are considerably smaller than the form layer 2, such that they form a patch that can be used for creating a integrated card into the form. This card is generated by a cut-out which is indicated in line 10 and which extends through the form layer 2, adhesive layer 3, intermediate layer 4, with magnetic layer 7 and support layer 8, the separating layer 5 and the film layer 9. The cut-out does not cut through the cover layer 6. Due to the cut-out, the layers within the cut-out form a card 12 which can be peeled off the cover layer 6. The cutout can have any shape. However, it is preferred that the cut-out has the shape of an essentially rectangular card. In a preferred embodiment, the size of the different layers can be such that the magnetic layer 7 is completely covered by the form layer 2 and the cover layer 6, such that no section of the magnetic layer is exposed to the outside. For manufacturing the form, it is possible to deliver a laminate 12 which comprises of the adhesive layer 3, intermediate layer 4, with magnetic layer 7 and support layer 8, the separating layer 5 and the cover layer 6 and the film layer 9. The laminate can be delivered to the manufacturer of the form who attaches the laminate through the adhesive layer 3 to the form layer 2. The advantages of the invention will be as follows: Due to covering the magnetic layer 7 by the form layer, the adhesive layer and the film layer 9 on the one side and the support layer 8, separating layer 5, cover layer 6 on the other side, the magnetic layer 7 is well protected against heat that might be generated in a printer. The form with the laminate 12 can therefore be printed with standard printers such as inkjet printers or laser printers which was not possible with the previous forms where the thicker magnets had to be glued to the already printed form. Also, even though the magnetic layer does not form the surface of the form, or the card itself, it still can generate enough magnetic force in order to securely attach it to a magnetic surface. Depending on the printer used, and depending on which side of the form is supposed to be printed, it is possible to locate the magnetic layer closer to the form layer or the cover layer by arranging the intermediate layer such that the magnetic layer faces the form layer or the cover layer respectively. The different thicknesses of the layers can be utilised to obtain sufficient gap between forms or sheets when stacked in order to allow or facilitate feeding of the forms to printers. As the magnetic layer 7 and the support layer 8 form a single intermediate layer 4, it is possible to generate very thin forms despite the magnet. Previous forms, where the magnet had to be attached separately to the form, tended to be rather thick. A second embodiment of the invention will now be explained referring to Figure 2. The second embodiment will be explained by referring to the differences between the first and second embodiments and like items will be referred to with the same reference numerals. The second embodiment comprises the same amount and the same type of layers, namely a form layer 2, an adhesive layer 3, an intermediate layer 4 with a magnetic layer 7, a support layer 8 and a separating layer 5 and a cover layer 6, as well as a film layer 9. Different to the first embodiment, the separating layer is now located between the intermediate layer 4 and the form layer 2. The adhesive layer 3 is located between the cover layer 6 and the intermediate layer 4. The optional film layer 9 is located between the intermediate layer and the adhesive layer. The cut-out extends now through the cover layer, the adhesive layer, the intermediate layer, the film layer and the separating layer. It does not extend through the form layer 2. Accordingly, a card can be peeled off the form layer 2. A third embodiment of the invention will be described referring to Figure 3. The third embodiment comprises the same type and amount of layers and also the same sequence of layers. However, the cut-out is not yet provided such that the arrangement of different layers constitutes the form itself. A fourth embodiment of the invention will be described referring to Figure 4. The fourth embodiment is only comprised of a form layer 2, a magnetic layer 7, a support layer 8 and an adhesive layer 3 between the form layer and the magnetic layer. The outermost layer is now the support layer, which covers the magnetic layer. The magnetic layer is now sandwiched between the form layer and the support layer. This allows to manufacture even thinner forms than with the previously described embodiments. Of course, additional layers may be provided in order to strengthen the form. In addition, the fourth embodiment comprises a perforation 13, which extends through the form layer, the adhesive layer, and the magnetic layer and the support layer, in order to allow to break the card out of the form. This allows to omit the separating layer. The card can have any desired shape. As in the fourth embodiment, the support layer is the outermost layer, the magnetic layer laminated to the support layer, is denoted as an integrated magnetic layer 14.

Claims: CLAIMS 1. Form comprising a form layer (2) with at least a section of printable material, an adhesive layer (3), a separating layer (5), an intermediate layer (4) between the adhesive layer and the separating layer, and a magnet, said adhesive layer, separating layer and intermediate layer are arranged between the form layer and a cover layer (6), characterised in that the magnet is a magnetic layer (7) integrated in the intermediate layer. 2. Form according to claim 1 , characterised in that the intermediate layer comprises a support layer (8). 3. Form according to claim 1 , characterised in that a support layer is formed by the cover layer. 4. Form according to claim 1 , characterised in that the support layer being adjacent to the magnetic layer. 5. Form according to claim 2 or 4, characterised in that the support layer and the magnetic layer form a single layer. 6. Form according to one of the preceding claims 1 , 2, 4 and 5, characterised in that the magnetic layer is permanently attached to the support layer. 7. Form according to one of the preceding claims 1 , 2, 4-6, characterised in that the magnetic layer is laminated to the support layer. 8. Form according to one of the preceding claims, characterised in that the separating layer is arranged between the form layer and the intermediate layer. 9. Form according to one of the preceding claims, characterised in that the separating layer is arranged between the intermediate layer and the cover layer. 10. Form according to one of the preceding claims, characterised in that the magnetic layer is arranged between the adhesive layer and the support layer. 11. Form according to one of the preceding claims, characterised in that the magnetic layer is arranged between the separating layer and the support layer. 12. Form according to one of the preceding claims, characterised by a second adhesive layer adjacent to the separating layer. 13. Form according to one of the preceding claims, characterised in that a cut-out (10) is provided through the form layer, the adhesive layer and the intermediate layer in order to form a removable card (11). 14. Form according to claim 13, characterised in that the die cut extends at least into the separating layer adjacent to the cover layer. 15. Form according to one of the preceding claims 1 -12, characterised in that the cut-out (10) is provided through the cover layer (6), the adhesive layer and the intermediate layer in order to form a removable card (11). 16. Form according to claim 15, characterised in that the die cut extends at least into the separating layer adjacent to the form layer. 17. Form according to one of the preceding claims, characterised in that a film layer (9) is provided between the adhesive layer and the intermediate layer. 18. Form according to one of the preceding claims, characterised in that the separating layer comprises two films that separate during separation of the form layer from the cover layer such that one of the films remains on the layers adjacent to the separating layer respectively. 19. Form according to one of the preceding claims 1 -17, characterised in that the separating layer comprises third adhesive layer and a varnish coating. 20. Form according to one of the preceding claims 1 -18, characterised in that the separating layer comprises a peelable glue. 21. Form according to one of the preceding claims 1 -18, characterised in that the separating layer comprises a release substance such as silicone. 22. Form according to one of the preceding claims, characterised in that the form layer extends beyond the adhesive layer, separating layer, intermediate layer and cover layer. 23. Form according to one of the preceding claims, characterised in that the magnetic layer is fully covered. 24. Laminate for creating a form, comprising an adhesive layer, a separating layer, an intermediate layer between the adhesive layer and the separating layer and a cover layer, characterised in that the intermediate layer comprises a magnetic layer. 25. Laminate according to claim 21 , characterised in that the separating layer is arranged between the intermediate layer and the cover layer. 26. Laminate according to claim 21 or 18, characterised in that the laminate being attachable to a form through the adhesive layer. 27. Form comprising a form layer with at least a section of printable material, a magnet and at least a support layer (8) characterised in that the magnet is a magnetic layer (7) laminated to the support layer to form an integrated magnetic layer (14) said magnet being located between the support layer and the form layer (2). 28. Form according to claim 27, characterised in that an adhesive layer is provided between the form layer and the magnetic layer. 29. Form according to claim 27, characterised in that a separating layer is provided between the magnetic layer and the form layer. 30. Form according to one of claims 27-29, characterised in that a perforation is provided, which extends at least through the form layer, the magnetic layer and the support layer to form a removable card.

Inventors: CASAGRANDE CHUCK, CASAGRANDE, CHUCK
Applicants: CASAGRANDE CHUCK, PREC COATED PRODUCTS LTD, CASAGRANDE, CHUCK, PRECISION COATED PRODUCTS LTD.
Application year: 2000
Main classification: B32B33
IPC codes: B32B7, B32B37, B42D5, B42F11, G09F3