Abstract:
A resealable label includes a leaflet having an upper surface and a base tab disposed adjacent the leaflet. The base tab includes a closure portion and a pull tab portion each having an upper surface and a lower surface. The closure portion and the pull tab portion are separated from one another by a cut line therebetween. A varnish coats the upper surface of the closure portion. The label further includes a laminate cover including a first laminate portion overlying the closure portion, a second laminate portion overlying the pull tab portion, and a third laminate portion overlying the leaflet. The label further includes a laminate adhesive including a first adhesive portion releasably and resealably securing the first laminate portion to the varnish on the upper surface of the closure portion, and a second adhesive portion securing the second laminate portion to the upper surface of the pull tab portion. A closure portion adhesive coats the lower surface of the closure portion. The lower surface of the pull tab is substantially free of adhesive.

Description:
RELATED APPLICATIONS  
       [0001]    This application claims the benefit of priority of U.S. Provisional Application Serial No. 60/205,358, filed May 18, 2000, the disclosure of which is incorporated herein by reference in its entirety. 
     
    
     
       FILED OF THE INVENTION  
         [0002]    The present invention relates to labels and, more particularly, to resealable extended text labels.  
         BACKGROUND OF THE INVENTION  
         [0003]    In the packaging of certain chemicals and pharmaceuticals, the manufacturer is often required or desires to provide a considerable amount of information concerning the chemical or pharmaceutical. In the case of pharmaceuticals, this is required by government regulations, however, the occasion may also arise, either separate from or in conjunction with government regulations, to provide the doctor, pharmacist or user with instructions on how the product should be used, what the product is, and safety precautions which should be followed in the use of the product. Similarly, it is often desirable to provide information in multiple languages so that a given product or packaging may be distributed in multiple locations or regions.  
           [0004]    Sometimes the literature, which is generally in the form of folded leaflets, is placed within a box along with the container carrying the chemical or pharmaceutical (referred to as “inserts”). The placement of leaflets within the box is expensive and a cumbersome operation to perform. Also, it is difficult to insure by later inspection that the proper literature has been inserted in the proper package. Most all products are packaged in outer cartons and many are not compatible with inserts. Further, the use of folded cartons is under scrutiny by environmental groups, as involving excessive packaging. In an effort to meet this challenge, many companies seek alternatives to folding cartons that carry containers inside.  
           [0005]    A different approach to solving this problem has developed over the last several years in which the folded literature is releasably attached to the face of the container (referred to as “outserts”), either directly to the container itself, or to a base label which, in turn, is secured to the container. The literature may then be removed by the customer. In such cases, the portion of the label remaining must carry both an “identification” of the product, for example, information such as trademark, manufacturer, etc., as well as certain “statutory information” (for example, lot number and expiration date).  
           [0006]    It is often desirable to provide an extended text label with resealability. Resealability may allow the user to open the label, inspect or remove the interior pages thereof, and thereafter reclose and reseal the label. The interior pages, if not removed, may then be referred to again later. Additionally, the various panels of the label are retained in a closed configuration so that they do not dangle and interfere with the handling of and detract from the appearance of the associated article.  
         SUMMARY OF THE INVENTION  
         [0007]    According to embodiments of the present invention, a resealable label includes a leaflet having an upper surface and a base tab disposed adjacent the leaflet. The base tab includes a closure portion and a pull tab portion each having an upper surface and a lower surface. The closure portion and the pull tab portion are separated from one another by a cut line therebetween. A varnish coats the upper surface of the closure portion. The label further includes a laminate cover including a first laminate portion overlying the closure portion, a second laminate portion overlying the pull tab portion, and a third laminate portion overlying the leaflet. The label further includes a laminate adhesive including a first adhesive portion releasably and resealably securing the first laminate portion to the varnish on the upper surface of the closure portion, and a second adhesive portion securing the second laminate portion to the upper surface of the pull tab portion. A closure portion adhesive coats the lower surface of the closure portion. The lower surface of the pull tab is substantially free of adhesive.  
           [0008]    The label may include a leaflet base adhesive coating a lower surface of the leaflet, wherein the leaflet base adhesive and the closure portion adhesive define an adhesive-free gap therebetween. The base tab may be disposed substantially immediately adjacent the leaflet and be separated therefrom by a second cut line, the second cut line overlying the adhesive-free gap.  
           [0009]    The leaflet may include a bottom panel and a top panel overlying and joined to the bottom panel along a fold, the upper surface of the leaflet being an upper surface of the top panel. The base tab is disposed adjacent the fold.  
           [0010]    The label may include a second base tab disposed adjacent an end of the leaflet opposite the base tab and a tab adhesive coating a lower surface of the second base tab. The laminate cover includes a marginal laminate portion overlying the second base tab. The laminate adhesive includes a marginal adhesive portion securing the marginal laminate portion to an upper surface of the second base tab. A second varnish may coat the upper surface of the second base tab, whereby the marginal adhesive portion releasably and resealably secures the marginal laminate portion to the second varnish on the upper surface of the second base tab.  
           [0011]    According to method embodiments of the present invention, a method for forming a resealable label includes providing a leaflet and forming a first cut line in the leaflet to form a leaflet portion and a base tab portion. A second cut line is formed in the base tab portion to form a closure portion and a pull tab portion. A lower surface of the closure portion is coated with a closure portion adhesive such that a lower surface of the pull tab portion remains substantially free of adhesive. An upper surface of the closure portion is coated with a varnish. A laminate web is applied over the leaflet portion, the closure portion and the pull tab portion such that the laminate web is adhered to at least the varnish coated upper surface of the closure portion and an upper surface of the pull tab portion.  
           [0012]    Objects of the present invention will be appreciated by those of ordinary skill in the art from a reading of the figures and the detailed description of the preferred embodiments which follow, such description being merely illustrative of the present invention.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]    [0013]FIG. 1 is an exploded, perspective view of a label according to the present invention disposed on a release liner;  
         [0014]    [0014]FIG. 2 is a perspective view of the label of FIG. 1 disposed on a release liner and in a stored position;  
         [0015]    [0015]FIG. 3 is a perspective view of the label of FIG. 1 mounted on an article and in an open position;  
         [0016]    [0016]FIG. 4 is a top view of a leaflet blank for forming the label of FIG. 1;  
         [0017]    [0017]FIG. 5 is a top view of the release liner with adhesive patches disposed thereon in accordance with a method according to the present invention for forming the label of FIG. 1;  
         [0018]    [0018]FIG. 6 is a top view of an intermediate construction according to the method of the present invention for forming the label of FIG. 1;  
         [0019]    [0019]FIG. 7 is a schematic diagram of an apparatus for forming the label of FIG. 1;  
         [0020]    [0020]FIG. 8 is an exploded, perspective view of a label according to a further embodiment of the present invention disposed on a release liner;  
         [0021]    [0021]FIG. 9 is a perspective view of the label of FIG. 8 disposed on the release liner and in a closed position; and  
         [0022]    [0022]FIG. 10 is a side elevational view of the leaflet and laminate cover of the label of FIG. 8 in a re-closed position. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0023]    The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout. The thicknesses of various layers may be exaggerated for clarity.  
         [0024]    With reference to FIGS.  1 - 3 , a label  100  according to embodiments of the present invention is shown therein disposed on a release liner  102 . The label includes adhesive patches  110 ,  112  and  114 , a leaflet  130 , a base tab  140 , a base tab  120 , and a self-adhesive laminate cover  150 . The label  100  may be mounted on an article, for example, the article  107  (see FIG. 3) by means of the adhesive patches  110 ,  112 ,  114 . The label  100  may thereafter be transitioned from a stored position as shown in FIG. 2 to an open position as shown in FIG. 3 (wherein the label  100  is shown partially open), as discussed in detail below. For the purposes of explanation, the label  100  has a lengthwise axis A-A (see FIG. 2).  
         [0025]    The adhesive patches  110 ,  112 ,  114  are preferably formed of a pressure-sensitive adhesive. Suitable pressure-sensitive adhesives include product number HL2203X available from H. B. Fuller Adhesives of Minneapolis, Minn. Preferably, the adhesive patches  110  and  112  form a single, continuous adhesive patch. The adhesive patch  114  is spaced from the adhesive patch  110  to define an adhesive-free gap  149  therebetween. Preferably, the gap  149  has a width G of between about {fraction (1/16)} and ⅜ inch (see FIG. 2). The adhesive patch  114  is truncated such that an adhesive void  115  is defined along an outer corner thereof.  
         [0026]    Preferably, the tab  120  is formed of the same material as the leaflet  130 , as discussed below. More preferably, the tab  120  and the leaflet  130  are formed from adjacent leaflet blanks  130 A (see FIG. 4) as described below. Indicia  127  such as lot and expiration prompts may be printed on the upper surface of the tab  120 .  
         [0027]    As best seen in FIG. 1, the leaflet  130  includes a bottom panel  132  and an interior panel  134  joined to the bottom panel  132  along a fold  133 . A top panel  136  is joined to the bottom panel  132  along a fold  135 . An integral extended flap  141  extends from the top panel  136  beyond the fold  133 .  
         [0028]    A transverse cut line  144  extends through the extended flap  141 . Preferably, the cut line  144  extends substantially perpendicular to the axis A-A and across the entire width of the extended flap  141 . The cut line  144  divides the extended flap  141  into a connected portion  145  which is connected to the top panel  136 , and the base tab  140  which is severed from the top panel  136  by the cut line  144 . A further, angular cut line  148  in the extended flap  141  (and, more particularly, in the base tab  140 ) separates a triangular pull tab portion  146  from a closure portion  142 . Preferably, the cut line  148  forms an angle of about 45 degrees with the cut line  144 . Alternatively, the cut line  148  may be disposed perpendicular to the cut line  144  so that the pull tab portion  146  is rectangular. Indicia  147  such as “PULL” or “LIFT” is printed on the pull tab  146 . Identification, informational or other indicia  137  may be printed on the upper and lower surfaces of the panels  132 ,  134 ,  136 . Indicia (not shown) such as lot and expiration prompts may be printed on the upper surface of the closure portion  142 .  
         [0029]    The closure portion  142  is coated on its rear surface by the adhesive patch  114  and is thereby releasably secured to the release liner  102 . The pull tab  146  overlies the adhesive void  115  so that the rear surface of the pull tab  146  is substantially free of adhesive. The connected portion  145 , the cut line  144  and an inner portion of the closure portion  142  overlie the adhesive-free gap  149  and are therefore also substantially free of adhesive on their lower surfaces.  
         [0030]    A varnish coating  143  is disposed on the upper surface of the closure portion  142 . Preferably, the varnish  143  coats the entirety of the upper surface of the closure portion  142 . The varnish  143  does not substantially coat the upper surface of the pull tab  146 . Suitable varnishes include product number L075 available from Paragon Inks of Boxburn, Scotland.  
         [0031]    The laminate cover  150  is coated on its rear surface by a pressure-sensitive adhesive  152 . A central portion  154  of the laminate cover  150  is adhered to the top panel  136  by an adhesive portion  152 A. A marginal portion  156  of the laminate cover  150  is adhered to the upper surface of the tab  120  by an adhesive portion  152 B. An opposed marginal portion  158  of the laminate cover  150  is adhered to the upper surfaces of the closure portion  142  and the pull tab  146  by an adhesive portion  152 C. Notably, the portion of the adhesive portion  152 C overlying the closure portion  142  engages the varnish  143  and the portion of the adhesive portion  152 C overlying the pull tab  146  directly engages and permanently adheres to the pull tab  146 .  
         [0032]    The laminate cover  150  is preferably formed of a 1.5 mil polypropylene film. Suitable laminate adhesives  152  include emulsion acrylic adhesives. Suitable laminate/laminate adhesive materials include product number  505  from Adhesive Coated Products of Troy, Ohio. The laminate cover  150  may be formed of a transparent material or of an opaque material. If the laminate cover  150  is opaque, then the indicia  147  should be printed on the portion of the marginal portion  158  overlying the pull tab  146 .  
         [0033]    The label  100  may be used in the following manner. The label  100  may be applied to the article  107  (see FIG. 3), for example, by means of the adhesive patches  110 ,  112 ,  114  and using suitable automatic or manual labeling equipment. Initially, the label  100  will be disposed in a stored position as shown in FIG. 2. When the user desires to open the label  100 , the user may grasp the pull tab  146  and the overlying laminate portion  158 . Notably, the pull tab  146  will be convenient to grasp because it is not coated on its rear surface with adhesive. The user may then lift the pull tab  146  upwardly and leftwardly along the axis A-A. As the pull tab  146  is pulled, the adhesive portion  152 C separates from the varnish  143  up to the cut line  144 . Thereafter, the top panel  136  and the central portion  154  of the laminate cover may be freely lifted to access the interior of the leaflet  130 . The closure portion  142  remains with the article  107  while the pull tab  146  remains with the laminate cover  150 . The user may reclose and reseal the label  100  by folding the top panel  136  down and reapplying the adhesive portion  152 C to the varnish  143 .  
         [0034]    Optionally, tear lines may be provided adjacent the fold  135  and between the laminate portions  154  and  156 . Alternatively or additionally, a tear line may be formed adjacent the fold  133 .  
         [0035]    The label may be formed using a method according to the present invention as follows. A multiple-up leaflet blank  130 A as shown in FIG. 4 is provided. The leaflet blank  130 A is preferably formed of a unitary sheet of paper, film or other suitable material. Preferably, the leaflet blank  130 A is cut from a web of such material following the printing and die cutting steps discussed just below.  
         [0036]    The leaflet blank  130 A includes panels  132 A,  134 A, and  136 A corresponding to the panels  132 ,  134  and  136 . The leaflet blank  130 A includes portions  145 A,  142 A,  146 A and  120 A corresponding to the portions  145 ,  142 ,  146  and  120 . Prior to cutting the leaflet blank  130 A, the indicia  127 ,  137 ,  147  are printed thereon. Additionally, cut lines  144 A and  148 A corresponding to the cut lines  144  and  148  are formed in the leaflet blank before the blank is cut from the web. A strip of varnish  143 A corresponding to the varnish  143  extends across the leaflet blank  130 A. The leaflet blank  130 A is folded about fold lines  133 A and  135 A (corresponding to the fold lines  133  and  135 ) to form a multiple-up leaflet  130 B (see FIG. 7) configured generally in the same manner as the leaflet  130  (see FIG. 1).  
         [0037]    With reference to FIG. 7, an apparatus  170  for forming the label  100  is shown therein. The release liner  102  is supplied from an unwind stand  172 . An adhesive applicator  174  prints adhesive patches  110 A,  112 A,  114 A as shown in FIG. 5. Preferably, the adhesive applicator  174  is a flexographic adhesive printer. The adhesive applicator  174  also leaves a pattern of voids  115 A and  149 A corresponding to the adhesive voids  115  and  149 . Suitable adhesive applicators include a FlexoCoat PrintCoat Pattern Applicator, model number HM410, available from FlexoCoat International, Inc.  
         [0038]    The multiple-up leaflets  130 B are applied to the adhesive coated release liner by a leaflet applicator  176 . Suitable leaflet applicators include an Onserter 750 available from Onserts, Inc.—Longford Equipment of Toronto, Canada. More particularly, the leaflet  130 B is applied such that the portion  120 A overlies the adhesive portion  112 A, the panel  132 A overlies the adhesive portion  110 A, the cut line  144 A and the portion  145 A overlie the adhesive void  149 A, the portions  146 A overlie the adhesive voids  115 A, and the portions  142 A overlie the adhesive portions  114 A. Preferably, and as shown in FIG. 6, the leaflets are applied end-to-end and, more preferably, substantially immediately adjacent.  
         [0039]    A self-adhesive laminate web  150 A (corresponding to the laminate cover  150 ) is supplied from an unwind stand  180  and married to the release liner  102  and the multiple-up leaflet  130 B by nip rollers  182 . The laminate web  150 A may be a self-wound self-adhesive web or may be a non-self-adhesive web to which the adhesive is applied on the apparatus  170 .  
         [0040]    A die cutter  184  forms cut lines  101  through the laminate web  150 A, the multiple-up leaflets  130 B, and the adhesive patches  110 A,  112 A,  114 A to form the intermediate construction as shown in FIG. 6. The die cut lines  101  sever a portion of each portion  120 A from the remainder of the corresponding leaflet blank  130 A such that the portion  120 A becomes a part of the adjacent label  100  rather than the label  100  that includes the leaflet formed from the same leaflet blank  130 A. The die cut lines  101  define the respective side by side and seriated labels  100  and preferably substantially intersect the cut lines  144 A and  148 A as shown in FIG. 6. A waste matrix  186  consisting of those portions of the laminate web  150 A, the leaflets  130 B, and the adhesive portions  110 A,  112 A,  114 A outside of the labels  100  is taken up on a wind stand  188 . The labels  100  which remain on the release liner  102  may thereafter be wound onto a roll  190 .  
         [0041]    Optionally, the cut lines  144 ,  148  may be formed in the leaflet  130  or the leaflet  130 B after the leaflet is placed on the web  102  by undercutting through the web  102  and up to the web  150 A, rather than forming the cuts in the blank  130 A prior to folding.  
         [0042]    As a further alternative, the release liner  102  may be replaced with a web including a release liner and an overlying self-adhesive face stock web. In this case, the finished labels will include a coextensive self-adhesive base label.  
         [0043]    With reference to FIGS. 8 and 9, a label  200  according to further embodiments of the present invention is shown therein disposed on a release liner  202 . The label  200  includes an adhesive patch  212 , an adhesive patch  214 , a leaflet  230 , a base tab  220 , a base tab  242  and a self-adhesive overlaminate  250 . The leaflet  230  includes a cut line  244  in its top panel  236  defining the severed base tab  242 . The leaflet  230  corresponds to the leaflet  130  except that no cut line corresponding to the cut line  148  is present and the varnish coating  243  coats the entirety of the base tab  242  separated by the cut line  244 . The laminate cover  250  corresponds to the laminate cover  150 . The adhesive patch  214  corresponds to the adhesive patch  114  except that adhesive is present in the region corresponding to the void  115 . Additionally, no adhesive patch corresponding to the adhesive patch  110  is present, so that the bottom panel  232  of the leaflet  230  directly engages the release liner  202 . Indicia may be printed on the bottom surface of the bottom panel  232 .  
         [0044]    An angular cut line  228  extends through the tab  220  to define a closure portion  222  and a pull tab  226 . A varnish  223  coats the upper surface of the closure portion  222  and an adhesive patch  212  coats the lower surface of the closure portion  222 . Preferably, the adhesive patch  212  does not extend beyond the cut line  228  so that the pull tab  226  is substantially free of adhesive on its undersurface. Indicia  227  such as “LIFT” or “PULL” may be printed on the upper surface of the pull tab  226 .  
         [0045]    The marginal portion  256  of the laminate cover  250  is adhered to the upper surface of the tab  220  by the laminate adhesive portion  252 B. More particularly, a portion of the laminate adhesive  252 B is releasably adhered to the varnish  223  of the closure portion  222  while another portion of the marginal portion  256  is permanently adhered to the upper surface of the pull tab  226 . On the other end of the label  200 , the marginal laminate cover portion  258  is releasably adhered to the varnish coated upper surface of the base tab  242 .  
         [0046]    In use, the label  200  may be secured to an article by means of the adhesive patches  212 ,  214 . When the user wishes to open the label  200 , the user may grasp the pull tab  226  and the overlying portion of the marginal portion  256  and pull the laminate cover  250  upwardly and rightwardly away from the tab  220 . In a manner similar to that described above, the laminate adhesive  252 B will peel away from the varnish  223 . The user may continue pulling the laminate cover  250  away, in which case the top panel  236  and the remainder of the leaflet  230  will separate from the tab  242  along the cut line  244  and the laminate adhesive  252 C underlying the marginal portion  258  will peel away from the varnish  243 . Because the bottom panel  232  is not directly adhered to the article and the central portion  254  of the laminate cover  250  is adhered to the top panel  236  by the laminate adhesive  252 A, the leaflet  230  (with the exception of the portion  242 ) will remain with the laminate cover  250  and will become separated from the article. Accordingly, only the tab  220  (less the pull tab  226 ) and the tab  242  will remain adhered to the article. Optionally, the tab  220  and the tab  242  may be printed with desired indicia (not shown).  
         [0047]    Optionally, the lower surface of the bottom panel  232  may be coated with a release varnish  232 A (see FIG. 10), for example, of the type described above with regard to the varnish  143 . When the leaflet  230  and the laminate cover  250  are pulled away from the article and the tabs  220 ,  242 , the laminate adhesive  252 C on the underside of the marginal portion  258  will remain with the leaflet  230  and will be exposed.  
         [0048]    The user may re-close the leaflet  230  by wrapping the marginal portion  258  about the adjacent end fold of the leaflet  230  and into engagement with the varnish coated surface of the bottom panel  232  as shown in FIG. 10. When the user desires to inspect the interior pages of the leaflet  230 , the user may reopen the leaflet  230  by peeling the laminate adhesive  252 C and the marginal portion  258  away from the varnish coated lower surface of the bottom panel  232 . In order to facilitate reopening, the tab  242  may be formed in the same manner as described with regard to the tab  142 . In this way, a pull tab corresponding to the pull tab  146  may be provided between the marginal portion  258  and the bottom panel  232  for grasping by the user to begin peeling the marginal portion  258  away.  
         [0049]    The exposed laminate adhesive  252 B and the marginal portion  256  may also be wrapped about the adjacent fold of the leaflet  230  and into engagement with the bottom panel  232 , as shown in FIG. 10, irrespective of whether a release varnish is provided on the underside of the bottom panel  232 . The varnish coating  232 A may or may not extend across the portion of the bottom panel  232  engaged by the laminate adhesive  252 B.  
         [0050]    Suitable means and methods for forming the label  200  will be apparent to those of ordinary skill in the art upon a reading of the foregoing description.  
         [0051]    According to further embodiments of the present invention, labels may be formed which include the pull tab arrangement as described with regard to the label  100  and, on an opposing end, the pull tab arrangement as described with regard to the label  200 . Labels according to these further embodiments may be opened from either end as selected by the user.  
         [0052]    It will be appreciated from a reading of the foregoing that various modifications may be made to the labels as described herein. For example, the leaflets  130 ,  230  may be configured in booklet form. For example, rather than the interior panel  134  being joined to the bottom panel  132  along a fold  133 , the panel  134  (as well as additional panels) may be glued or stapled along the fold  135 . The interior and/or bottom panels may be omitted so the leaflet includes only a top panel and a bottom panel or only a top panel.  
         [0053]    The foregoing is illustrative of the present invention and is not to be construed as limiting thereof. Although a few exemplary embodiments of this invention have been described, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Therefore, it is to be understood that the foregoing is illustrative of the present invention and is not to be construed as limited to the specific embodiments disclosed, and that modifications to the disclosed embodiments, as well as other embodiments, are intended to be included within the scope of the appended claims. The invention is defined by the following claims, with equivalents of the claims to be included therein.