Patent Publication Number: US-8540839-B2

Title: Method of making resealable multi-ply labels

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a division of U.S. patent application Ser. No. 12/722,229 filed Mar. 11, 2010, which application is hereby incorporated by reference. 
    
    
     TECHNICAL FIELD 
     The invention relates to multi-ply labels, particularly resealable multi-ply labels, providing additional printable label space beyond the footprint dimensions of the labels and to manufacturing methods for constructing such labels along inline presses. 
     BACKGROUND OF THE INVENTION 
     The amount of space available for the labels on products or product packaging can be less than the amount of space that is needed for conveying a desired amount of information to consumers. Such products, which include pharmaceuticals and cosmetics, often require additional label space for listing ingredients, directing usage, and otherwise fulfilling regulatory requirements. Additional label space is also useful for such purposes as brand promotion. 
     Multi-ply labels provide additional label space by incorporating overlapping printable surfaces within an articulated structure that allows the overlapping printable surfaces to be relatively moved into positions for viewing. For example, panels can be hinged and swung into view for revealing a back side of the swung panels as well as the front side of any panel immediately beneath. The panels can be fan-folded or otherwise bound together and released for unfolding or pivoting into view. Resealable multi-ply labels include reusable bonds that allow interior panels to be released from a closed position for viewing and restored to the closed position with the reusable bonds intact. 
     Resealable multi-ply labels of this sort are disclosed in U.S. Pat. No. 6,749,916 to Matthews et al., which is commonly owned with this application. The known resealable multi-ply labels, which are sold under the trade name EasyTab® labels, include three primary substrates (referred to as plies) that are mounted on a carrier web prior to their application to articles. The three plies include a base label ply, an upper label ply, and an overlaminate. The base label ply includes an adhesive layer for mounting the labels to articles. The adhesive layer of the base label ply also temporarily holds the labels on a release surface of the carrier web. The overlaminate also includes an adhesive layer that bonds the overlaminate to areas of both the upper label ply and the base label ply. The upper label ply is die cut leaving a main area and an offset tab area, which are both permanently bonded to the overlaminate. Cut away sections of the upper label ply expose areas of the base label ply, namely, a hinge area and an attachment area. The base label ply, with the exception of the hinge area, is covered by a release layer. Accordingly, the adhesive layer of the overlaminate forms a permanent bond with the hinge area of the base label ply and forms a reusable bond with the attachment area of the base label ply. 
     The overlaminate can be clear, i.e., transparent or at least translucent, to reveal printing on the topside of the upper label ply, which largely corresponds to the printed area of a conventional label. In addition, the overlaminate together with the bonded upper label ply can be released from the attachment area of the base label ply and pivoted about the hinge area of the base label ply for revealing printing on the underside of the upper label ply and on the topside base label ply. A tab, which is formed by bonding the offset tab area of the upper label ply to the overlaminate, provides a ready grip for releasing the overlaminate together with the main area of the upper label ply from its reusable bond to the base label ply. The main areas of both the upper label ply and the base label ply function as viewable panels for increasing label space. One or more intermediate printable plies can be affixed in staggered contact with the adhesive of the overlaminate to form a multi-sheet booklet for providing more label space. 
     SUMMARY OF THE INVENTION 
     The invention, among its preferred embodiments, improves upon other resealable multi-ply labels by simplifying the design and manufacture of the resealable multi-ply labels. In contrast to other resealable multi-ply labels, a resealable multi-ply label preferred for the practice of the invention makes additional use of a base label ply and replaces an upper label ply with the face panel of an onsert (e.g. a printable piece carried by one of the plies), particularly for capturing multiple label panels between an overlaminate and the base label ply. A tab, which is affixed to the overlaminate for providing a gripping surface, is drawn from the base label ply instead of from an upper label ply, and a panel, which is also affixed to the overlaminate for providing additional the label space, is drawn from an onsert instead of from the upper label ply. The preferred design eliminates a layer (the upper label ply) while providing more flexibility for accommodating multi-panel onserts. The onserts can be booklets formed by binding a plurality sheets or by folding a single sheet. 
     One version of the invention as a resealable multi-ply label includes a base ply having top and bottom surfaces and an adhesive layer on the bottom surface of the base ply for mounting the resealable multi-ply label to an article. An onsert displays at least one of text and graphics. An overlaminate captures the onsert between the overlaminate and the top surface of the base ply, which includes a hinge area, an attachment area, a tab area, and an intermediate area separating the hinge area from the attachment area. The tab area is separated from the attachment area of the base ply. The bottom surface of the base ply within the tab area of the base ply is effectively devoid of adhesive. The overlaminate permanently bonds to both the hinge area and the tab area on the top surface of the base ply and reusably bonds to the attachment area on the top surface of the base ply. 
     Preferably, the permanently bonded tab area of the base ply provides access (i.e., a finger grip) for releasing the overlaminate from the attachment area of the base ply. The overlaminate is releasable from the attachment area of the base ply and pivotable together with the permanently bonded tab area about the hinge area for accessing the onsert. 
     The onsert preferably has a face panel, and the overlaminate is preferably permanently bonded to the face panel. The overlaminate is preferably transparent or at least translucent for revealing the text or graphics displayed on the face panel. The onsert can include additional panels that are connected together but viewable by folding or unfolding the panels. The overlaminate is releasable from the attachment area of the base ply together with both the permanently bonded tab area of the base ply and the permanently bonded face panel of the onsert and is pivotable about the hinge area for revealing the additional panels of the onsert. 
     Another version of the invention as a method of making a succession of resealable multi-ply labels includes advancing a base web, having a base ply with an adhesive backing carried on a release liner, along an inline press. The adhesive backing on the base ply is deadened within tab areas of a succession of base label plies. In a cutting operation through the base ply, the tab areas are separated from attachment areas of the base label plies. An overlaminate web, which is also advanced along the inline press, is laminated to the base web capturing printable panels between the overlaminate web and the base label plies. The laminating operation forms permanent bonds between the overlaminate web and both the tab areas and hinge areas of the base label plies and forms reusable bonds between the overlaminate web and the attachment areas of the base label plies. A cutting operation through the overlaminate web separates individual resealable multi-ply labels carried along the inline press on the release liner. 
     Before deadening the adhesive backing within the tab areas, the base ply is preferably delaminated from the release liner for exposing the adhesive backing within the tab areas of the base label plies. After deadening the tab areas, the base ply is preferably re-laminated to the release liner for supporting the base ply on the release liner. 
     An intermediate web is also preferably advanced along the inline press and arranged, such as by folding or binding, into the printable panels. The printable panels can be applied to either one of the base web and the overlaminate web in advance of the step of laminating the overlaminate web to the base web. In addition to cutting through the overlaminate web, both the base ply and the printable panels can also be through cut in the same operation to separate the individual resealable multi-ply labels carried along the inline press on the release liner. The same cutting operation can be arranged to intersect the cuts through the base ply that separate the tab areas from the attachment areas for also separating the tab areas from a remainder of the base ply. 
     Preferably, the overlaminate web includes an adhesive backing. A release layer is applied to the attachment areas of the base label plies while excluding the release layer from the tab areas and the hinge areas of the base label plies. The printable panels preferably include a face panel, and the laminating operation preferably includes forming permanent bonds between the overlaminate web and face panel of the printable panels. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING FIGURES 
         FIG. 1  is a cross-sectional side view of a resealable multi-ply label in accordance with the invention, which label is shown carried on a release liner and expanded in thickness for better illustrating its constituent layers. 
         FIG. 2  is a similar cross-sectional side view of the resealable multi-ply label of  FIG. 1  mounted on an object intended for labeling and partially opened to expose interior panels of a onsert that is itself partially unfolded in the view. 
         FIG. 3  is a schematic diagram of an inline web press for constructing a succession of resealable multi-ply labels in accordance with the invention. 
         FIGS. 4A-4F  include cut-away plan views of different stages in the construction of the succession of resealable multi-ply labels along the inline web press of  FIG. 3 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     A resealable multi-ply label  10 , which is depicted in  FIGS. 1 and 2  as example of a type of label envisioned by the subject invention, includes three main plies: a base ply  12 , an onsert  14 , and an overlaminate  16 . In the view of  FIG. 1 , the three plies  12 ,  14 , and  16  of the resealable multi-ply label  10  are shown carried on a release liner  18 , which provides for protecting and transporting the individual resealable multi-ply label  10  or a group of similar resealable multi-ply labels. In the view of  FIG. 2 , the three plies  12 ,  14 , and  16  of the resealable multi-ply label  10  are shown mounted on an object  20  intended for labeling. 
     The base ply  12  has top and bottom surfaces  22  and  24 . The bottom surface  24  of the base ply  12  is covered by a pressure-sensitive adhesive layer  26  for permanently mounting the multi-ply label  10  on objects requiring labeling such as the object  20  shown in  FIG. 2 . Preferably, the pressure-sensitive adhesive layer  26  is a hot melt pressure-sensitive adhesive, but other adhesives could also be used including acrylic, UV curable, solvent based, or water based pressure-sensitive adhesives. Although the object  20  is shown with a planar surface  21 , the multi-ply label  10  is specially adapted for mounting on highly curved surfaces. In particular, a gap  28  is formed in the base ply  12  to adapt the base ply  12  to curved surfaces and to resize the base ply  12  relative to the overlaminate  16  so that the multi-ply label  10  conforms to the object surface without buckling. 
     A small portion  30  of the pressure-sensitive adhesive layer  26  within a tab area  32  of the base ply  12  is deadened or otherwise rendered effectively devoid of adhesive. For example, a varnish can be printed over the pressure-sensitive adhesive layer  26  within a tab area  32  of the base ply  12  to deaden the pressure-sensitive adhesive layer within the tab area  32 . Alternatively, the pressure-sensitive adhesive layer  26  could be applied in a pattern over the bottom surface  24  of the base ply  12  excluding the tab area  32 . The tab area  32  could also be pre-treated so that the pressure-sensitive adhesive layer  26  applied over the entire bottom surface  24  of the base ply  12  does not adhere to the base ply  12  within the tab area  32 . 
     A release layer  34  (e.g., a varnish or silicone material) is pattern-coated on the top surface  22  of the base ply  12  within both an attachment area  36  of the base ply  12  and an intermediate area  38  of the base ply  12 . Areas excluded from coverage of the release layer  34  include the tab area  32  of the base ply  12  and a hinge area  40  of the base ply  12 . The tab area  32  is surrounded on three sides by the attachment area  36 , and the intermediate area  38  separates the attachment area  36  from the hinge area  40 . 
     The overlaminate  16 , which includes top and bottom surfaces  42  and  44 , captures the onsert  14  between the overlaminate  16  and the base ply  12 . Preferably, the overlaminate  16  is made of a clear film but the overlaminate  16  could also be made of paper or other printable materials including polyester, polypropylene, polyethylene, polystyrene, polyolefin, vinyl or acetate. A pressure-sensitive adhesive layer  46  carried on the bottom surface  44  of the overlaminate  16  permanently bonds the overlaminate  16  to both the tab area  32  and the hinge area  40  of the base ply  12 . Preferably, the pressure-sensitive layer  46  is a pressure-sensitive acrylic adhesive, but other adhesives could also be used such as listed for the pressure-sensitive layer  26 . Through the intermediacy of the release layer  34 , the pressure-sensitive adhesive layer  46  of the overlaminate  16  also forms a reusable bond with the attachment area  36  of the base ply  12 . The overlaminate  16  is releasable from the attachment area  36  of the base ply  12  and is pivotable about the hinge area  40  of the base ply  12 . 
     The onsert  14  includes a face panel  52 , a bottom panel  54 , and an extended panel  56 , which are folded together to fit between the overlaminate  16  and the base ply  12  largely within the intermediate area  38  of the base ply  12 . The face panel  52  is permanently bonded to the overlaminate  16  through the pressure-sensitive adhesive layer  46 . Preferably, the overlaminate  16  is optically transmissive, i.e., transparent or at least translucent, for revealing text or graphics printed on the face panel  52 . 
     A cut  58 , e.g., a die cut, through the base ply  12  renders the tab area  32  separable from the surrounding attachment area  36 . Thus, the cutout tab area  32  of the base ply  12  is pivotable together with the overlaminate  16  apart from the remainder of the base ply  12  including the attachment area  36 , intermediate area  38 , and hinge area  40 , which remain affixed to the object  20 . As shown in  FIG. 2 , both the cutout tab area  32  of the base ply  12  and the face panel  52  of the onsert  14  pivot together with the overlaminate  16  about the hinge area  40  of the base ply  12 . Once the overlaminate  16  is released from the attachment area  36  and pivoted about the hinge area  40 , the bottom and extended panels  54  and  56  of the onsert  14  can be unfolded and exposed for viewing. Printing in the form of text or graphics can be applied to opposite side surfaces of the panels  52 ,  54 , and  56  to provide for conveying information, such as about the object  20  or its contents, over an area much larger than the footprint of the multi-ply label  10  on the object  20 . Printing can also be applied to the top surface  22  of the base ply  12 , and the printing within the intermediate area  38  of the base ply  12  can be similarly rendered visible by releasing and pivoting the overlaminate  16 . 
     The cutout tab area  32  of the base ply  12 , as shown affixed to the overlaminate  16  in  FIGS. 1 and 2 , provides a ready grip for releasing the overlaminate  16  from its reusable bond with the attachment area  36  of the base ply. Unlike the remaining areas of the base ply  12 , which include the attachment area  36 , the intermediate area  38 , and the hinge area  40 , the cutout tab area  32  is not bonded to the surface of the object  20 . Thus, the cutout tab area  32  can be readily separated from the surface of the object  20  as a starting point for releasing the overlaminate  16  from the attachment area  36  of the base ply  12 . The combination of the pressure-sensitive adhesive layer  46  of the overlaminate  16  with the release layer  34  on the attachment area  36  of the base ply  12  provides a reusable bond that allows the overlaminate  16  to be resealed to the attachment area  36  of the base ply  12 , preferably over multiple cycles of use. 
       FIG. 3 , together with  FIGS. 4A through 4D , depicts the construction of similar resealable multi-ply labels  60  along an inline press  100 . From an unwinder  102 , a base web  62  of pressure-sensitive label stock is advanced into the inline press  100 . The advancing base web  62  is separated at a delaminator  104  into a release liner web  64  and a base ply web  66  having a pressure-sensitive adhesive backing  68 . Substrates for both the release liner web  64  and the base ply web  66  are preferably made of paper typical of conventional pressure-sensitive label stocks, but other label substrate materials can be used as required for particular labeling applications or environments of use. A pattern printer  106  applies a deadening varnish layer  70  (see  FIG. 4A ) to the exposed pressure-sensitive adhesive backing  68  within designated tab areas  72  on the temporarily inverted base ply web  66 . A re-laminator  108  rejoins the base ply web  66  to the release liner web  64  for advancing together along the remainder of the inline press  100 . 
     A pattern printer  110  applies a release layer  74  (see  FIG. 4B ) to designated attachment areas  76  and intermediate areas  78  of the base ply web  66  in registration with the previously printed deadening varnish layer  70  within the designated tab areas  72  on the opposite side of the base ply web  66 . A die cutter  112  forms U-shaped cuts  80  for separating the tab areas  72  from the adjacent attachment areas  76  of the base ply web  66 . Preferably, both the deadening varnish layer  70  and the release layer  74  slightly overlap the U-shaped cuts  80  so that the cutout tab areas  72  are completely devoid of adhesive and the surrounding attachment areas  76  are completely covered by the release layer  74 . Although not shown, the same or a similar die cut station can be used to cut out gaps within the base ply web  66  between the attachment areas  76  and the intermediate areas  78  for use as an expansion or contraction joint. 
     An intermediate web  82  of printable and foldable stock, also preferably made of paper or other printable materials, is advanced into the inline press  100  from an unwinder  114 . One or more printing stations  116  print desired text or graphics on opposite sides of the intermediate web  82 . A trimming and folding station  118  sizes sections of the intermediate web  82 , folds the sections of the intermediate web  82  together into individual onserts  84 , and applies the individual onserts  84  to the intermediate areas  78  of the base ply web  66  as shown in  FIG. 4C . Face panels  86  of the onserts  84  are preferably printed with information  87  intended to be viewed within the intended footprints of the multi-ply labels  60 . 
     An overlaminate web  88  of pressure-sensitive laminating stock, which includes a pressure-sensitive adhesive backing, is advanced into the inline press  100  from an unwinder  120 . Preferably, the substrate of the overlaminate web  88  is made of a clear film but the overlaminate web  88  could also be made of paper or other printable materials. A laminator  122  laminates the overlaminate web  88  to the base ply web  66  (see  FIG. 4D ) capturing the onserts  84  between the overlaminate web  88  and the base ply web  66 . The pressure-sensitive adhesive backing of the overlaminate web  88  forms permanent bonds with hinge areas  90  and the cutout tab areas  72  of the base ply web  66  and with the face panels  86  of the onserts. In combination with the patterned release layer  74 , the pressure-sensitive adhesive backing of the overlaminate web  88  also forms reusable bonds with the attachment areas  76  of the base ply web  66 . To the extent that the overlaminate web  88  is substantially clear, the printing  87  on the face panels  86  of the onserts  84  is visible through the overlaminate web  88 . The overlaminate web  88  can be of a self-wound type, where a top surface of the overlaminate web  88  functions as a release surface against the pressure-sensitive adhesive backing on a bottom surface of the overlaminate web  88 , or a release liner can be temporarily laminated against the pressure-sensitive adhesive backing of the overlaminate web  88  for isolating the pressure-sensitive adhesive backing until the overlaminate web  88  is laminated to the base ply web  66 . 
     A die cutter  124  cuts through the overlaminate web  88 , the onserts  84 , and the base ply web  66  to form the external shape, i.e., outlines  92 , of the multi-ply labels  60 . The die cut outlines  92  intersect the U-shaped cuts  80  so that the cutout tab areas  72  are completely separated from the remainder of the base ply web  66 . 
     A waste remover  126  removes an unwanted matrix  94  beyond the die-cut outlines  92  of the multi-ply labels  60  and a rewinder  128  winds the matrix  94  into a disposable rolls. A rewinder  130  winds a succession of the multi-ply labels  60  carried on the release liner web  64  into a roll for delivery to a customer or other intended user of the multi-ply labels  60 . In place of the rewinder  130 , a folder could be used for fan-folding the multi-ply labels  60  on the release liner web  64 . 
     Additional printing stations (not shown) can be positioned along the inline press  90  for printing on other of the printable surfaces including the base ply web  66  and the overlaminate web  88 . Alternatively, the intermediate web  82  or the base ply web  66  can be preprinted in a separate offline printing operation and registered to other features for constructing the individual resealable multi-ply labels  60 . In addition to arrangements of folded panels, the onserts  84  can take a variety of other forms from single panels printed on one or both sides to multi-panel books that include a plurality of panels bound together or bound separately at one staggered end to the overlaminate web  88 . Instead of positioning the onserts  84  on the base ply web  66  prior to laminating the onserts  84  between the overlaminate web  88  and the base ply web  66 , the onserts  84  could be first affixed to the overlaminate web  88  prior to their lamination. The onserts  84  can be used for a variety of purposes, particularly as informational pieces, but also as decorative or promotional pieces, such as coupons. Line of perforation can be formed, such as between panels of the onserts, for removing portions of the onserts from the resealable labels. 
     Although described with respect to a limited number of embodiments, those of skill in the art will appreciate that a variety of modifications and substitutions can be made to the above-described resealable multi-ply labels, their means of delivery, and their methods of manufacture within the overall teaching of this invention.