Patent Publication Number: US-10332428-B2

Title: Wrap-around expanded content label

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to labels, and more particularly to expanded content labels configured to wrap around a curved surface. 
     Expanded content labels provide a simple and effective means for securing relatively large amounts of printed information to a product or its packaging. They often replace leaflets and other materials otherwise packaged with products. A typical expanded content label (ECL) includes a booklet or leaflet that is either secured directly to the product or to a base label that is in turn secured to the product. The booklet is pre-printed with information such as instructions, product warnings, or ingredients. 
     A challenge is presented when expanded content labels are applied to curved surfaces, such as cans or bottles. An expanded content label has thickness, and consequently the layers have different radii of curvature when the label is mounted on a curved surface. Typically, the layers are intersecured in at least one of the longitudinal and lateral directions. Consequently, at least one of the layers may buckle or wrinkle when one attempts to secure the label to a can or bottle. This effect can prevent the label from being smoothly secured to the can or bottle, presenting an unsightly and otherwise unacceptable situation. In addition, the strain on the booklet may cause the label to pop open or to peel away from the container. 
     Another common type of label is a simple “glue-label” or “glue-applied label.” Used widely in the canned food industry, a glue-applied label typically includes a single layer of printed paper adhered to a surface using a traditional “sheet fed” manufacturing process. Conventional glue, such as a hot melt adhesive, is used to secure the label to the container, can, bottle, etc. Glue-applied labels are considered to be the least expensive to produce and apply of all container labels and are therefore preferred for high volume applications. 
     Adding booklets and leaflets to traditional glue-applied labels could add information to labels. However, adding a booklet or leaflet to a glue-applied label applied to a curved or cylindrical surface presents the problems noted above. 
     SUMMARY OF THE INVENTION 
     The noted problems are addressed by the present invention providing an expanded content label that enables the entire label to readily conform to a curved surface. The present wrap-around ECL permits the label, including the booklet, to more effectively move and conform to the curved surface. 
     In one embodiment, the wrap-around ECL includes a base label free of adhesive, a booklet, and an overlaminate having a pressure sensitive adhesive layer on an underside thereof. The overlaminate overlies and adheres to the booklet, and first and second lateral portions of the overlaminate extend beyond the edges of the booklet and adhere to the base label. The first lateral portion of the overlaminate is substantially permanently bonded to the base label in the area adjacent a bound edge of the booklet to provide a hinge between the booklet and the base label. The second lateral portion of the overlaminate is resealably bonded to the base label in the area adjacent a free lateral edge of the booklet, enabling the booklet to be opened. 
     The base label may include a release coating in at least the area of the second lateral portion of the overlaminate to provide the releasability. 
     The booklet may include a base sheet not adhered to the base label. This arrangement enables the base sheet to move and conform to a curved surface to reduce buckling or wrinkling when the label is wrapped around a curved container. 
     A method of manufacturing and applying a wrap-around ECL includes providing a continuous web of base label stock to form a plurality of base labels having upper and lower surfaces, the lower surface being free of adhesive; placing a booklet on the upper surface of the base label; applying an overlaminate having adhesive on a lower surface thereof, the overlaminate overlying and adhering to the booklets and the base label; die cutting the overlaminate and the booklets; and stripping the resulting waste matrix. 
     The wrap-around ECL reduces buckling and wrinkling. 
     These and other features and advantages of the invention will be more fully understood and appreciated by reference to the entire application including the specification, the claims, and the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a wrap-around expanded content label applied to a container; 
         FIG. 2  is a perspective view of the wrap-around expanded content label affixed to the container, illustrating a booklet of the label partially open; 
         FIG. 3  is a top plan view of the wrap-around expanded content label; 
         FIG. 4  is a cross-sectional view of the wrap-around expanded content label; and 
         FIG. 5  is a cross-sectional view of the wrap-around expanded content label, illustrating the label as applied to a container. 
     
    
    
     DESCRIPTION OF THE CURRENT EMBODIMENTS 
     I. Structure 
     A wrap-around expanded content label (ECL)  10  for use with a curved or cylindrical container  12  in accordance with one embodiment is illustrated in  FIGS. 1-5 . The wrap-around expanded content label  10  includes an easy open, resealable booklet that is adapted for use on curved surface, for example cylindrical consumer products such as spray paint, pesticide spray, or other products provided in but not limited to aerosol cans. The label  10  may include a multi-page booklet and provides an all-in-one label useful for regulatory information, coupons, and more. Of course, it should be understood that the label  10  can also readily be applied to and used on a flat container or surface. 
     The wrap-around expanded content label  10  includes a base label  14 , a booklet  16 , and a protective overlaminate  18  adhered to both the booklet  16  and the base label  14 . The base label  14  may be provided in a roll, strips, or sheets and has upper and lower surfaces  30  and  32 , and first and second opposed edges  34  and  36 . The distance between the edges  34  and  36  defines a base label length that enables the edges  34  and  36  to overlap and form a lap seal  38  when the label  10  is wrapped around a container  12 . The lower surface  30  of the base label  14  is free of adhesive and the base label  14  can be manufactured from many materials, including polypropylene, paper, plastic, foil, metals, and the like. The base label  14  may also include indicia printed thereon. Additionally, the base label  14  includes an eye mark  39  (see  FIG. 3 ) printed or otherwise marked on the upper surface  30  and/or the lower surface  32  to mark and trigger cutting the edge  34 ,  36  of the label  10  later in the application process, as discussed below. 
     Booklet  16  is generally well known to those having skill in the ECL art and may include a plurality of pre-printed pages that are folded or bound together using conventional methods. The booklet  16  is pre-printed with product ingredients, directions, installation instructions, product warnings, coupons, advertisements, and/or other information. The booklet  16  overlies the upper surface  30  of the base label  14  and includes longitudinally opposed bound and free lateral edges  40  and  42 , respectively. The booklet  16  includes a top sheet  44  that has a tab  46  that extends from the free lateral edge  42 . To open the booklet  16 , a user may lift the tab  46  to unseal the top sheet  44  as described below. 
     The booklet  16  may include more one or more interior sheets  48  and a base sheet  50 . The free edges  42  of all booklet sheets, other than the top sheet  44 , are generally aligned with one another. The free edge  42  of the top sheet  44  extends longitudinally beyond the other sheets so that overlaminate  18  does not adhere directly to the other sheets. The base sheet  50  is not adhered to the base label  14 . This enables the base sheet  50  to move and conform to a curved surface and reduces buckling and wrinkling of the booklet  16  and/or base label  14 , as described below. While the present invention is described in conjunction with a booklet, other constructions, such as leaflets, can be readily substituted therefor. 
     Overlaminate  18  includes first and second lateral portions  60  and  62  and upper and lower surfaces  64  and  66 . The lower surface  66  of the overlaminate  18  includes a pressure-sensitive adhesive layer  68  and the overlaminate  18  overlies and is adhered to the booklet  16 . Further, the first and second lateral portions  60  and  62  extend laterally beyond the booklet  18  and overlie the base label  14 . The first lateral portion  60  of the overlaminate  18  is substantially permanently bonded to the base label  14  in an area adjacent the bound lateral edge  40  of the booklet  16 . The second lateral portion  62  of the overlaminate  18  is resealably bonded to the base label  14  in an area adjacent the free lateral edge  42  of the booklet  16 . 
     Overlaminate  18  may be a transparent material which enables viewing of material printed on the top sheet  44  of the booklet  16 . Suitable materials and adhesives for the overlaminate  18  are well known to those having ordinary skill in the ECL art. Optionally, the overlaminate  18  may also include indicia printed thereon. Further, any suitable adhesive may be used on the lower surface of the overlaminate, and is not limited to pressure-sensitive adhesive. 
     The wrap-around expanded content label  10  may include a release coating  70  on the base label  14 . The upper surface  30  of the base label  14  is covered with a release coating  70  in at least the area of the second lateral portion  60  of the overlaminate  18 . Optionally, the release coating  70  covers substantially the entire upper surface  30  of the base label  14 , but is void in the area of the first lateral portion  60  of the overlaminate  18 . The absence of release coating  70  under the first lateral portion  60  of the overlaminate  18  enables the overlaminate  18  to substantially permanently bond to the base label  14 . 
     The base label  14  includes release coating  70  under the second lateral portion  60  of the overlaminate  18 , adjacent the free lateral edge  42  of the booklet  16 , so that the overlaminate  18  is resealably bonded to the base label  14  in this area. Additionally, the booklet tab  46  extends over the release coating  70  so that the booklet top sheet  44  and the second lateral portion  62  of the overlaminate  18  can be unsealed to open the booklet  16 . The release coating or agent reduces the degree of adhesion between the pressure sensitive adhesive  68  on the overlaminate  18  and the base label  14 , enabling the second lateral portion  62  of the overlaminate  18  (and booklet top sheet  44 ) to be readily peeled back while the first lateral portion  60  remains adhered to the base label  14 . Further, the release coating  70  may be applied in a pattern in the area under the overlaminate second lateral portion  62 , enabling the overlaminate  18  to be resealed to the base label  14  and the close the booklet  16 . The release coating  70  may also be either void or applied in a pattern in the area that will later become the lap seal  38 , so that the base label  14  will remain affixed to itself once applied to a container. As is well known in the art, a silicone material may be used as the release coating or agent. 
     The wrap-around expanded content label  10  is configured to wrap around a container  12 . The label  10  is secured to the container  12  with adhesive (not shown) applied to the lower surface  32  of the base label  14  at the time the label  10  is affixed to the container  12  during a typical roll-fed labeling manufacturing process. In one exemplary use, the wrap-around expanded content label  10  is used on curved consumer products such as spray paint, pesticide spray, or other products typically provided in aerosol cans. Because the booklet  16  is not adhered directly to the base label  14 , the booklet  14  is free to flex and conform to a curved surface. Placing the booklet  14  over a non-adhesive area enables the booklet  14  to conform to the surface without buckling and wrinkling. 
     II. Method of Production and Application 
     A method for producing the wrap-around expanded content label in accordance with the above described embodiment will now be described in connection with  FIGS. 1-5 . While it is possible to produce labels one at a time, the presently preferred method is to produce a plurality of labels on a continuous roll of completed labels. 
     The method begins with a continuous web of base label stock that is free of adhesive. A release coating  70  is applied to the upper surface  30  of the base label  14 . A void is provided in the release coating  70  in the area that will align with the first lateral portion  60  of the overlaminate  18  when later applied. Further, the release coating  70  may be applied in a pattern, and optionally may be applied in a pattern only in the area where the second lateral portion  62  of the overlaminate  18  will align. 
     Next, the booklet  16  is aligned and placed on the upper surface  30  of the base label  14 . No adhesive secures the booklet  16  to the base label  14 , enabling the booklet  16  to move freely with respect to the base label  14 , which is relevant when the completed label  10  is affixed to a curved surface. 
     Overlaminate  18  is applied directly over the base label  14  and booklet  16  such that the adhesive  68  on the lower surface  66  adheres to the base label  14  and booklet  16 . As illustrated in  FIG. 4 , adhesive  68  on the lower surface  66  of overlaminate  18  secures the booklet  16  to the base label  14 . 
     The assembly is die cut through the overlaminate  18  and booklet  16  down to, but not through the base material, using conventional methods and the offal, or waste matrix, is stripped away to form the finished overlaminate  18  and booklet  16 . The release coating  70  on the base label  14  enables the overlaminate  18  to be removed from the base label  14 . This die-cutting step forms (1) finished edges around the perimeter of the overlaminate and (2) finished edges on the upper and lower longitudinal edges of the booklet  14 . Of note, the bound and free lateral edges  40  and  42  of the booklet  16  are not die cut in this process. A continuous roll of wrap-around expanded content labels  10  with uncut first and second edges  34  and  36  is supplied. 
     The continuous web of labels  10  is supplied to conventional label application machinery in a conventional fashion. Roll-fed labels  10  are fed and cut in precise registration using the printed graphic or eye mark  39  to form the first and second edges  34  and  36  of the base label  14 . The cutting machinery is triggered to cut by the eye mark  39  on the base label  14 . The cut label  10  is transferred to a rotating vacuum drum and a hot melt adhesive is applied to the label  10  using a rotating glue wheel. The adhesive is applied to the lower surface  32  of the base label  14  along the horizontal axis. Cut labels with adhesive are then applied to individual containers which are rotated until the base label  14  overlaps itself, to create the lap seal  38  and complete the label application process. Of course, other manufacturing methods, glues, glue patterns, etc. may be used to affix the label to a container, including a container having a substantially flat surface. 
     The completed wrap-around expanded content label  10  facilitates application of the label  10  to a curved surface, such as an aerosol can  12  or bottle. As the label  10  “rolls” around the curved container  12 , the booklet  16  is free to move relative to the base label  14  so that the booklet  16  is more flexible in conforming to the curved shape. Consequently, the booklet  16  and label  10  readily conform to the curved surface. 
     The above descriptions are those of current embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. Any reference to elements in the singular, for example, using the articles “a,” “an,” “the,” or “said,” is not to be construed as limiting the element to the singular.