Patent Abstract:
The present invention relates to a magnetic enclosure for temporarily retaining documents, printed indicia, photographs or the like. More particularly, the present invention provides an enclosure that is created by laminating a magnetic material to a transparent sleeve created through the production process. The magnetic material serves as a backing member for mounting, displaying and securing printed indicia, creative content or other material in a convenient to use fashion.

Full Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
   None. 
   FIELD OF THE INVENTION 
   The present invention relates to a magnetic enclosure for temporarily retaining documents, printed indicia, photographs or the like. More particularly, the present invention provides an enclosure that is created in an economical manner by laminating a magnetic material to a transparent sleeve created through the production process. The magnetic material serves as a backing member for mounting, displaying and for securing printed indicia, creative content or other material in a convenient to use fashion. 
   BACKGROUND OF THE INVENTION 
   There are a number of sleeves and other constructions that are available today for holding documents and displaying materials. These constructions can be produced in a number of configurations and may include a pair of plastic sheets, the combination of an opaque sheet and a transparent sheet as well as the use of partially translucent sheets. 
   In a construction that utilizes two transparent sheets, the sheets are usually aligned with one another and are then bonded or fused either through the use of heat or adhesive along three sides. This creates an opening, usually along the top end edge that can be used to insert the material to be held within the sleeve. With a pair of transparent sheets, a two-sided document can be inserted and is visible on each of the faces of the document, however, if the sleeve is attached to an opaque structure only one side of the document to be displayed is visible. 
   A similar construction may be produced using the combination of one transparent sheet and one opaque sheet. In such an arrangement, the sheets are again aligned with one another and typically three edges are bonded or fused together to create an enclosure. The opening can be along any edge, but again as provided above, the opening is commonly found along the top end edge. As one of the sheets is opaque, the inserted material is visible only on a single side. 
   As with each of the foregoing constructions, while the inserted material is viewable, at least on one side, the user of the assembly must then still either pin, tape or otherwise adhere or affix the sleeve to a wall, bulletin board, appliance, structure or the like in order for the passersby to see or witness the material that has been inserted. In addition, such constructions are often flimsy, due to the materials used in fabricating the construction and depending upon the size and/or thickness of the material to be inserted, use of the sleeve can be awkward. 
   In a number of applications or situations it is generally desirable to be able to temporarily hang or display indicia, creative material or the like. Typically, this is done through the use of repositional or removable adhesives, tapes, tacks and the like. With adhesives, a residue can be left, particularly if the sleeve is left for a prolonged period of time. Likewise, tape may also leave a residue and may be difficult to peel off from the structure to which it has been applied. Tacks of course, while not leaving an adhesive residue will create holes or punctures in the structure that they are used with and after repeated hangings a number of holes will be produced, requiring patching and/or painting to again conceal. The foregoing can be avoided through the use of a bulletin board, cork panels or the like, but this however limits positioning of the display to the location of such panels. In addition, the user is required to purchase the additional structure in order to prepare the display. 
   Other mechanisms by which to hang or display indicia or creative material include the use of individual magnets, which may be decorative in appearance. Magnets are particularly suitable in today&#39;s office environment as cubicle walls and the like often have components which are susceptible to receiving magnets. However, in order to use individual magnets, one must first locate a magnet, which often means removing a magnet that was supporting something else, likely to the detriment of the person who had used the magnet in the first place. Alternatively, the magnet may be used to hold up numerous displays, making the area looked cluttered. In addition, with a build-up of sheet material or thickness beneath the magnet, the strength of the magnetic forces is also diminished and as such the materials supported by the magnet as well as the magnet itself may fall to the ground. 
   A still further problem with magnets, is that when decorative or theme based magnets are used, particularly in an office or communal environment, the decorative elements may be distasteful or even offensive to individuals who may view the display. In addition, use of colorful magnets can also detract from the message that the magnets are being used to display. 
   Use of magnet sign supports is generally well known in the signage industry but surprisingly, such devices have not found their way into the office environment or small or home office setting. This is likely due to the complexity and cost associated with such products thereby limiting the potential applications. Such magnetic backing material may include a set of preformed ridges that can be used to temporarily hold or support a plastic film or even the material to be displayed itself. In the former instance, the film is inserted into the ridged areas thereby creating something of a sleeve into which the material to be displayed can be inserted. However, with this construction as neither the plastic sheet material nor visual indicia is held in position, the sheet and indicia is subject to loss due to slipping from the ridged area. Moreover, the manufacture of such ridged areas is expensive in that creating the ridges and sleeve fixtures adds additional steps to the process of producing the construction. 
   Other uses of magnetically backed display material include magnetic material having a pre-coated layer of adhesive disposed on the material, which is in turn covered by a release liner. This material has a width of about ¼″ to around ½″ and resembles a roll of adhesive tape in that the product is often wound on itself The user, cuts a piece of the magnetic material to the desired length and then removes the release liner and applies the magnetic material in strips to the back of the material to be displayed. For example, a magnetic strip could be applied to one of the prior art type sleeves discussed above. Producing such a construction is however time consuming, in that it requires cutting of the magnetic material to length, removing the release liner material and positioning of the magnetic strips to complete the assembly. While this ad hoc approach may be a suitable temporary arrangement, it does not solve the long term need of the user, as the adhesive bond between the substrate and the magnetic material mail fail over time causing the display to fall to the ground. 
   What is needed therefore, is a display assembly, that can easily accommodate and confine material and indicia to be viewed and that overcomes the drawbacks set forth above. In addition, the assembly must be one that can be produced in an economical and efficient manner; such as through an in-line press application that facilitates the production of the display assembly of the present invention. 
   BRIEF SUMMARY OF THE PRESENT INVENTION 
   The embodiments of the present invention described below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the present invention. 
   In one embodiment of the present invention, a laminated construction for containing visual material to be viewed is described and includes a magnetic layer, which has first and second end edges and first and second longitudinally extending sides. The magnetic layer has a predetermined size and configuration and first and second faces that are opposite one another. A first adhesive layer is disposed in a pattern on the magnetic layer on one of the first and second faces. A first imageable layer is provided and has first and second faces, first and second transversely extending end edges and first and second longitudinally extending sides. One of the faces is placed in contact with the first adhesive layer that has been applied or coated on the magnetic layer. A second adhesive pattern is also provided and is applied to the other face of the first imageable layer in a pattern that is distinct from the pattern of the first adhesive layer. A second imageable layer is provided and includes first and second faces, first and second longitudinally extending sides and first and second transversely extending end edges. The construction that is formed when the second imageable layer is adhered to the first imageable layer by the second pattern of adhesive creates an open space that has a size and configuration which is less than the size and configuration of magnetic layer. The open space is used to contain the document or other visible indicia. 
   In a further embodiment of the present invention, a method of making laminated construction for containing visual material to be viewed is described and includes the steps of initially providing a web of magnetic material having first and second faces. Then a pattern of adhesive is coated on one of the faces of the web of magnetic material. Next, a first imageable layer of material having first and second faces is advanced to an assembly point whereupon the layer is placed into contact with the first pattern of adhesive. A second pattern of adhesive is applied to the other face of the imageable sheet opposite that of the face in contact with the first pattern of adhesive. A second layer of material with first and second faces is applied to the second adhesive pattern such that the imageable layer, second layer and second pattern of adhesive form a pocket to retain visual material. 
   A still further embodiment of the present invention is described and includes a method of producing a magnetic display form. This embodiment includes the steps of initially providing a laminate that has magnetic properties and a first face and a second face, one of the faces is capable of receiving print or images. Next, a pattern of adhesive is applied to the laminate on one of the first and second faces. The pattern of adhesive has first and second portions. A first web of material is advanced in a machine or first direction and has a first dimension. A second web of material is also advanced in a machine direction and has a second dimension that is different than the first dimension. Then the first web of material is adhered to the first portion of the pattern of adhesive and the second web is applied or adhered to the second portion of the pattern of adhesive. An overlapping arrangement is created between the first and second webs of material so as to provide an accessible opening to a cavity formed between the first and second webs and the laminate. 
   In yet a still further embodiment of the present invention a substantially quadrate, display assembly is described and includes a magnetic material having a thickness ranging from about 10 to 25 mils and having a first face and a second face. The magnetic material is capable of traversing an in-line press. The substantially quadrate assembly also includes sheet stock that is adhered to a magnetic material and can receive indicia. The sheet stock is selected from a group of materials including bond paper, tag stock and combinations thereof and the sheet stock can transverse an in-line press in conjunction with the magnetic layer. The assembly also includes a transparent layer that has a thickness of greater than about 2 mils and is adhered to the sheet stock through a pattern of adhesive. The sheet stock and transparent layer are adhered together in such a manner so as to create a space between the sheet stock and the transparent layer, and the space has a size less than the sheet stock. The magnetic layer, sheet stock and transparent layer once formed into a laminated construction can be produced from an in-line configuration. 
   These and other objects of the invention will become clearer from a review of the figures and detailed description of the invention. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     These, as well as other objects and advantages of this invention, will be more completely understood and appreciated by referring to the following more detailed description of the presently preferred exemplary embodiments of the invention in conjunction with the accompanying drawings, of which: 
       FIG. 1  depicts a front elevation of the visual display form prepared in accordance with the present invention; 
       FIG. 2  is a cross sectional view of  FIG. 1  shown along line  3 — 3  depicting the layers of the present invention; 
       FIG. 3  is cross sectional view of  FIG. 1  shown along line  3 — 3 , illustrating a further embodiment of the present invention; 
       FIG. 4  a front elevation illustrating the layers adhered to one another; 
       FIG. 5  is a schematic view of an exemplary embodiment used in the construction of the present invention; 
       FIG. 6  is a further schematic view of the process depicted in  FIG. 5 ; 
       FIG. 7  is a schematic depiction of a process used in the preparation of a further embodiment of the present invention; and 
       FIG. 8  is a further schematic of the process used in  FIG. 7  above. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   The present invention is now illustrated in greater detail by way of the following detailed description, but it should be understood that the present invention is not to be construed as being limited thereto. 
   The present invention provides for a much more economical and efficient manner of producing a visual display form construction having an internally formed pocket, cavity, recess or the like on a substrate or laminate that has magnetic properties. The present invention is directed to both the product configuration as well as the methods for producing the assembly, including the ability to produce the assembly in an in-line configuration. 
   Turning now to  FIG. 1 , an exemplary embodiment of the present invention is depicted generally by reference to numeral  10 . The assembly  10  has first and second transversely extending end edges  12  and  14 , respectively, and first and second longitudinally extending sides  16  and  18 , respectively. As illustrated in  FIG. 1 , the assembly  10  has been provided with rounded or die cut corners, however, it should be understood that the invention may have squared off edges, diagonal corners and the like. In addition, the configuration of the present invention may be configured into any number of geometric and animate shapes. The manufacturing process described below is adapted to producing such shapes by altering the patterns of adhesive that are applied to the construction and die cutting the assembly  10  into the desired shape as will be understood by those having ordinary skill in the art. 
     FIG. 2  provides a cross section of assembly  10 . The base of the assembly  10  comprises a magnetic layer  20 , which has first and second faces  21  and  23 , respectively. The magnetic layer  20 , as with each of the other layers ( 22 ,  24  and  28 ) of the construction herein, excluding the adhesive patterns, each have first and second transversely extending end edges and first and second longitudinally extending sides. Each of the sides and end edges held generally within the confines of the side and edges of assembly  10  shall be simply referred to with respect to the numerical limitations provided above 12, 14, 16 and 18. 
   The magnetic material may be purchased from Flexmag Industries, of Marietta Ohio and may have a thickness ranging from 5 to 30 mils, with 10 to 25 mils being preferred and approximately 15 mils being more preferred. 
   The second face  23  of the magnetic layer  20  has a pattern of adhesive  22  applied to the second face  23 . The adhesive layer or pattern  22  may include generally any permanent type adhesive such as pressure sensitive adhesives, acrylic based adhesives, hot melts, cold glues, etc. One such supplier of permanent adhesives is HB Fuller of St. Paul, Minn. 
   The pattern or layer of adhesive  22  may be coated or applied in any number of configurations. For example, the adhesive  22  may cover the entire face  23  of the magnetic layer  20 , may be applied in a spot or other geometric pattern such as lines or stripes. The adhesive layer  22  must however be coated in a sufficient manner and amount so as to provide adequate coverage and adhesion between the layers of the assembly. 
   Still referring to  FIG. 2 , an imageable layer  24  is then applied over the pattern of adhesive  23 . The term “imageable” as used herein, includes a substrate that is capable of receiving print, indicia or images such as through the use of ink jet, dot matrix, electrostatic and other non-impact printing or imaging means. In addition, the term includes a substrate to which a coating may be applied so as to make it more receptive to receiving print or images. The imageable layer has first and second faces  25 ″ and  25 ′, respectively. The imageable layer  24  may be selected from any number of appropriate materials such as 20–24 pound bond paper, tag or card stock, printable films such as a polyethylene based film or the like. The material for the imageable layer  24  should be selected for its ability to receive toner or accept ink. However, it should be understood that the layer  24  need not be provided with any printing or imaging and may remain blank. In addition, layer  24  may be colored so as to provide a background or contrast to the visual indicia to be inserted within the construction. 
   Where the imageable layer  24  is provided with printing or images, the printing or imaging may include instructions on use of the form, complimentary graphics to the intended insert or the like. Complimentary graphics may include printed pattern, warning indicia such as the terms “NOTICE” or “CAUTION” or the like. Such printing can be provided off line from the manufacturing operation of the assembly  10  and accomplished by electrostatic print engines, ink jet, and the like. When accomplished apart or away from the manufacturing apparatus, the printing may be done in repetitive patterns so that during the cutting and processing of the assembly  10 , it is not significant where the imageable layer  24  is cut or separated from the web on which it is printed. 
   A second layer or pattern of adhesive  26  is then coated or applied and positioned on the second face  25 ′ of the imageable layer  24 . Unlike the first pattern of adhesive  22 , the second pattern  26  is applied in a “U” or an inverted “U” shaped configuration. This is required so as to facilitate the preparation of a cavity, recess, pocket or the like so as to be able to receive the material to be displayed in the configuration. The second pattern  26  has a width of about ¼ of an inch to about ½ of an inch with about ⅜ of an inch being preferred. The width of the adhesive pattern  26  must be sufficient in order to prevent the inserted material from poking through the edge of the construction so that rips or weaknesses are not created in the assembly  10 . That is, if a substantially rigid piece is inserted into the assembly  10 , the piece may have a sharp corner that could puncture or break through the pattern of adhesive. 
     FIG. 2  also illustrates the imposition of the next layer  28  on the assembly  10 . The layer  28  again may be imageable so that complimentary graphics, colors, or indicia can be provided to the construction to highlight or facilitate the communication of the message of the insert to be provided in the assembly  10 . 
   Layer  28  is adhered to the assembly  10  through the pattern of adhesive  26  on its first face. The second face would then serve as the visible exterior face of the layer  28  and hence assembly  10 . 
   The layer  28  is desirably at least translucent if not transparent, which is preferred. In addition, the layer  28  may be provided with only portions of the layer being transparent with other areas of layer  28  being only translucent or opaque. In this way, use instructions can be provided on the sides of the insert, and would be concealed from view due to the translucence or opaque characteristics of the layer  28 . 
   The combination of layer  28 , adhesive pattern  26  and layer  24  form to create a pocket, recess, cavity or the like  30 , which can accommodate a variety of inserts. The size of the cavity would vary depending upon the size of the layers  20 ,  24  and  26 , respectively. For example, if the layers  20 ,  24  and  26  were each 8½ by 11 inches, then the interior cavity  30  would be approximately 7½″ by 10½″. Obviously, other sizes and dimensions are possible. 
   In still a further embodiment layer  28  could be provided with a patterned transparency so as to serve as part of a sweepstakes or promotion. Users or recipients of a game piece would bring the game piece to a predetermined location and insert the piece into the assembly. The patterned transparency would illustrate whether the consumer or recipient revealed a specific code or message such as “WINNER” or a combination that may unlock a prize. 
   Turning now to  FIG. 3 , a further embodiment of the present invention is provided. In this embodiment, the construction of the layers is similar to that as depicted above, however, layer  28  is now portioned into first and second portions,  28 A and  28 B, respectively. As depicted in the drawing, portion  28 A is substantially smaller than portion  28 B, but may be approximately equal to portion  28 B, that is each portion may be between 50 to 60% of the length and width of layer  28 . For greater clarity, and in order to create the overlapping arrangement, if one portion were provided that made up 50% of the length and width of the layer  28 , then the other portion would have to be at least slightly larger than the other portion, approximately 51–100% of the size of the sheet so that an overlap was created between the two portions and more preferably about 51 to about 65%. In an exemplary embodiment, the amount of overlap ranges from at least ⅛ of an inch to about ¾ of an inch with about ⅜ of an inch being preferred. That is, one of sheets  28 A or  28 B would preferably have from 51% to 65% of the size of the other of sheets  28 A or  28 B. 
     FIG. 4  provides a front elevational view showing overlapping portions  28 A and  28 B. Reference to numeral  20  in this embodiment includes not only the magnetic layer by also a laminated magnetic layer having a imageable layer applied thereover. 
   The overlap created by portions  28 A and  28 B in effect provides a resealable enclosure for the material to be inserted in the cavity  30 . In addition, in a further embodiment of the present invention, the second pattern of adhesive  26  may then be provided in an almost full perimeter seal. That is, the adhesive extends nearly substantially entirely around the perimeter of the sheet or layer  26 . The break in the adhesive seal corresponds with the area of the overlap of the assembly  10 . In this embodiment, a pouch like structure is created wherein the inserts provided in cavity  30  cannot fallout regardless of the positions of the assembly. This is do to the nearly complete perimeter seal retains the insert in a secure position and the overlapping flap create a closure that requires manipulation in order for the material to be removed from the interior. 
   In the present invention, either one or both of the layers  24  or  28  may be printed with indicia or images, such as graphics. The printing or imaging may be complimentary or supplemental to the material to be inserted. The printing on layer  24  may also be viewable through changing the pattern of transparencies on layer  28 , so that a changeable sign or background can be created by the construction without the need to create an entirely new assembly  10 . 
   Turning now to  FIG. 5 , where an exemplary schematic is provided for producing the present invention. In this example, a continuous web of magnetic material  20  is provided. The present invention may also be made in a cut sheet arrangement, wherein the difference includes supplying a stack of cut sheets of magnetic material to the manufacturing operation. It should also be understood that the web of material may be a laminated construction in which a magnetic sheet has an imageable layer already adhered to one side of the web. 
   The web of magnetic material  20  is provided to a rotary press  100  where a pattern of adhesive  102  is applied to the web of material  20 . Where the web is provided in a non-laminated arrangement, the web  20  first has an imageable layer applied to the layer through the use of a permanent adhesive as described above and is then supplied to the rotary press  100 . 
   Once the pattern of adhesive  102  is applied to the web  20 , the web  20  is provided to a nip roller  104 . It should be understood that depending on the configuration of the final assembly  10 , the adhesive pattern  102  may comprise a “U” shaped pattern, an inverted “U” or other shapes as are necessary, including a perimeter seal and a nearly complete perimeter seal. 
   At the nip roller  104 , the web of material  20  having the pattern of adhesive  102  applied thereto is joined with a second layer  28  that is supplied from a continuous web arrangement. Again, in a cut sheet embodiment, previously cut sheets of layer  28  would be fed into a cooperative arrangement with the layer of magnetic material  20 . 
   The nip roller  104  causes the web of material  20  to be bound or adhesively secured to the second layer  28  due to the adhesive pattern  102 . The web of material continues to travel in a machine direction and is severed into individual assemblies  10  by a die or other cutting mechanisms  106 . After the cutting or severing operation, the individual assemblies are collected for distribution (not shown). 
   Now with respect to  FIG. 6 , a side view of the schematic apparatus as described above in reference to  FIG. 5  is provided. The web of magnetic material  20  is advanced in a machine direction. As provided previously, the web  20  may be provided in a laminated or non-laminated configuration, that is, with or without a layer of imageable material thereon. The web  20  of material is passed through a rotary press  100  that applies a pattern of adhesive  102  to the web  20 . The coated web  20  may then be passed through an UV treatment zone (curing, drying)  108  to cure the adhesive. Next, the web  20  travels in the machine direction through a nip roller  104  where layer  28  is bound or adhesively secured to the web  20  to create a further laminated construction. The laminated construction may then pass through a second UV station  110  and then finally to a die cutting or severing station  106  after which the individual assemblies  10  are created and then stacked for distribution (not shown). 
   Turning now to  FIG. 7 , where a further illustrative embodiment of the present invention is presented. Again a web  220  of magnetic material is moved in a machine direction and passed to a rotary press  200  to apply a pattern of adhesive  202 . The coated web is then passed to a nip roller  204  where first and second portions,  28 A and  28 B, respectively, of a second layer are provided. The nip roller  204  presses the first and second portions of the layer  28  into contact with the adhesive pattern  202 , thereby forming an adhesive bond and a laminated structure. The structure is then forwarded to a die cutting or severing step  206  where the web is separated into individual pieces. 
     FIG. 8  provides an alternative configuration for the method of the present invention. In  FIG. 8 , unwinds are provided for each of the first and second portions  28 A and  28 B of the present invention. The first and second portions  28 A and  28 B are provided in an overlapping arrangement so as to create a resealable area that prevents the inserts from escaping from the cavity  30  as provided in  FIG. 1 . 
   The overlapping arrangement of the first and second portions  28 A and  28 B of the present invention may also be provided with a repositional adhesive or a cohesive seal (mating patterns of adhesive that bond only to one another) so that a further secure closure can be provided. In this embodiment, one of the first and second portions  28 A and  28 B would be provided in a pre-coated arrangement and fed into the manufacturing arrangement as provided in accordance with the present invention. 
   It will thus be seen according to the present invention a highly advantageous visual display form has been provided. While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it will be apparent to those of ordinary skill in the art that the invention is not to be limited to the disclosed embodiment, that many modifications and equivalent arrangements may be made thereof within the scope of the invention, which scope is to be accorded the broadest interpretation of the appended claims so as to encompass all equivalent structures and products.

Technology Classification (CPC): 1