Abstract:
The present invention includes a label for a nursery container. The label includes a protective first layer having a first adhesive layer affixed to at least a portion of a second side of the protective first layer. The label also includes a second layer having a top surface and a bottom surface, the top surface contacting at least a portion of the first adhesive layer. The label further includes a base adhesive layer having a first side and a second side, the first side affixed to at least a portion of the bottom surface of the second layer and the second side of the base adhesive affixed to the container. In addition, at least a portion of the first adhesive layer is affixed to the container. A method for creating the label is also defined.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates to a labeling system for nursery containers and similar growing containers and, more particularly, to a multi-layer labeling that is removable from the container.  
       BACKGROUND  
       [0002]     Nursery containers traditionally have served a single primary purpose—to provide a mechanism for growing and transporting a plant. As such, nursery owners using the container paid little attention to details of the container. As long as the container was priced appropriately and could survive a growing season, the nursery owner would purchase the container.  
         [0003]     In recent years, uses for nursery containers have grown. For example, in and above ground plant growing systems have led to the use of containers to grow larger plants, including trees, that were previously grown directly in the ground. As such, the containers have been modified to last longer, as well as designed to accommodate larger and heavy plants. For example, U.S. Pat. No. 5,503,886 to Guarriello, et al., describes an innovative blow molded container with a rim designed to provide structural rigidity with cushioning. Also for example, the container, sold by Nursery Supplies, Inc., Chambersburg, Pa., under the trademark GRIP-LIP®, permits larger and heavier loads to be carried in the container.  
         [0004]     Although innovations have been made in recent years to the containers, one of the areas that has not achieved much attention has been in labeling of the containers. As noted above, containers have typically been considered throw away items and, as such, have not been considered as being anything but temporary carriers. As a result, placement of labeling on the containers has been limited to simply applying stickers to the container, such as stickers that identify the plant or include the nursery owner&#39;s or container manufacturer&#39;s name on it. If the label includes the manufacturer&#39;s name, it is usually removed by the nursery owner before the nursery owner displays the product. If the label includes the nursery owner&#39;s name, it is generally not removed by the end user because the end user will generally discard the container after the plant is removed.  
         [0005]     Another form of labeling that is currently being used is the application of labeling ink (i.e., paint) directly to the container. Because this form of labeling is permanent, generally only the name of the nursery owner is applied with this form of label. The problem with this permanent form of labeling is that it is typically applied by the container manufacturer. As such, the manufacturer must manufacture and store the labeled containers separately from containers for other customers. This can lead to logistical problems.  
         [0006]     As described above, it is now common for containers to be left in the growing fields for more than one growing season. Typically plants are grown for three or more years before they are sold. In the growing fields, the containers are exposed to a variety of weather conditions and chemicals. As a result, any label that is placed on the container would quickly become weathered and damaged, detracting from its marketing ability.  
         [0007]     Thus, an improved labeling system is needed that can withstand weather and chemicals while still providing the marketing required by nurseries.  
       SUMMARY OF THE INVENTION  
       [0008]     One embodiment of the present invention is a label for a nursery container. The label includes a protective first layer having a first side and a second side. A first adhesive layer is affixed to at least a portion of the second side of the protective first layer. The label also includes a second layer having a top surface and a bottom surface, the top surface contacting at least a portion of the first adhesive layer. The label also includes a base adhesive layer having a first side and a second side, the first side affixed to at least a portion of the bottom surface of the second layer and the second side of the base adhesive affixed to the container. In addition, at least a portion of the first adhesive layer is affixed to the container.  
         [0009]     Another embodiment of the present invention includes a method of making a label for a nursery container. The method includes providing a first material and a second material. A first adhesive is applied to the first material to form a protective first layer. A top or bottom surface of the second material is reverse printed and a base adhesive is applied to the bottom surface of the second material. The second material is then die cut into a desired shape to form a second layer. The second layer is registered with the first layer. Finally, the first layer is die cut, leaving the first layer on top of the second layer to form the label. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]     For the purpose of illustrating the invention, there is shown in the drawings various forms which are presently disclosed; it being understood, however, that this invention is not limited to the precise arrangements and instrumentalities particularly shown.  
         [0011]      FIG. 1  is a perspective view of a nursery container having a label of the present invention.  
         [0012]      FIG. 2  is a perspective view of a nursery container having a label of the present invention.  
         [0013]      FIG. 3  is a perspective view of a nursery container having a label of the present invention.  
         [0014]      FIG. 4  is a perspective view of a nursery container having a label of the present invention being peeled off of the container.  
         [0015]      FIG. 5  is a cross-section view of a label of the present invention.  
         [0016]      FIG. 5A  is a cross-section view of a layer of the label of the present invention.  
         [0017]      FIG. 6  is a schematic detailing a method for making a label of the present invention.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0018]     Referring to  FIGS. 1-5 , an embodiment of a label  10  according to the present invention is shown on a nursery container  12 . The label includes a protective first layer  14  and a second label layer  16 . The second layer  16  is preferably removably adhered to the container  12 . The first layer  14  overlays the second layer  16  and is removably adhered to the container  12  and/or the second layer  16 . As shown, the first layer  14  is larger than the second layer  16 . However, the first layer  14  can have the same or smaller dimensions than the second layer  16 .  
         [0019]     More particularly, the first layer  14  is made from a material that prevents or minimizes water or other environment/chemical seepage through the layer (e.g., is a moisture and chemical barrier or inhibitor). In one embodiment, the first layer  14  is made from a polyester material. Preferably the material is opaque or semi-transparent (translucent) so as to provide differentiation from the second layer  16 . This provides some degree of assurance that the first layer  14  will not be inadvertently left on the second layer when sold by the nursery owner. It is also preferable that the first layer permit writing on it, such as with a marker. This gives the nursery owner or the container manufacturer the ability to mark the label without damaging the second layer.  
         [0020]     A material suitable for the first layer is Fasson® 2 Mil White Polyester TC/S730/50# SCK ABC, sold by Fasson Roll North America. This material is a white facestock with good tear strength, heat resistance, dimensional stability, opacity and chemical resistance.  
         [0021]     While the figures illustrate an opaque layer with no markings on it, it is also contemplated that the first layer may include printing, such as the manufacturer&#39;s name, or indicia that assists in tracking/inventorying the container (e.g., bar coding).  
         [0022]     The second layer  16  is designed to provide the labeling. As such, the second layer  16  is preferably made from a material that can accept printing. One preferred label material is Fasson® 1 Mil Clear Polyester TC/S730/50# SCK ABC. This material is a transparent film with good tear strength, heat resistance, dimensional stability and chemical resistance. This material is also designed for printing with most solvent and some water-based flexographic inks.  
         [0023]     The labeling system of the present invention requires that the first layer  14  be removable so as to permit viewing of the second layer  16 . Thus, the first layer  14  must be attached to the container  12  and/or the second layer  16  in a manner that would permit the first layer  14  to be easily removed without removing the second layer  16 . This is accomplished through the use of a first adhesive layer  18 , which will be discussed in more detail below.  
         [0024]     The second layer  16  is attached to the container  12  with a base adhesive  20 . Since the second layer  16  is likely to be removed from the container by the end user and thus is not likely to be subject to frequent growing seasons, the adhesive need only last until the container  12  is sold to the end user. While the second label  16  may be made to stay permanently on the container, it is preferable that the base adhesive  20  permits the second label  16  to be removed from the container  12  at some point after sale to the end user.  
         [0025]     While a nursery owner prefers to include a label on its container when it is sold, the nursery owner would prefer that the label is removed by the end user after the container is sold. As our society becomes more and more conscience of the benefits of recycling, it also becomes more conscience of companies and individuals that do not do their part in the recycling effort. Once a container leaves a nursery, the nursery owner has no control over the container. Hence, while the nursery owner may be environmentally conscious and an advocate of recycling, the end user of the product in the container may not be. If the end user tosses a container into the trash with the nursery owner&#39;s company logo on it, people who see the container naturally think negatively of the nursery owner&#39;s recycling habits even though the nursery owner had nothing to do with the container being discarded.  
         [0026]     The present invention addresses this problem by selecting a base adhesive  20  that permits the second layer  16  to be removed. Most nursery containers are made from polyethylene material which has natural oils in it. As such, a permanent adhesive can be used as the base adhesive  20  to attach the second label  16  to the container  12 . The natural oils reduce the permanence of the permanent adhesive, thus permitting the second label  16  to be removed relatively easily. One preferred form of permanent adhesive is S 730  adhesive. S 730  adhesive is a clear adhesive featuring good initial tack, high shear, minimal cold flow and will adhere to a wide variety of substrates.  
         [0027]     However, as should be apparent, the choice of adhesive will depend on several factors, including the container material and the label material. It is contemplated that pressure sensitive materials (e.g, pressure sensitive adhesives) can also be used.  
         [0028]     In order to encourage the end user to remove the second layer, it is preferable to include planting instructions that are visible from the inside surface  22  of the second layer  16 . The outside surface  24  could include a form of indicia  26  informing the purchaser that the reverse side includes important information. Once the user pulls off the second layer  16 , it will likely be discarded.  
         [0029]     As discussed above, the protective first layer  14  is attached to the container and/or the second layer  16  so as to be removable without removing the second layer  16 . The degree of adhesion of the first layer  14  to the container  12  and/or the second layer  16 , should be less than the adhesion provided by the base adhesive  20 . This can be achieved by selecting an adhesive for use as the first adhesive  18  that has less adhesive strength than the base adhesive  20 .  
         [0030]     Alternately, if the first layer  14  is adhered to only the container  12  and not the second layer  16 , then any suitable type of adhesive can be used. For convenience, the first adhesive  18  can be the same as the base adhesive  20 . There are various ways to prevent the first adhesive  18  from adhering to the second layer  16 , such as coating the second layer  16  with a release layer  19 , pattern applying the first adhesive  18  such that the first adhesive is not present on the portion of the first layer  14  that overlays the second layer  16 , or deadening the first adhesive  18 , such as with a varnish, in the area overlaying the second layer  16 . Those skilled in the art would be readily capable of configuring the first adhesive  18  in light of the teachings provided herein.  
         [0031]     Referring to  FIG. 5A , the second layer includes a transparent polyester layer  25 , and at least one print layer  27 , which can be applied through reverse printing. Preferably there are a plurality of print layers  28 ,  30 . At least one layer  28  includes printing that forms the image and/or text that is visible on the outside surface  24  of the second layer  16 . This may be, for instance, the ink that forms the nursery owner&#39;s logo or other marketing information.  
         [0032]     At least one layer  30  includes printing that forms the image and/or text that is visible on the inside surface  22  of the second layer  16 . This may be, for instance, the ink that forms the instructions for planting.  
         [0033]     Referring now to  FIG. 6 , a schematic representation of the process  100  for forming the label  10  in accordance with one embodiment of the invention is shown. The process involves transferring the material  102  that forms the second layer  16  on a carrier through the reverse printing application stages  104 . The formation of reverse printing on a substrate is well known in the printing art and, thus, no further details are necessary. The second layer material  102  is then transferred through a stage  106  where the base adhesive  20  is applied. The material  102  is then transferred through a die cutting station  108  where the shape of the second layer  16  is cut from the material  102 . The remaining matrix  110  of the material  102  is removed and discarded.  
         [0034]     If a release layer  19  is applied between the first and second layers  14 ,  16 , it may be applied  112  to the outside surface of the second layer  16 . The release characteristics can be from chemical release properties and/or mechanical release properties. Migratory, non-migratory, and reacted-in slip agents provide chemical release properties to the release layer. Examples of slip agents include acids, esters, fatty acid amines, and natural wax. Inorganic additives can provide mechanical release properties to the release layer. Examples of inorganic additives include calcium carbonate, synthetic silica, synthetic clay, talc, zeolite, and ceramic and glass spheres.  
         [0035]     The material  114  that forms the first layer  14  is transferred past an adhesive application station  116  where the first adhesive  18  is applied. If, instead of a release layer being applied between the first and second layers  14 ,  16  the adhesive is deadened, then the material  114  is transferred through a deadening station (not shown), where an adhesive deadening agent is added to the adhesive layer  18  in the region which overlies the second layer  16 . Examples of suitable adhesive deadening agents include silicone and paraffin.  
         [0036]     The material  114  is next brought into register with the second layer  16  and the combination is transferred through a second die cutting station  118  which cuts the first layer  14  from the material  114 . The matrix  120  of material  114  is removed and discarded, leaving the first layer  14  on top of the second layer  16 . The carrier then is either wound in combination with the labels  10  for storing the labels  10  for later use, or transfers the labels  10  to an application station where the labels  10  are applied to a nursery container.  
         [0037]     In an alternate embodiment of the invention, the second layer  16  is applied to the container  12  during the container molding process using an in-mold labeling system. In-mold labeling systems are well known in the art. As such, a detailed discussion is not necessary. Generally, the process involves placing a label on the inside surface of the mold and then molding the product such that the moldable material forming the product surface adheres with the label. In the present case, the second layer  16  is placed within the mold against the mold inner surface. A parison of plastic is extruded into the mold and blown against the mold surfaces using a conventional blow molding method. The second label adheres to the surface of the container  12 .  
         [0038]     Once the container  12  is released from the mold, the protective first layer  14  is applied over the second layer  16 . As described above, the first layer  14  can adhere to the second layer  16  or the container  12 . Due to the relatively rigid adherence of the second layer to the container using the in-mold processing, a variety of adhesives can be used as the first adhesive  18 .  
         [0039]     In this embodiment of the invention, the second layer (i.e., the printed label) is preferably made from a multilayer plastic material or a high-density polyethylene fibrous material, such as TYVEK® material. TYVEK is a registered trademark of DuPont Company, Wilmington, Del. Alternate materials can be used. The materials would be selected based on the container material. Those skilled in the art of labeling would readily appreciate the diverse materials that can be used to form a second layer for adherence to a nursery container using an in-mold labeling process.  
         [0040]     One of the benefits of this embodiment of the invention is that a base adhesive layer is not necessary for adhering the second layer to the container. Instead, the molding process itself results in the adherence of the second layer.  
         [0041]     The above describes two alternate methods for forming a label in accordance with the present invention. Those skilled in the art would readily appreciate that various modifications can be made to these processes without departing from the scope of the invention. For example, the base adhesive can be applied after the first and second layer are brought into registry with one another.  
         [0042]     It will be appreciated by those skilled in the art that the present invention may be practiced in various forms and configurations. The previously detailed description of the disclosed embodiments is presented for purposes of clarity of understanding only, and no unnecessary limitations should be implied therefrom.