Patent Publication Number: US-6905747-B2

Title: Label and disposition of adhesive and adhesive release

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This is a continuation-in-part of U.S. Provisional Application Ser. No. 60/450,455, filed Feb. 26, 2003. 

   BACKGROUND OF THE INVENTION 
   This invention relates to labels and forms, including business or postal forms which are used with non-impact printers, for example, laser printers. Many types of specialized business forms are made of a porous paper or other relatively porous printable material, e.g., acetate, for use with non-impact printers such as laser printing devices. Adhesive and adhesive-release (e.g., silicon) are typical, if not required, components of pressure-sensitive mailing form or label products. 
   A common problem with such forms is that after passing the form through the printing device to imprint variable information, the print toner fails to properly bond to the form and can flake away or is easily removed from the surface of the form when manipulated by a user. This problem is especially prominent when the form is a peel-off label wherein the label is bent or otherwise manipulated to be peeled away from a backing substrate to expose adhesive. 
   It is perceived that the flaking of print toner, e.g., a xerographic toner which can comprise a granulated thermoplastic having a magnetic component formulated therein, results from the toner being improperly affixed or fused to the paper or other substrate material used in pressure-sensitive products, even after being heat-fixed by conventional printer processing. This improper fusion results from the adhesive and/or adhesive-release material disposed onto the surface of the substrate conducting heat away from any area on which it is applied. Thus, the toner cannot be properly heat-fixed onto the substrate. In addition, the toner may be prevented from absorbing into the pores or adsorbing onto the substrate where adhesive and adhesive-release are applied, and is thereby prevented from properly fusing to the substrate in a way that provides for substantially permanent bonding. 
   Thus, what is needed in the art is a label or other business mailing form which provides a print surface which substantially eliminates improper bonding or fusion of print toner, e.g., laser xerographic or thermoplastic print toner, and which can thereby prevent flaking or easy removal of the toner from the substrate surface following printing and heat-fixing. 
   SUMMARY OF THE INVENTION 
   In accordance with the subject invention, there is provided a form or label made of material which can receive, substantially permanently, laser toner on its outer or top face, and an adhesive for affixing the form or label to another surface disposed on its opposing inner face, the adhesive being disposed in a manner which does not interfere with the substantial permanence of the laser toner disposed on the outer face. 
   In a preferred embodiment, the subject invention concerns a two-ply form or label having a top ply and a backing ply wherein the top ply can have die-cuts or perforations defining the shape of the form or label. Preferably, the top ply comprises an outer face for receiving print toner for printing variable information on the form or label and an inner face comprising adhesive. 
   The backing ply has a back or outer face which typically does not receive variable print information, but which can be printed with instructional or other non-variable information (including source information, logos, or the like), and an inner face on which adhesive-release material can be disposed. Most preferably, the adhesive-release material is disposed in a pattern wherein it mates to the adhesive material disposed on the inner surface of the top ply such that the top and back plies can be separated from one another to expose the adhesive for affixing the top ply label or form to a different surface. 
   In a more preferred embodiment, the subject invention comprises adhesive and adhesive-release material patternly disposed on the inner surfaces of the top and back plies. The adhesive and adhesive release material is disposed in a pattern such that any area corresponding to the outer face of the top ply that receives print toner is adhesive-free and/or adhesive release-free. Thus, it is contemplated that the adhesive-free and adhesive release-free area is preferably disposed along an outer edge or on a perimeter edge of the label or form to border or frame the print area of the top ply outer surface. 
   For a rectangular shaped label, the framing pattern of adhesive and/or adhesive release material can be disposed on at least one perimeter edge of the inner faces of the plies, preferably along at least two opposing perimeter edges of the plies, more preferably along three perimeter edges of the inner faces of the plies, and most preferably along all four perimeter edges of the inner faces of the plies. A person of ordinary skill in the art would recognize that the disposition pattern of the adhesive and adhesive release material could vary according to size and shape of the label or form, as well as the intended adhesion desired. For example, it is desired to obtain the maximum adhesion for the label with another surface; therefore, a frame of adhesive and adhesive release material bordering the entire perimeter edge of the label would be preferred. In addition, the preferred embodiment of the subject invention comprises a adhesive or adhesive release material which is slightly offset from the outer edge of the label sheet so that an adhesive-free or adhesive release-free gap is provided between the edge of the label sheet in order to prevent oozing of the adhesive or adhesive release material beyond the edges of the label sheet during the printing process. A preferred embodiment has no such gap of adhesive and/or adhesive material along the perimeter edges of the die-cuts forming the peel-off labels disposed on the sheet. 
   In one preferred embodiment of the subject invention, the labels can be formed with slits or pores die-cut or otherwise formed therein. These slits or pores provide a means for releasing air from air pockets that can form under the label, within the perimeter frame of adhesive when the label is in use, e.g., when applied to another surface. Preferably, these slits or pores are formed of a small dimension so that the integrity of the label is unaffected when it is in use or otherwise being manipulated by the user. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Preferred embodiments of the subject invention are herein described with specific reference being made to the following Figures, in which: 
       FIG. 1  is a plan view of the front, or outer, face of the top ply of a label sheet assembly according to one embodiment of the subject invention, illustrating by dotted lines a print area of each label formed in the label sheet (said dotted lines framing the print area forming no part of the invention); 
       FIG. 2  is a plan view of the back (inner) face of the top ply of a label sheet assembly according to one embodiment of the subject invention, illustrating the configuration of adhesive (shown as shading) disposed on said inner face to provide said adhesive around the perimeter edges of each label formed in the sheet and an adhesive-free area on each label, the adhesive-free area corresponding positionally to the print area of each label on the outer face of said ply; 
       FIG. 3  is a partial plan view of the inner face of the back ply of a label sheet assembly according to one embodiment of the subject invention, illustrating the configuration of adhesive release material (shown as stippling) disposed on said inner face to provide said adhesive release around the perimeter edges of each label formed in the sheet and an adhesive release-free area on each label, the adhesive release-free area corresponding positionally to the print area of each label on the outer face of said ply; 
       FIG. 4  is a plan view of the outer face of the back ply of a label sheet assembly according to one embodiment of the subject invention; 
       FIGS. 5A and 5B  are a plan view of two alternative embodiments of the subject invention showing adhesive and adhesive release material disposed on at least two opposing perimeter edges of a label; 
       FIGS. 6A ,  6 B and  6 C are a stepwise illustration of an embodiment of the subject invention in use, the illustration showing steps:
         (a) Peeling off a label from the label sheet assembly;   (b) removing the label completely from the label sheet to expose adhesive disposed on the inner face of the label; and   (c) adhering the removed label onto another surface;       
       FIGS. 7A and 7B  show two embodiments of a label according to the subject invention having slits formed therein (FIG.  7 A), or pores formed therein (FIG.  7 B), said slits or pores being provided to allow the escape of air from the adhesive-free area and thereby prevent formation of air pockets under the label when the label is applied to another surface. 
   

   DETAILED DESCRIPTION 
   The subject invention concerns a novel label sheet or printed form assembly which can advantageously prevent flaking or unintentional removal of print toner deposited onto the outer surface of the label or form. A preferred embodiment of the subject invention comprises a label or form assembly constructed of at least two plies preferably affixed together to form a single sheet label or form assembly. The first ply provides a label or other print substrate printable by a non-impact printer, e.g., a laser printer, wherein the adhesive or adhesive release material is disposed between the plies in a manner that prevents or reduces the incidence of flaking or unintentional removal of the print toner following heat-fixing of the toner onto the outer surface of the label or form. The second ply is a backing ply, the inner face of which opposes the inner face of the top ply. Adhesive release material can be disposed on this inner face of the backing ply in a pattern corresponding to the adhesive pattern of the inner face of the top ply. 
   As would be readily understood by persons of ordinary skill in the art, the manufacture of the label or form assembly comprises providing a sheet of paper or other printable material for each ply, and patternly disposing adhesive and/or adhesive release material on the desired areas on one face of each ply. The plies can then be adjoined to form a single, two-ply sheet which can be pre-printed to provide desired color, text, or other printed features specific to the forms of the assembly. The assembly can then be perforated or die-cut as predetermined by the intended design of the assembly. 
   Preferred embodiments of the subject invention are shown in  FIGS. 1-7 .  FIG. 1  is a plan view of the front, or outer, face of the top ply of a label sheet assembly  10  according to the subject invention showing multiple labels  11  configured therein. The multiple labels on the label sheet assembly are formed by die-cuts  12  in the top ply bordering each of the labels. It is understood and well recognized in the art that label sheet assemblies can comprise a single label or multiple labels. Moreover, it should be understood for purposes of the subject invention that the rectangular shaped labels are shown for illustration purposes only. The subject invention can be readily applied to any shape of label, including rectangular or square, circular or oval, and any irregular shape which has a border or edge. The embodiment shown, which is a standard mailing label sheet assembly provided on an 8.5×11 sheet, comprises thirty (30) rectangular labels configured in three columns of ten (10) labels each. 
   One or more vertical perforations  13  can be optionally provided in the assembly sheet to separate the columns. Alternatively, such perforations can be formed horizontally to separate rows of labels formed in the assembly. These horizontal or vertical perforations are preferably formed through both plies to provide for convenient separation. A print area A shown in the top, left label of the assembly shown in  FIG. 1  is defined by dotted lines around the perimeter of the label. These dotted lines form no part of the invention and merely illustrate the area on which print toner is typically disposed on the label when passed through a printer. 
     FIG. 2  is a plan view of the back (inner) face of the top ply of a label sheet assembly  10  according to one embodiment of the subject invention. Adhesive (shown as shading) is disposed on said inner face in a configuration which provides said adhesive around the perimeter edges of each label, leaving a centrally positioned adhesive-free area  20  on each label. As illustrated by the dotted lines shown in the top row of labels, the adhesive-free area preferably corresponds positionally to the print area of each label on the outer face of said top ply. Die-cuts  11  are also shown in this view and define the perimeter edges of the label formed in said top ply. In addition, the adhesive can preferably be disposed on the inner face of the top ply to provide an adhesive-free gap  21  bordering the perimeter edges of the assembly. This gap can be about one-sixteenth to about three-eighths inches in dimension so that the adhesive does not ooze from the edge of the form assembly and result in damage to the printer. 
     FIG. 3  is a partial plan view of the inner face of the back ply of a label sheet assembly  10  according to one embodiment of the subject invention. Adhesive release material (shown as stippling) is disposed on said inner face in a configuration which provides said adhesive release material around the perimeter edges of each label, leaving a centrally positioned adhesive-free area  30  on each label. As illustrated by the dotted lines, the adhesive release-free area preferably corresponds positionally to the print area of each label on the outer face of the top ply. In addition, the adhesive release material on the inner face of the back ply can preferably be disposed to provide an adhesive release-free gap  31  bordering the perimeter edges of the assembly. This gap can be about one-sixteenth to about three-eighths inches in dimension so that the adhesive does not ooze from the edge of the form assembly and result in damage to the printer. Alternatively, a wider adhesive release-free gap can be provided around the perimeter edge of the assembly such that adhesive disposed on the opposing face can adhere to the edges of the assembly and thereby prevent or substantially reduce the chance of separation of the plies. 
     FIG. 4  is a partial plan view of the outer face of the back ply of a label form assembly  10  according to the subject invention. This illustration shows the optional vertical perforations  13  that can be provided in the assembly to facilitate separation of columns of labels. As described, one or more of such perforations can also be provided as horizontal perforations which can facilitate separation of rows of labels. 
     FIGS. 5A and 5B  are plan views of two alternative embodiments  50  and  51  of label assemblies according to the subject invention showing adhesive (shading) and adhesive release (stippling) materials disposed on at least two opposing perimeter edges of a label.  FIG. 5A  shows adhesive and adhesive release material disposed on the top and bottom edges of label  52 , and  FIG. 5B  shows adhesive and adhesive release material disposed on both side edges of label  53 . 
     FIG. 6  is a stepwise illustration of the use of a label assembly  60  according to the subject invention, showing steps:
         (a) peeling off a label  61  from the label assembly  60 , exposing adhesive  62  and adhesive release  63  disposed on each ply of the label assembly to provide a removable label having adhesive framingly disposed on its perimeter edges;   (b) removing completely from the label assembly  60  label  61  formed in the top ply of the label assembly, said label  61  having adhesive  62  framingly disposed on its perimeter edges; and   (c) adhering the removed label  61  onto another surface       
   In addition to the labels described herein having adhesive and/or adhesive release framingly disposed thereon, a particular advantage of these labels can be realized by incorporating a plurality of slits or pores in the plies so that these slits or pores are provided in each of the labels of the assembly. When a label comprising these slits or pores is applied to a surface, air that may be trapped within the adhesive frame can escape from the label through these slits or pores. These slits or pores do not need to be formed as any particular size or shape; however, they are preferably small enough so that their presence does not affect the integrity of the label. Labels according to these embodiments of the subject invention are illustrated in  FIGS. 7A and 7B . Specifically, an embodiment of a label  70  having slits  71  formed therein is shown in FIG.  7 A. An embodiment of a label  72  having pores  73  formed therein is shown in FIG.  7 B. The slits and pores shown in these Figures are exaggerated here for purposes of illustration only. Typically, these slits or pores are small enough so that they are not readily seen by the naked eye, and are visible only upon close inspection. The small dimension of these slits or pores helps maintain the integrity of the label before, during, and after its use. 
   The subject invention can prevent or substantially reduce the incidence of flaking or unintentional removal of toner from a label or form being printed by a laser printer. It was previously known that toner can improperly affix to certain adhesive-backed labels or forms and result in flaking of the toner when the user of said label manipulates the label. However, it was not previously recognized why such flaking was caused by, inter alia, the presence of adhesive or adhesive release material. The adhesive and adhesive release material can absorb into the pores of the substrate material and thereby prevent toner applied during the printing process to properly absorb onto or into the substrate be heat-fixed thereon. In addition, because toner can be a magnetic thermoplastic material which requires heat to properly affix to the substrate, it is now understood that adhesive or adhesive release material disposed behind the print area of the label can direct the required heat away from the print area of the label and prevent the toner from reaching critical temperatures necessary for heat-fixing. 
   To address this problem of toner flaking from the label, the subject invention provides an adhesive-free and adhesive release-free area on the inner faces of a two-ply label or form assembly corresponding to the print area on the outer face of the label or form. By framing the perimeter edges of the inner faces of the label or form with adhesive and adhesive-release material, the print area on the front face of the label or form does not have adhesive or adhesive-release material directly behind it. Accordingly, the pores of the substrate are not filled with adhesive or adhesive release material and are free to absorb toner. Moreover, the heat required to affix the toner is not carried away from the print area by adhesive or adhesive release material. Accordingly, the toner can be optimally disposed and affixed to the label surface. 
   Generally, the invention has been described in its preferred form or embodiment with some degree of particularity, it is to be understood that this description has been given only by way of example and that numerous changes in the details of construction, fabrication and use, including the combination and arrangement of parts, may be made without departing from the spirit and scope of the invention.