Patent Abstract:
A form that incorporates either a label or card such that the form can be reliably printed on by the end user and manufactured less expensively. The integrated label form includes a top printable substrate and a liner substrate mated together by an adhesive. The top printable substrate serves at least partially as removable portions capable of being reapplied. Weakened lines of substrate may be provided to define removable portions on the top printable substrate. The form also may include a similar printable substrate mated to the other side of the liner by adhesive. Weakened lines of substrate also may formed in the second substrate to define removable portions. The integrated card form includes a printable substrate and a first and second laminate mated to the substrate and together by an adhesive. Weakened lines of substrate and first laminate define an integrated removable portion capable of being held in the form by the second laminate and easily removed manually when desired. In the integrated card form and the integrated label form, a recess may be provided adjacent the removable portion to facilitate removal of the removable portion. The integrated forms are easily manufactured by a single piece of equipment.

Full Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]    This application is a continuation-in-part of patent application Ser. No. 10/395,360, filed Mar. 24, 2003, which is a continuation of patent application Ser. No. 09/417,372, filed Oct. 13, 1999, now U.S. Pat. No. 6,656,555. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    This invention relates generally to printable forms and methods of making such forms and, more particularly, to printable forms with integrated labels and cards.  
         BACKGROUND OF THE INVENTION  
         [0003]    There is a need for improved integrated business forms and methods of manufacturing such forms. Integrated forms consolidate different business objectives or services into a single form. A goal of such forms is not only to offer end users the flexibility to provide a variety of information and information transfer options through a single form, but to also reduce the time, money and material associated with using such business forms for both the end users and the form manufacturers. In the end, truly integrated forms increase the reliability, confidence and convenience in exchanging information between businesses and consumers.  
           [0004]    The concept of an integrated form can be employed in numerous varieties depending on the objects of the particular end use. For example, an integrated form may consist of an invoice portion and a label portion incorporated into the same form. Thus, the business can print both the invoice information as well as the address information at the same time.  
           [0005]    The mail order industry is a prime example of where such type of label is desired to ensure accurate billing and convenience to the consumer. For instance, in the mail order industry, the mail order company includes with the product an invoice, a shipping card addressed to the consumer and affixed to the packaging and a return card so that the consumer can conveniently return the purchased product within the return period. The obvious shortcoming with this process is the expense, time and possible confusion with purchasing, stocking and printing three separates pieces (i.e., the invoice, the addressee label, and the return address label or card).  
           [0006]    An attempt to address these shortcomings is the use of a dedicated section on the invoice for printing of the return address. Thus, the form is sent through a printer which prints both the invoicing information and the return address in one process. In one form, the dedicated section may be outlined by a perforated section for detachment by the consumer. The obvious shortcomings include that the consumer must cut or tear the return address section from the form and affix it to the package with durable tape or adhesive in a manner that does not obstruct the address information. Because consumers do not always have adequate tape or adhesive, they use whatever they have available, which experience has shown, tends not to withstand the stresses associated with commercial shipping. As a result, the return address section is susceptible to falling off, which, when it occurs, often leads to disruption of the mailing system, disputes over whether the package was returned timely and damaged goods.  
           [0007]    An attempt to address the return address situation has been made by adding a label to the form. These types of forms are commonly made by mating one side of a liner (such as a silicone coated liner) to the form and having a pressure sensitive label on the other side of the liner. The label then carries the address information, as well as the appropriate adhesive for reliable affixation to a return package. A shortcoming with this type of form is that the thickness created by the stacking of the form, the liner and the label often causes problems during the printing step. That is, the form jams the printer and prevents further use until appropriate service is undertaken. Another shortcoming is associated with pre-dispensing of the label because the label is not truly integrated with the form. That is, the label separates from the form and sticks to the rollers and/or drum of the printer. Thus, there is potential for serious damage to the printer. An even further shortcoming is the requirement additional materials to produce a three layer form, which is only capable of providing a limited number of labels on one side of the form.  
           [0008]    Integrated forms also are desired in industries that have the need to distribute cards, such as membership cards for identification or other programs (e.g., frequent buyer programs and insurance programs). The cards traditionally have been printed separately and, to distribute such cards, they have been forwarded to the consumer under a separate forwarding cover letter. To address this situation, some companies attach the card to a form (such as a form forwarding letter) with a releasable adhesive. The obvious shortcoming is that the form is typically pre-printed and then run through a separate machine to add adhesive and the card. As a result, the card does not always become adequately affixed to the form, making it difficult to handle and susceptible to becoming unintentionally detached from the form. In addition, during removal of the card, it tends to peal off the top layer of the form, thereby reducing (and, in most cases eliminating) the backside of the card as a place for printed information.  
           [0009]    Moreover, because the card tends to be inadequately secured to the form, it is not practical to consider printing after the card has been affixed. That is, the cards tend to fall off during the printing stage and bind up the printer. As explained above for labels, there is potential for serious damage to the printer. Thus, there is need for truly integrated forms that incorporate labels, cards, etc. into the form.  
           [0010]    There also is the need to improve the methods of manufacturing such forms. The typical manufacturing equipment includes a paper infeed unit, a vacuum applicator unit, an unwind unit containing transfer tape, a hot melt applicator head, a feed control unit, an integral die cut unit, a hot melt unit and a fold-to-fold delivery unit. This processing equipment is commonly contained in two separate pieces of equipment. In other words, the manufacturing process is not one straight through in-line process, and therefore, tends to be expensive and labor intensive. The use of multiple machines slows the entire manufacturing process, increases costs and requires additional personnel.  
           [0011]    Accordingly, it has been determined that there exist the need for an improved integrated form that is more end user friendly and that facilitates a more economical method of manufacturing.  
         SUMMARY OF THE INVENTION  
         [0012]    In accordance with the invention, an improved integrated form is provided that enhances the use by end users and the manufacturing of such forms. In one form, there is provided an integrated from that includes a first printable substrate on one side of the form and a liner adjacent the first printable substrate. The liner has a first and second side. Adhesive on the first side of the liner maintains the first printable substrate to the first side of the liner in a manner that facilitates printing on the form without detachment of the first printable substrate. The first side of the liner is treated to permit a predetermined force to selectively remove the first printable substrate from the linear such that adhesive removes with the first printable substrate.  
           [0013]    The first printable substrate may include a weakened line of substrate that defines at least in part a predetermined sized portion of substrate removable from the form. The weakened line of substrate resists unintentional detachment of the first printable substrate from the liner. The first printable substrate also may include a portion that extends beyond the liner.  
           [0014]    The form may further include a second printable substrate on the other side of the form. The liner is intermediate the first and second printable substrates. Adhesive on the second side of liner maintains the second printable substrate to the second side of the liner in a manner that facilitates printing on the form without detachment of the second printable substrate. The second side of the liner being treated to permit a predetermined force to selectively remove the second printable substrate from the linear such that adhesive removes with the second printable substrate.  
           [0015]    The second printable substrate also may include a weakened line of substrate that defines at least in part a predetermined sized portion of substrate removable from the form. The weakened line of substrate resists unintentional detachment of the second printable substrate from the liner.  
           [0016]    The first printable substrate may also include a portion adjacent the removable portion of substrate that has been removed from the form to facilitate manual removal of the removable portion of substrate.  
           [0017]    In another form, there is provided an integrated form that includes a printable substrate having a first side, a second side and a removable portion. A first layer of laminate covers at least a portion of one of the first and second sides of the printable substrate such that at least the removable portion of the printable substrate is covered. The first layer of laminate has a portion that is removable with the removable portion of the printable substrate. A second layer of laminate covers at least a portion of the first layer of laminate such that the second layer holds the removable portion of the substrate and first layer of laminate in the form while also allowing a predetermined force to remove the removable portion of the first layer of laminate and printable substrate from the form.  
           [0018]    The integrated form may include a line of weakness extending through both the printable substrate and the first layer of laminate to define at least in part the removable portion of the printable substrate. The removable portion of the printable substrate also may have perimeter portion and the second layer of laminate may affix to the first layer of laminate only at the perimeter portion of the printable substrate. The form also may include a second portion of the printable substrate that is removable to facilitate removal of the other removable portion.  
           [0019]    There also is provided a method of making an integrated form. The method includes the steps of providing a first printable substrate and providing a liner having a first and second side. Adhesive is applied to the first sides of the liner, and the first printable substrate is mated to the first side of the liner. Weakened lines of substrate in the first printable substrate are formed to define a label of predetermined size.  
           [0020]    The method may include the steps of providing a second printable substrate, applying adhesive to the second side of the liner and mating the second printable substrate to the second side of the liner. Weakened lines of substrate may be formed in the second printable substrate to define a label of predetermined size.  
           [0021]    The method also may include the steps of blocking the application of adhesive to a portion of the liner to be mated with the first printable substrate and removing a portion of the first printable substrate to facilitate easy removal of the label.  
           [0022]    In another manner, there is provided a method of making an integrated form that includes the steps of providing a printable substrate having a first side and second side, applying a first layer of laminate to the second side of the printable substrate and applying a second layer of laminate to the first layer of laminate. Cut lines are formed through the printable substrate and the first layer of laminate to define a removable portion of the form being maintained in the form by the second layer of laminate until intentional removal from the form.  
           [0023]    The method may include the step of removing a portion of the second layer of laminate across the removable portion of the printable substrate to reduce the amount a force necessary to remove the removable portion from the form. The method also may include cutting of a removable section of the form adjacent to the removable portion to facilitate removal of the removable portion. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0024]    [0024]FIG. 1 is a top perspective view of an integrated label form embodying features in accordance with the present invention;  
         [0025]    [0025]FIG. 2 is a bottom perspective view of the integrated form of FIG. 1;  
         [0026]    [0026]FIG. 3 is a cross-section view taken along line  3 - 3  of the integrated form of FIG. 1;  
         [0027]    [0027]FIG. 4 is an exploded perspective view of another embodiment of an integrated label form in accordance with the present invention;  
         [0028]    [0028]FIG. 5 is a cross-sectional view taken along line  5 - 5  of the integrated from of FIG. 4 as assembled;  
         [0029]    [0029]FIG. 6 is a cross-sectional view of an integrated form similar to that illustrated in FIG. 5 with the addition of multiple labels on one side;  
         [0030]    [0030]FIG. 7 is a cross-sectional view of an integrated form similar to that illustrated in FIG. 6 with the addition of multiple labels on both sides;  
         [0031]    [0031]FIG. 8 is a top perspective view of another embodiment of an integrated label form in accordance with the present invention;  
         [0032]    [0032]FIG. 9 is a bottom perspective view of the integrated from of FIG. 8;  
         [0033]    [0033]FIG. 10 is a cross-sectional view taken along line  10 - 10  of the integrated form of FIG. 8;  
         [0034]    [0034]FIG. 11 is a top perspective view of an integrated card form embodying features in accordance with the present invention;  
         [0035]    [0035]FIG. 12 is a top perspective view of the integrated card form of FIG. 11 with card removed;  
         [0036]    [0036]FIG. 13 is a cross-sectional view taken along line  13 - 13  of the integrated card form of FIG. 11;  
         [0037]    [0037]FIG. 14 is an exploded perspective view of the integrated card form of FIG. 11;  
         [0038]    [0038]FIG. 15 is a exploded cross-sectional view taken along line  15 - 15  of the integrated card form of FIG. 14 with a corresponding cross-section of the card suspended above;  
         [0039]    [0039]FIG. 16 is a top perspective view of another embodiment of an integrated card form embodying features in accordance with the present invention;  
         [0040]    [0040]FIG. 17 is a bottom perspective view of the integrated card form of FIG. 16;  
         [0041]    [0041]FIG. 18 is a cross-sectional view taken along line  18 - 18  of the integrated card form of FIG. 16;  
         [0042]    [0042]FIG. 19 is an exploded perspective view of the integrated card form of FIG. 16;  
         [0043]    [0043]FIG. 20 is a exploded cross-sectional view taken along line  20 - 20  of the integrated card form of FIG. 19 with a corresponding cross-section of the card suspended above;  
         [0044]    [0044]FIG. 21 is a top perspective view of an integrated label form embodying features in accordance with the present invention;  
         [0045]    [0045]FIG. 22 is a cross-section view taken along line  22 - 22  of the integrated form of FIG. 21;  
         [0046]    [0046]FIG. 23 is a schematic view of an apparatus and materials for making a precut laminate;  
         [0047]    [0047]FIG. 24 is a perspective view of materials being used in the apparatus of FIG. 23 to make the precut laminate;  
         [0048]    [0048]FIG. 25 is a schematic view of an apparatus and materials for making business forms using the precut laminate made using the apparatus of FIG. 23; and  
         [0049]    [0049]FIG. 26 is a perspective view of materials being used in the apparatus of FIG. 25 to make the business forms. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0050]    Referring to FIGS. 1-3, there is illustrated a form  10  embodying the truly integrated label features of the present invention. The integrated form  10  facilities reliable printing by the end user and convenient labels for the end user as well as others (such as consumers).  
         [0051]    The form  10  is composed of three substrate layers: a top printable substrate  12 ; an intermediate liner substrate  14 ; and a bottom printable substrate  16 . The top and bottom substrates  12  and  16  are made of material that is capable of being readily printed on using conventional printers, such as laser printers. Such materials include paper, card stock or even printable polymer based substrates.  
         [0052]    The liner substrate  14  is mated to the top and bottom substrates  12  and  16  with a pressure sensitive adhesive  18  on both sides. The liner substrate  14  is made of material and treated such that it has reduced binding characteristics to allow a label portion  22  to be easily separated for use by the end user but that will not become detached during printing. Such liner material includes silicone coated glassine, on both sides, as well as Teflon® coated glassine, and bleachcraft may be substituted for glassine.  
         [0053]    In manufacturing the form  10 , the top and bottom printable substrates  12  and  16  are mated to the liner substrate  14  by adhesive  18 . The adhesive  18  is hot melt adhesive or any other adhesive capable of releasably attaching the substrates  12  and  16  to liner substrate  14 . The form  10  is then sent through a die press to create weakened lines  20  on the top substrate  12  to define top labels  22   a  and  22   b  and on the bottom substrate  16  to define bottom label  22   c.  As a result, dedicated sections of the printable substrates  12  and  16  become the labels  22   a  and  22   b,  thereby providing a form  10  with truly integrated labels.  
         [0054]    Alternatively, the bottom side of liner  14  may already include the bottom printable substrate  16 , (a pre-labeled liner). In this case, adhesive  18  is applied to the side of the liner  14  not having the label  22   c,  and mated to first printable substrate  12 . The combination of substrates is then taken through a die press where the first printable substrate is pressed creating labels  22   a  and  22   b.  Alternatively, the pre-labeled liner  14  may not have been die pressed as of yet thereby requiring the second printable substrate  16  to be die pressed as well.  
         [0055]    As illustrated in FIG. 1, the top printable substrate  12  includes two labels  22   a  and  22   b.  The remainder  24  of the top substrate  12  is left to supply printed information that does not required transfer capability via a label. Hence, the liner  14  does not extend below portion  24  of the top substrate  12 . As an example, if the form  10  was an integrated label invoice form, section  24  would include the order information  22 , label  22   a  would be the shipping label, label  22   b  would be the return shipping label and label  22   c  would be an additional label for other purposes. Thus, the form  10  only consumes the minimal amount of material necessary to provide the required form space and number of labels.  
         [0056]    Where additional labels are required because more of the information on the form must be transferred, an alternate form  26  is constructed in which a larger liner substrate is incorporated into the form. Referring to FIGS. 4-7, the form  26  includes a liner substrate  28  and/or a bottom printable substrate  30  that extends over as much of the top printable substrate  32  as is necessary to provide the desired number and size of labels. As a result, the cost of supplying additional labels to transfer more information is reduced because labels are formed on both sides of the liner substrate  28  with the top substrate  32  and the bottom substrate  30 .  
         [0057]    More specifically, as illustrated, the liner substrate  28  and the bottom substrate  30  are sized such that their edges are co-extensive with the top substrate  32 . The liner substrate  26  is intermediate the top substrate  32  and the bottom substrate  30 , and is affixed to such substrates with an adhesive  34 . As illustrated in FIG. 5, the bottom and top substrates  30  and  32  each constitute one large label. As illustrated in FIG. 6, the top substrate  32  constitutes one large label, and the bottom substrate  30  is die cut to include cut lines  36  that define a number of labels  38 . As illustrated in FIG. 7, the top substrate  32  also is die cut to include cut lines  36  which define a number of labels  40 . The material for the top and bottom substrates ( 32  and  30 ), the liner  26  and the adhesive  34  is the same as that described above for form  10  of FIGS. 1-3.  
         [0058]    Referring to FIGS. 8-10, an integrated label form  42  in accordance with another aspect of the invention is shown. The form  42  includes a printable substrate  44  and a liner substrate  46 . With form  42 , the liner substrate  46  does not include any indentations or deformations as a result of die cutting to form the labels because the printable substrate  44  is die pressed before being mated to the liner substrate  46 . By die pressing printable substrate  44  prior to mating it with liner substrate  46 , the liner substrate  46  is not exposed to any possibility of being weakened or deformed due to the die cutting process. This ensures that the liner substrate  46  will be as smooth and uniform as possible, and increases the likelihood that the integrated form  42  will print properly.  
         [0059]    More specifically, the printable substrate  44  is affixed to the liner substrate  46  by adhesive  48 . Prior to affixing these substrates, the printable substrate  44  is die pressed to form lines of weakness  50  (or perforations) that define a number of labels  52 . As illustrated with label  52   a,  one can easily peal the labels from the liner substrate  46  along the lines of weakness  50 . The adhesive  48  lifts off the liner substrate  46  and remains with the label  52   a  so that it can be transferred and affixed to another surface.  
         [0060]    To manufacture this form  42 , the printable substrate  44  is printed with the desired graphics and/or text and is then die pressed to designated the labels  52  with the appropriate lines of weakness  50 . Finally, the printed substrate  44  is mated to the liner with the adhesive  48 .  
         [0061]    Referring to FIGS. 11-15, there is illustrated an integrated card form  54  embodying features of the present invention. The form  54  includes a printable substrate  56  from which is formed a card  58 . The printable substrate  56  has a top side  60  and a bottom side  62  upon which both sides can be printed any desired graphics and/or text.  
         [0062]    The bottom side  62  is covered with a first layer of laminate  64  over the card portion  58 . The first layer of laminate  64  provides rigidity and protection to the card  58 . A second layer of laminate  66  is affixed to the first layer  64  to hold the card  58  in place in the form. Both layers of laminate include a layer of adhesive  68  on one side for affixation to the substrate  56  and the other layer of laminate  64 .  
         [0063]    The card  58  is defined by a number of lines of weakness or cuts  70  die cut through the substrate  56  and the first layer of laminate  64 . The second layer of laminate  66  includes an aperture  72  at the card  58  which is defined by a ledge  74  that extends inward beyond the cuts  70  to expose the adhesive  68  to secure the card  58  in place. The ledge may have a width of ⅛th of an inch width.  
         [0064]    In other words, the card  58  rests against the ledge  74  and the adhesive  68  at the ledge  74  affixes to the first layer of laminate  74  about the perimeter portion of the card  58  in a manner that prevents unintentional release of the card  58  while also allowing the card  58  to be intentionally removed. For instance, to remove the card  58 , one can easily press from the backside of the card  58  to push the card from the form  54 . The size of the ledge  74  and the amount and type of adhesive  68  is coordinated to provide the appropriate gripping action on the card  58 .  
         [0065]    Alternatively, the second layer of laminate may not have an aperture, but may act as a transparent window exposing the bottom of the card. In this instance, it is preferred that the entire window area not be covered completely with adhesive to facilitate removal of the card.  
         [0066]    To manufacture the integrated card form  54 , the top side  60  and bottom side  62  of card  58  are printed with graphics and text as desired. Next, the first layer of laminate  64  is mated with the back side of substrate  56  and then the second layer of laminate  66 . The lines of weakened substrate or cuts  70  are die cut from the top side  60  of the substrate  56  through the first layer of laminate  64  to form the card  58 . The second layer of laminate  66  is not cut so that it can hold the card  58  in the form  54  against unintentional detachment. Alternatively, the second layer of laminate  66  may be cut to remove a portion at the card and to form the ledge  74 . This is performed prior to mating the second layer of laminate  66  with the first layer of laminate  64 . The entire process is to be done on a single machine. Feed structure  76  is provided to aid with feeding the integrated form through a printer (not shown). However in alternate embodiments no feed structure  76  may be provided.  
         [0067]    To further assist in card removal, the form  54  also includes a recess  78  adjacent the card  58  for one to insert a finger, thumb, or part thereof to facilitate removal. The recess extends through the printable substrate  56  and both the layers of laminate  64  and  66 . Recess  78  could be used in a similar manner in integrated form  10  (FIGS. 1-3), form  26  (FIGS. 4-7), and form  42  (FIGS. 8-10). That is, a portion of the substrate could be die cut prior to being mated with the liner and the liner could be blocked from receiving adhesive at that section. As a result, a portion of the liner is exposed and one can easily peel the label from the liner to separate it from the form.  
         [0068]    Turning now to a variation on the business form  54  having an integrated removable card  58  as discussed above with respect to FIGS. 11-15, a business form  154  is provided having a removable integrated card  158  attached by gaps between perforations  170 . The business form  154  is constructed using a base layer  156  and a liner layer  164 , as disclosed in FIGS. 16-20. The base layer  156  is attached on one of its sides to the liner layer  164  using adhesive  168 . The integrated removable card  158  comprises at least a portion of the base layer  156  and the liner layer  164  of the business form  154 . By using only two layers, the base and liner layers  156  and  164 , to generally produce the form  154 , the amount of material used in producing the form  154 , and thus the cost of the form  154 , can be reduced as compared to having more than two layers. However, other layers, such as the cover layer discussed below, may also be combined with the base and liner layers  156  and  164  of the form  154 .  
         [0069]    The card  158  has a periphery edge substantially defined by a plurality of die cuts  170  extending substantially through both the base and liner layers  156  and  164 . The plurality of die cuts or perforations  170  and gaps therebetween form a perforated periphery of the card  158 . The perforated periphery of the integrated removable card  158  allows for the card  158  to readily be removable from the business form  154 , while also maintaining the card  158  in the business form  154  and protecting against unintentional removal. To this end, the perforations  170  are spaced apart a sufficient distance from adjacent perforations  170  in order to have a plurality of bridging portions  179  disposed therebetween to assist in maintaining the card  158  in the form  154  against unintentional removal from the form  154 .  
         [0070]    An optional cut-out  178  is positioned adjacent the periphery of the card  158  to assist in removal of the card  158  from the form  154 . The cut-out  178  preferably extends through both the base and liner layers  156  and  164  of the integrated business form  154 . Feed holes  176  optionally may be positioned on opposing longitudinal edges of the form  154 .  
         [0071]    The base layer  156  is generally rectangular and the liner layer  164  extends generally along the entirety of at least one of the dimensions of the base layer  156 , as illustrated in FIGS. 16-20. As shown in FIG. 17, however, the liner layer  164  need not completely cover the base layer  156 .  
         [0072]    The base layer  156  has a printable first side  160  and an opposing printable second side  162 . Preferably, the base layer  156  may be printed, either before or after construction of the business form  154 , such as by using either a printing press or a typical office or home printer. The base layer  156  may be formed of a cardstock material and the liner layer  164  may be formed of a transparent film. Forming the liner layer  164  of a transparent film allows for any printing or other indicia on the second side  162  of the base layer  156  to be visible through the liner layer  164 . Unprinted space capable of receiving printed indicia may also be provided on the first side  160  of the card  158 .  
         [0073]    A cover layer may be adhesively attached to the first side  160  of the base layer  156  opposite the liner layer  164 . The cover layer may be at least partially transparent, permitting printing or other indicia on the first side  160  of the base layer  156  to be visible through the cover layer. When the cover layer and liner layer  164  are both used on the business form  154 , additional stiffness of the removable card portion  158  can be achieved. The cover layer or liner layer  164  may comprise materials selected to allow for printing of indicia thereon.  
         [0074]    A method is also provided of making a business form  154  having an integrated removable card portion  158 , such as the form illustrated in FIGS. 16-20. The method includes providing a base layer  156  having a first side  160  and an opposing second side  162 . A liner layer  164  is secured using adhesive  168  to at least a portion of the second side  162  of the base layer  156 . Printing on both the first and second sides  160  and  162  of the base layer  156  may occur prior to attachment of the liner layer  164 , and/or the first side  160  of the base layer  156  may be printed after attachment of the liner layer  164 . Printing may also be placed on the liner layer  164 . After the liner layer  164  is secured to the base layer  156 , a plurality of spaced die cuts  170  extending substantially through the base and liner layers  156  and  164  are formed. Bridging portions  179  disposed between adjacent die cuts  170  remain to connect the card  158  and the form  156  so that the card  158  is maintained in the form  156  against unintentional removal therefrom. A cut-out  178  is cut through the base and liner layers  156  and  164  adjacent the periphery of the card  158  to facilitate removal of the card  158  from the form  156 .  
         [0075]    A business form  210  having removable integrated portions  222   a  and  222   b,  similar to the removal integrated portions  22   a  and  22   b  discussed above with respect to FIGS. 1-3, is provided having an integrated tab  225 , as shown in FIGS. 21 and 22. The integrated tab  225  is provided in one or both of the removal integrated portions  222   a  and  222   b  of the business form  210 . One or both of the removable integrated portions  222   a  and  222   b  of the form  210  may be removed and, for example, adhered onto an object, such as an envelope or a package. The integrated tab  225  of the removable integrated portion  222   b  can be at least partially removed to expose a previously hidden or covered portion of a liner layer  214  of the removable integrated label portion  222   b,  as shown in FIG. 21.  
         [0076]    The business form comprises a base layer  224 , the liner layer  214 , and a backing layer  216 , as shown in FIG. 22. The liner layer  214  is secured using adhesive  218   a  to at least a portion of the base layer  224 . The backing layer  216  is secured using adhesive  218   b  to at least a portion of the liner layer  214  on a side of the liner layer  214  opposite the base layer  224 .  
         [0077]    A top printable substrate  212  includes two regions  221  and  224 , a region  221  having the integrated removable portions  222   a  and  222   b  and a region  224  lacking the integrated removable portions, as illustrated in FIG. 21. As illustrated, the remainder region  224  of the top substrate  212  does not have integrated removable portions  222   a  and  222   b.  The liner and backing layers  214  and  216  are only positioned below the region  21  of the top substrate  212 . Thus, the form  210  may only consume the minimal amount of material necessary to provide the required form space and number of labels. However, the entire form  210  may have integrated removable portions and, therefore, the liner and backing layers  214  and  216  extending under the base layer  224 . Although the business form  210  is described and depicted in FIGS. 21 and 22 as having two integrated removable portions  222   a  and  222   b,  one of which has an integrated tab  225 , multiple integrated portions may be provided on the business form and one or more tabs may be provided on each integrated removable portion.  
         [0078]    The integrated removable label portion  222   a  and  222   b  of the form  210  comprises at least a portion of the base layer  224  and the liner layer  214 . The integrated removable portion has a periphery edge substantially defined by a first die cut  220  extending substantially through the base and liner layers  224  and  214  so that the backing layer  216  maintains the integrated removable portion  222   a  or  222   b  in the form  210  against unintentional removal from the form  210 . To remove the integrated removable portion  222   a  or  222   b  from the form  210 , the portion  222   a  or  222   b,  comprising the base layer  224  and the liner layer  214 , is separated from the backing layer  216 . A cut-out  278  may be positioned adjacent the integrated removable portion  222   a  or  222   b  and may extend through the base, liner and backing layers  224 ,  214  and  216  to assist in removal of the integrated removable portion  222   a  or  222   b  from the form  210 .  
         [0079]    The side of the backing layer  216  adjacent the liner layer  214  may have a lesser affinity for the adhesive  218   b  than the adjacent side of the liner layer  214 , thereby allowing the adhesive  218   b , once the integrated removable portion  222   a  or  222   b  of the form  210  is removed, to remain on the side of the liner layer  214  opposite the base layer  224 . Thus, the integrated removable portion  222   a  or  222   b  comprises a label that can be adhered to an object. Alternatively, the side of the backing layer  216  adjacent the liner layer  214  may have a greater affinity for the adhesive  218   b  than the adjacent side of the liner layer  214 , thereby allowing the adhesive  218   b , once the integrated removable portion  222   a  or  222   b  of the form  210  is removed, to remain on the side of the backing layer  216 . In this aspect, the integrated removable portion  222   a  or  222   b  may comprise a card.  
         [0080]    The integrated tab  225  may be opened either before or after removal of the integrated removable portion  222   b  from the form  210 . The integrated tab  225  comprises a portion of the base layer  224  and is coextensive with the integrated removable portion  222   b . The integrated tab  225  is at least partially removable from the base layer  224 . A periphery edge of the integrated tab is generally defined by a plurality of die cuts  223  extending substantially through the base layer  224  so that the liner layer  214  at least partially maintains the integrated tab  225  in the integrated removable portion  222   b  against unintentional removal from the portion  222   b.    
         [0081]    The integrated tab  225  can be lifted to expose a portion of the liner layer  214 . The integrated tab  225  may be at least partially hinged to the base layer  224 , such as by an uncut portion or partially uncut portion  223 ′ extending therebetween, as illustrated in FIG. 21. Alternatively, the integrated tab  225  may be completely removable from the removable integrated portion  222   b . A cut-out  279  may extend through the base and liner layers  224  and  214  of the integrated removable portion  222   b  and may be positioned adjacent the periphery edge of the tab  225  to allow the tab  225  to be readily removed from the integrated removable portion  222   b.    
         [0082]    The base layer  224  may have a lesser affinity for retaining the adhesive  218   a  than the adjacent side of the tab  225 , thereby allowing the tab  225  to be removed from the removable integrated portion  222   b  and adhered to an object. Alternatively, the base layer  224  may have a greater affinity for retaining the adhesive  218   a  than the adjacent side of the tab, thereby allowing the adhesive  218   a  to remain on the removable integrated portion  222   b , as opposed to on the adjacent side of the tab  225 , after removal of the tab  225 .  
         [0083]    Various combinations of printing on different locations of the form  210  can be used to customize usage of the form  210 . To facilitate such uses, any or all of the components, such as the base, liner and backing layers  224 ,  214  and  216  may comprise materials suitable for being printed upon. For example, the form  210  may comprise an invoice for an item receivable via shipping. As an example, region  224  could include the order information, label  222   a  could be the shipping label, and label  222   b  could be the return shipping label. A barcode or other information may be printed on the portion of liner layer  214  beneath the integrated tab  225  such that when the integrated tab  225  is lifted or removed, the information is exposed. Alternatively or in addition, information may be printed on one or both sides of the integrated tab  225 . Thus use of the tab  225  allows for the selective display or access to the printing on the side of the tab  225  adjacent the liner layer  214  or on the portion of the liner layer  214  disposed beneath the tab  225  and visible once the tab  225  is opened or removed.  
         [0084]    A method of making the business form  210  having the integrated removable portions  222   a  and  222   b  and the tab  225  includes providing the base layer  224 , using the adhesive  218   a  to secure the liner layer  214  to at least a portion of the base layer  214 , and using the adhesive  218   b  to secure the backing layer  216  to the liner layer  214 . A plurality of first die cuts  220  extending substantially through the base and liner layers  224  and  214  are made to define the periphery edges of the integrated removable portions  222   a  and  222   b . A plurality of second die cuts  223  are made extending substantially through the base layer  224  and coextensive with the integrated removable portion  222   b  substantially define the periphery edges of the integrated tab  225 .  
         [0085]    Business forms, such as those described above with respect to FIGS. 11-15, may be made in a process using a precut laminate  380  in one or more form manufacturing apparatus, as illustrated in FIGS. 23-26. The precut laminate  380  may comprise a backing layer  364  secured using adhesive  368  to a liner layer  366 , as illustrated in FIG. 24. The precut laminate  380  has an integrated removable card portion  374  defined by a plurality of die cuts. The integrated removable card portion  374  can be left in the precut laminate  380 . Alternative, and as illustrated in the card of FIGS. 11-15, the removable card portion  374  can be punched out and removed from the precut laminate  380 . The die cuts are substantially through the the backing layer  364  but not completely through the liner layer  366 , thereby allowing the integrated removable card portion  374  of the backing layer  364  to be supported by the liner layer  366 .  
         [0086]    After formation of the precut laminate, a base layer  360  is attached to the precut laminate  380 , such as by using adhesive  369 . A plurality of die cuts are formed substantially through the base and liner layers  380  and  366  in order to define an integrated removable card  370 . The die cuts at least partially surround the integrated removable card portion  374  of the backing layer  364  so that the backing layer  364  maintains the card  370  in the form against unintentional removable from the form. A cut-out may be positioned adjacent the periphery of the card  370  and through the base, liner and backing layers  360 ,  366  and  364  in order to facilitate removal of the integrated card  370  from the form.  
         [0087]    The apparatus used to produce the pre-cut laminate  380  receives the backing and liner layers  364  and  366 , for example, in roll form, as illustrated in FIG. 23. The backing layer  364  is unwound and the adhesive  368  is applied thereto using an adhesive application station  368   a.  The liner layer  366  is also unwound, and is directed onto the adhesive  368  applied to the backing layer  364  in order to mate the backing and liner layers  364  and  366 . Alternatively, the adhesive  368  may be applied to the liner layer  366  and the backing layer  364  mated therewith. After the adhesive  368  is applied and the backing and liner layers  364  and  366  are mated, a die cut station  374   a  makes the die cuts substantially through the backing layer  364  to define the integrated removable card portion  374  of the backing layer  364 .  
         [0088]    After die cutting, the precut laminate  380  is converted to in a dispensing configuration. The dispensing configuration is adapted to allow the precut laminate  380  to be attached using adhesive  369  to the base layer  360 . For example, the dispensing configuration of the precut laminate  380  may be a roll which would allow the precut laminate  380  to be unwound into a generally planer feed configuration for feeding through the apparatus used to attach the base layer  360  to the precut laminate  380 , as illustrated in FIG. 26. Another example of a dispensing configuration is a fan-folded configuration. For example, the fan-folding configuration may comprise one or more integrated removable card portions  374  in sheets that are folded relative to each other. The sheets of adjacent fan-folded stacks may be connected to allow for the continuous use of stacks of precut laminate  380  without having to stop the apparatus.  
         [0089]    The apparatus used to produce the business form receives the pre-cut laminate  380  and the base layer  360 , for example, in roll form, as illustrated in FIG. 25. The pre-cut laminate  380  is unwound and the adhesive  369  is applied to the liner layer  366  using an adhesive application station  369 a. The base layer  360  is also unwound, and is directed onto the adhesive  369  applied to the liner layer  366  in order to mate the pre-cut laminate  380  and the base layer  360 . Alternatively, the adhesive  369  may be applied to the base layer  360  and the pre-cut laminate  380  mated therewith. After the adhesive  369  is applied and the pre-cut laminate  380  and base layer  360  are mated, a die cut station  370   a  makes the die cuts substantially through the backing layer  364  to define the integrated removable card  370 . A cut-out for assisting in removal of the card  370  from the form may be made through the backing, liner and base layers  364 , 366  and  360  and positioned adjacent the card  370  using a punching station  378 . After manufacture of the forms, the forms may be provided in an output configuration, such as by winding into a roll  390 , fan-folding, sheeting or the like.  
         [0090]    Printing  367  may be placed on the business form and the components thereof at various stages, such as illustrated in FIG. 25. For example, printing may be placed upon the top and bottom sides of the base layer  360  using printing stations  367   a  and  367   b.  Printing may also be placed on the backing layer  364  of the pre-cut laminate  380  using a printing station  367   c.    
         [0091]    The use of the pre-cut laminate  380  allows for business forms having integrated removable cards or labels  370  to be produced in a multi-step process. For example, a single apparatus may be configured to produce the pre-cut laminate, and then used to produce the business forms by combining the pre-cut laminate  380  with the base layer  360 . This allows for a single machine, having a smaller size and requiring fewer die cut, printing, and adhesive stations, to produce the business forms. Alternatively, the pre-cut laminate  380  may be produced on a different apparatus than that used to combine the pre-cut laminate  380  with the base layer  360 . For example, the pre-cut laminate  380  may be made off-site and delivered to the location of the apparatus for combination with the base layer  360 .  
         [0092]    While there have been illustrated and described particular embodiments of the present invention, it will be appreciated that numerous changes and modifications will occur to those skilled in the art, and it is intended in the appended claims to cover all those changes and modifications which fall within the true spirit and scope of the present invention.

Technology Classification (CPC): 1