CA2192841A1

CA2192841A1 - Label and method for forming a label from double coated tape and transfer tape

Info

Publication number: CA2192841A1
Application number: CA002192841A
Authority: CA
Inventors: Carl W. Treleaven
Original assignee: Individual
Current assignee: Pharmagraphics Midwest LLC; Pharmagraphics Southeast LLC
Priority date: 1994-06-15
Filing date: 1995-06-07
Publication date: 1995-12-21
Also published as: DE69520674D1; US5830550A; US5605730A; DE69520674T2; WO1995034421A1; EP0766623A1; US6027780A; EP0766623A4; EP0766623B1

Abstract

A label product (10) including a web of double coated tape or, in the alternative, an adhesive transfer tape, and a plurality of outserts (50) affixedthereto. The web of double coated tape includes a release liner (48) having an upper surface and a carrier (44) having an upper surface and a lower surface. The lower surface of the carrier (44) is coated with a first adhesive layer (46) and the upper surface of the carrier is coated with a second adhesive layer (42). The carrier (44) is releasably secured to the upper surface of the release liner (48) by the first adhesive layer (46) and the outserts (50) are positioned in spaced relation to one another along the web. The web of adhesive transfer tape includes a release liner (48) having an upper surface and an adhesive layer (46) coating the upper surface. The outserts (50) are positioned in spaced relation to one another along the web.

Description

2 1 9284 1 LABLL AND MErHOD FOR FORit~NG A LABEL
FROM DOUBLE COATED TAPE AND TRANSFER TAPE
This qprlj~ntinn is a i ' tirn-in-part of pending 2.1",1i~Li ll Serial ~o. 08/259,856 filed on June 15, 1994.
Field Of The Inveoffon The present invention is directed to a package iabel and method of forming a package label, and, more particularly, to an adhesive backed label having an outsert carried thereon and a method for forming the same from a double coated adhesive tape or an adhesive transfer tape.
~-kL.~ ' O~The i~enffQn In the paci~aging of certain chemicals and pl~ lc, the is often required or desires to provide a considerable amount of ~.. ".-.. ~ the chemical or ph~l ' l. In the case of chemicals and I' .-I~lltirqlc this is required by ~u.. l I ..l~ c 20 However, the occasion may also arise, either separate frQm or in CVJ.~
with fjV._l r~f~lqtirnC to pr^vvide the doctor, rhq ict or user with .,t~ Li!v,ls on how the product should be used, what the product is, and safeLy ,u,~uLivl~s which should be followed in the use of the product~ S~ the literature, which is genera~ly in the form of folded leaflets, is placed within a box 25 along with the container carrying the chemical or ph..l ~ I (referred to as "inserts"). At the same time, in additiûn to the insert, a primary label must beapplied to the outside of the paci~age to remain therewith. This requires a second assemhvly operation. The placement of leaflets within the box is expensive and a ~ ~ operation to perform. Aiso, it is difficult as well as ecpensive 30 to ~nsure by later inspection that the proper literature has been inserted in the proper package.
A different approach to solving this problem has developed over the last several years in which the folded literature or leafiets are releasably attached to a face of the container (referred tû as "outserts"), either directly to the container 35 itself, or to a base label which, in turn, is secured to the container. The 2~ 928~1 iterature may then be removed by the customer. ln many of such cases, the portion of the label remaining on the container must carry both an ri. At;..~ of the product defined as information such as trademark and/or product id~nt;firAtion number, rnsr.-lfsrhlrer and location, etc., as well as certain 5 "stahutory i.,r~ r" (defined as lot number and expiration date).
Thus, in order to meet the objectives of such labeling techniques, certain criterli must be meL First of all, the portion of the label which remains after the folded literahure is removed must contain both the hl~ntifirstir,n of the product, as well as the sLahutory information co..c~ the lot number and expiration date. F~urther, after the literature leatlet is assembled or affixed to the base label, the indicated area for stahutory information COI~C.,.llil.~ Iot number and expiration date must be accessible for stamping or printing by the pil~ company at the time the pl~ c~ i~l product is r snllfsrhlred and packaged. This information must be visible to the consumer in addition to the i~h~ntifir~t~~ of the product. The folded leaflet portion remains affixed to the label portion until the customer (doctor, rhsl t, consumer) desires its removal. It is critical that the proper literahure must beaffixed to the proper base label. Finally, all of the above criteria must be accomplished in a ~ -~Irin~ technique that insures quality and is cost-effectiYe.
Examples of types of labels in the prior art which have addressed some oi these criteria are described in U.S. Patent Nos. 1,273,105 to VanDyke et al.;
4,621,837 to Macir, and 4,323,608 to Denny et al. They are examples of labels which have removable portions thereto.
In U.S. Patents Nos. 5,207,746 and 5,263,743 to Jones, there are disclosed label constructions whereby the underlying base label is~ ' t~l The literahure, base label, and area for stahutory infol -t- are all combined into aunitary or integral product. The label constructions as disclosed therein have abottom hlrntifi( ~tif ~ panel which is adhered to a package by means of a pressure sensitive adhesive coating on its underside. To facilitate handling, the labels ale pre~b~ m~unled on a slli~ t~i ~Ibase liner.

2 1 q284 1 ' Three methods are known for applying adhesive to a folded leaflet or to tile underside of a separate base label as taught in the prior art. An adhesive patch may be applied to the upper surface of a release liner followed by the placement of an outsert or base label thereon. All~ .-Li~lJ, adhesive may be S applied to the underside of the bottom panel of the outsert or to the underside of the base label followed by the placement of the outsert or base label onto the release liner. Finally, a c, - layer of adhesive may be applied to the release liner followed by the placement of outserts or base labels thereon.
Each of the ~ d~livcv methods for applying pressure sensitive 10 adhesive suffers v ~ nt drav~backs and limit:lti-m~ For the first two methods, it is generally necessary to coordinate the application of adhesive andbottom panels or base labels to insure proper registration. If patches of adhesive are used, they must be , ' '~, covered by the outser-ts or base label to avoid blnding when the strip of labels is ultimately rewound and unwound.
15 Where adhesive is applied on the underside of the bottom panel or base label, it is necessary to stop applying when an outsert or base label is not in place to avold applying adhesive over the work area.
If a ~ ~ strip of adhesive is applied to the release liner, either a - base stock must be applied or the excess adhesive must be remoYed 20 prior to placement of the base labels or outserts thereon. If the adhesive is to be removed, then the outsert or base label placement must be coordinated as discussed above v,~ith regard to adhesive patches.
Thus, there exists a need for a method for forming pressure sensitive adheslve backed labels mounted on a release liner wbich does not require an ZS adhesive applying station. FUI~ there exists a need for such a label u~Lion method wherein the bottom panel of an outsert becomes adhesive coated and is designed to remain with the associated package as a primary label when the .~.. illd~. of the outsert is removed.
Summarv Of The Invention The present Invention is directed to a pressure sensitive adhesive backed outsert and a method for forming the same. According to the present invention, ' t~e lear~ets or outserts are i ~ affixed to what is known as ~double coated tape" or, alt~ L~ r, to adhesive transier tape.
"Double coated tape", as used herein, includes a silicon release liner and a first layer of adhesive covered by a carrier which is in turn coated with a second 5 adhesive layer. The first layer of adhesive is releasably mounted on the liner while the carrier is ~ coated on opposite sides by the first and second adhesive layers. Preferably, the carrier is a relatively thin pol.",~ n~ film.
Labels having varying advantages and characteristics may be formed by the following methods of forming labels utilizing the double coated tape as described 10 above.
labels according to a first: hotl' ~ may be formed by the following method. Outserts or the like are placed on the second layer of adhesive. A layerof clear film laminate is then placed over the outsert and is secured to the tape along the portion or the second layer of adhesive not covered by the outserts.
1~ The construction is then diecut about the periphery of the outsert so that a border is formed adjacent to at least two sides of the outsert. The waste matrixis then removed. Because a laminate cover is provided, a non-coated and/or non-varnished printing stock may be used to form the outsert. Further, the laminate protects the bookiet and provides greater integrity to the label.
20 Labels according to a second ~ may be ~O.. a~ll.. ~d by the following method. The unwound, double coated tape is diecut through the carrier and both layers of adhesive to the release liner to form patches of the size (or smaller) and shape of the object to be carried thereon, e.g., an outsert.
The unv~anted portion of the tape or the waste matrix is then removed from the 25 liner. The outserts or the like are then placed on the patches.
Labels according to a third . ' ~ ~ may be formed by the following method. A deadening agent (a substance which remoYes the adherent property of adhesive) is applied to the exposed adhesive such that a portion of adhesive remains exposed. The outserts are p~aced on the exposed portion of the second 30 layer of adhesive. The tape is then diecut leaving a border around the outsert, through the two adhesive layers and mer down to the liner and the waste matrix is remoYed. It Y~ill be ~ ~ that the "deadened" adhesi~e w~l n~t cause binding when the strip of labels is wound.
"AdhesiYe transfer tape", as used herein, includes a silicon release liner merely coYered by an adhesiYe layer without a carrier or p~ GIJ.~ Iayer.
5 The adhesiYe is releasable from the liner. Labels haYing Yarying ad~ and .l.al.lc~.~iaLi-s may be formed by the following methods of forming labels usingthe transfer tape as described.
Labels according to a fourth: 'c '~ may be formed by the following method. Outserts or the like are placed on the layer of adhesiYe. A layer of 10 clear film laminate is then placed oYer the outsert and is secured to the tape along the portion of the layer of adhesiYe not coYered by the outserts. The c~..LI. is then diecut about the periphery of the outsert so that a border is formed adjacent to at least two sides of the outsert. The Yaste matrix is then remoYed. Because a laminate coYer is proYided, a non-coated and/or non-15 Yarnished printing stock may be uâed to form the outsert. Further, the laminateprotects the bookiet and proYides greater integrity to the label.
As an alternatiYe to the preceding method, labels according to the fourth ~-mhod may be formed by the following method. First, the transfer tape is unwound from a roll. A multiple up book is then placed on the adhesiYe layer.
20 A clear laminate haYing adhesiYe on the side facing the transfer tape is thenapplied over the transfer tape and the multiple up booi~s. The laminate and books are then face cut do Yn to the release liner, creating two or more side-by-side indiYidual outserts from each multiple up book. The waste matrix including the adhesive between the indiYidual outserts and the outsert waste portion 25 between the indiYidual outserts is then remoYed by pulling up the clear laminate.
Labels according to a fifth: ' :' may be formed by the following method. The transfer tape is unwound and outserts or the like are placed thereon. Multiple outsert applying magazines may be used. A non-adhesive laminate is placed oYer the web and the outserts, and the construction is passeù30 tbrougil a nip roller. The laminate, along with the adhesiYe not coYered by the outsert, is then remoYed.

2192~1 . As an alternative to the preceding method, labels according to the fifth r~hod may be formed by the following method. First, the transfer tape web is unwound and multiple up books are placed thereon. The multiple up books are then face cut, creating the foot print of the individual outserts and the 5 respective labels. Next, a second web of clear laminate material having no adhesiYe is unwound. The clear laminate is run through a print station which applies a band of adhesive in the web direction. The bands are si~ed and configured to run between each of the individual outserts, being ap,v~
the same width as the outsert waste portions. Next, the clear laminate material 10 with the adhesiYe bands is laminated to the transfer tape and outserts. The laminate material is removed. Removal of the laminate material pulls up the exposed adhesive between the multiple outserts and pulls away the waste material between the parts of the multiple up respective outserts.
Labels according to a slxth ~-mho~-- may be formed by the following 15 method. A deadening agent is applied to the exposed adhesive such that a portion of adhesive remains exposed. The outserts are placed on the exposed portlon of the layer of adhesive. It will be appreciated that the "deadened"
adhesive v~ill not cause binding when the strip of labels is wound.
As an alternative to the preceding method, labels according to the sixth 20 ~ ' ~'' may be formed by the following method. First, adhesive deadener is applied to the unwound transfer tape web at areas where no books are to be applied. Next, multiple up books are placed on the web. The multiple web books are then face cut to the release liner to form individual outserts. Bands of adhesive are applied to a clear laminate material and the laminate material is 25 then laminated to the transfer tape. Thereafter, the laminate material is removed, taking up the outsert v~aste portions therewith.
It is an object of the present invention to provide a label o~ the type including an outsert or leafiet having a pressure sensltive adhesive backing.
It is another object of the present invention to provide a label of the type 30 described which creates a unitary cv~ u~lh).. which carries both the primary label and the information normally carried separately on an insert or outsert.

. ~ .

2 1 9284 ~
' It is an object of the present invention to provide a method for forming a label as described above.
lt is an object of the present invention to provide a label as described above, which does not require the application of adhesive to the label or the 5 leaflet.
It is an object of the present invention to provide a method as described above which is cost effective and ....;~..t.
It is an object of the present invention to provide a label as described above which may also include a laminate cover and a method for forming the 10 same.
Brier D~ ' ' Of The Dra~ s FIGURE 1 is a p~a~.Li~ view of a first embodiment according to the present invention.
FIGURE 2 is a side f~l~v~t;~ l view of a section of the double coated tape of the present invention.
FIGURE 3 is a p.~a~ . of a typical type of outsert intended for use in the preferred ~r~ho~' of the present invention.
FIGURE 4 is a diagrammatic side elevational view of an apparatus ~0 adapted to produce the labels of FIGURES 1-3.
FIGURE 5 is a p. a~ view of a second Pmhorl of the present invention.
FIGURE 6 is a diagrammatic side elevational view of an apparatus adapted to produce the labels of FIGURE 5.
Z5 FIGURE 7 is a p/, a~.. Li ~ view of a third . ' :'' according to the present invention.
FIGU~E 8 is a di.~ ..... ti~ side elevational view of an apparatus adapted to produce the labels of FIGURE 7.
FIGURE 9 is a p~a~.liv~ view of a fourth l~rnhol'' according to the 30 present invention.
FTGURE 10 is a side elevational view of a section of the adhesive transfe~
tape of the presen~ invention.

FIGURE 11 is a l/~a~u~ view of a fifth ' G ~imPnt of the present invention.
FIGURE 12 is a l.~.a~ view of a sixth: ' -'im~nf according to the present invention.
FIGURE 13 is a p.~a,u~.Li . view of a web of adhesive transfer tape with a multiple up book piaced on the upper surface thereof.
FIGURE 14 is a ii~6. - side ~1~. l view of an apparatus adapted to produce the labels of FIGURE 9 using multiple up books.
nGURE 15 is a di.~6. fje side ~ -l view of an apparatus adapted to produce the labels of FIGURE 11 using multiple up books.
.~FIGURE 16 is a dia6l fi~ side elevationa! view of an apparatus adapted to produce the labels of FIGURE 12 using multiple up books.
Detaiied Description Or the Inverltiorl As used herein, the term "outsertn means any type of outsert, leaflet, sheet, or the like for carr~Ying information thereon and/or serving as a primarylabel.
The unique aspect of the present invention resides in the use of the double coated tape 40 or, in the alternative, adhesive transfer tape 540 to wbich the outserts or leaflets are affu~ed and the manner in which the labels are produced.
Referring now to FlGUi~ES 1, 5, and 7, first, second, and third '-' of the present invention, ~ .ly~ are shown therein, each being formeti from double coated tape. Labei 10 of FIGURE 1 includes a film laminate cover. Label 110 of FIGURE 5 is ~ l and is formed without a border surrounding the outserf Label 210 of FIGURE 7 is likewise llnlomirl~f~tl but includes a border 264 au~Luulldill~, the outsert in which the adhesive has been removed.
The double coated tape 40 is best seen in FIGURE 2. Tape 40 includes liner 48, adhesive layer 46, carrier 44, and second adhesive layer 42. Adhesive layers 46, 42 are preferably formed from pressure sensitive adhesive. Carrier 44is preferably formed from a pûly,ul~ .. substrate haYing a thickness of 2 ~ 9284 1 b~e~n 0.5 mil (.0005 inch) and 4.5 mlls (.0045 inch). Dou~le coated tape such as 3M Scotch Brand Tape product number 9458 is exemplary of one product v~hich may be used. Double coated tapes having a second re~ease liner layer located on second adhesive layer 42 may also be used. Note that the relative si~e of the tape and thickness of the layers has been ~ b~ L~ in the drawings for the sake of clarity. ~referably, layers 42, 44, 46 which remain with Inbel 10 when the same is removed from liner 48 will appear as a thin adhesive film on the lower surface of bottom panel 56.
Referring now to FIGUE~ES 1-4 in general and to FIGURE I in particular, a first and preferred: ' ~' of the label of the present invention, generally denoted 10, is shown therein. Label 10 includes a supporting patch 22 formed from the POIY~IUIJYI~ Iayer 44, which is releasably secured to release liner 48,and outsert 50 which is secured to the top of patch 22. Laminate cover 60 coversboth outsert 50 and its support patch 22.
Outsert 50, as best seen in FIGURE 3, is preferably of the type disclosed in U.S. Patent No. 5,263,743. However, it will be appreclated that other types of outserts, leaflets, sheets and the like may be used. Outsert 50 includes bottom panel 56, title panel 54, marginal edge portion 55, and i.,t... _lid~e panels 52.
Tear lines 57 and 58 are provided between bottom panel 56 and panels 52 and 54, ~ ly. Tear line 59 is provided between panel 54 and marginal edge portion 55. Bottom panel 56 and the inner surface of marginal edge portion 55 are adhered to second adhesive layer 42. Depending on the application, outserts may be used which do not have marginal edge portion 55 and/or one or more of tear lines 59, 58, and 57. If marginal edge portion 55 is not used, it may be preferable to apply adhesive between the underside of panel 54 and the mating surface of panel 52. Statutory illful ).1 may be printed on panels 54, 56, or borders 62, 264 (as described below) and/or the laminate cover.
Patch 22 is somewhat larger than outsert 50, thereby forming borders 62.
Film layer 60 is formed by a preferably clear film secured to patch 22 along theperipheral portion of second adhesive layer 42 located in borders 62. Preferably, laminate 60 does not have adhesive on its inner surface so that it covers outsert 50 with~ t adherin to the same. Laminate 60 se~ es to protect outsert 50 l~m 2 ~ 9284 1 ' ~amage during handling of the package. Laminate 60 is provided veith a perîoration 61 to facilitate access to the outsert.
Label 10 according to the first . ' - may be ~ ~_t ~i as follows and v~ith reference to FIGURE 4. A co ' strip of tape 40 is removed from 5 a roll, or ~.... ' ~ station 340 as described above such that second adhesive layer 42 faces upwardly. A succession of outserts 50 are fed from a supply hopper or outsert applying station 350 at spaced intervals along tape 40. Station 350 preferably applies outserts in response to r~ 352 whose eye senses marks previously printed on the release liner. These marks may be 10 printed after the roll is unwound using a printing station (not shown). A
' layer of film 60 is fed from a supply roll or laminate applying station 360 over second adhesive layer 42 and outserts 50. It will be appreciated that laminate 60 will be adhered to the portion of adhesive layer 42 not covered by an outsert 50. Tape 40, laminate 60, and outsert 50 are then passed through nip rollers 362 to secure the assembly. A diecutter 370 forms perforation 61 in laminate 60 and a cut line framing each outsert. r-~f~,.a~ 61 goes only through the lamlnaffon. The cut line e~tends dov~n through both adhesive layers 42, 46 and through carrier 44 to release liner 48. The cut line is preferably spaced from the edges of outsert 50 such that borders 62 are formed on two 20 sides. Following the cutting operation, the resulting waste matrix 80 (i.e., those portions of layers 42, 44, 46, 50 and 60 not within the periphery of the cut lines) is removed from the construction at removal station 380. Upon removal of the v~aste matrix, labels 10 remain on release liner 48. The release liner and labels may be wound onto a take-up roll or v~inding station 390 or fan folded into a 25 stack. The finished web may be slit I " lly if desired, for example, to form a four wide or "four-up" label roll into four separate label rolls. It v~ill be appreciated that because all of second adhesive layer 42 has been either removedor covered by iaminate 60, the liner and labels may be suL,~ , '.r unwound for use without bindin~. It V~ill be appreciated from the foregoing that the method 30 as described allows a margin of error for placement of the outsert and location of the diecut.

21 92~4 1 A label 110 according to a second: ~imPnt of the present inventiOn, best seen in FIGUr~E 5, is formed without the use of a laminate cover. The numerals 158, 154,150,159,155,146,144,142, 152,156,148 and 157 indicate elements which CO~r~ to elements 58, 54, 50, 59, 55, 46, 44, 42, 52, 56, 48, and 57, ~ .lJ, of the first: ': ' Label 110 includes a patch 120 identical to patch 22 of the first ~ except that patch 120 is sized and shaped to fft at or within the periphery of outsert 150. It will be '~I'r~ ~;atal that because outsert 150 covers all of the second adhesive layer 142 of patch 120, the liner and labels may be rolled and unrolled viithout binding.
Labels 110 of the second: ' ~ ' may be constructed as follows and v~ith reference to FrGURE 6. Tape 140 is unwound from a roll at unwinding station 440. Tape 140 is diecut at cutting staffon 470 down to liner 148 and in the shape of patches 120. The resulting waste matrix 182 is then removed at removal station 480, leaving patches 120 on liner 148. As patches 120 pass under outsert applying station 450, outserts 150 are ~ .ly placed thereon whereby they are adllered to second adhesive layer 142. Resultant labels 110 may then be wound onto a roll by winding station 490. The order of steps as described above is preferred because it requires less exact placement of the cutlines. That is, patch 120 may be cut smaller than the area of outsert 150 to allow for error in the placement of outsert 150.
Labels 210 according to a third ~...I,odj,.._.~t of the present invention, as best seen in FIGURE 7, may be formed without a laminate cover while still providing a patch 222 which extends beyond the periphery of outsert 250. The numbers 258, 254, 250, 259, 255, 256, 242, 244, 246, 248, 252, and 222 indicate elements which .Oll~_, ' to elements 58, 54, 50, 59, SS, 56, 42, 44, 46, 48, 52 and 22, ~ , of the first Pmho~l~mPnt Label 210 includes patch 222 which is larger than outsert 250 such that borders 264 extend be~ond the edges of outsert 50. The portions of second adhesive layer 242 which make up borders 264 are treated with a deadening agent such that they are no longer adherent.
Deadening agents suitable for this purpose include product number FM1512 from K&W Printing, Inc., or Franklin P~rii, Ill~nois. rt will be appreciated that 2]928~
' l~bels 210 mounted on release liner 248 may be rolled and unrolled ~thout bind~ng because no adherent adhesiYe is exposed.
Labels 210 according to the third ~ may be formed as follows and with reference to FIGURE 8. A strip of tape 240 is unwound 5 from a supply roll at unwinding station 540. A deadening agent is applied onto the ~ by coating station 595 such that a portion of non-deadened adhesive rema~ns exposed. Outserts 250 are then ~ applied to the ' adhesiYe on the upper surface of tape 240 at outsert applying station 550. At cutting station 570 diecuts are formed around each outsert 250 down to liner 248 such that borders 264 are formed thereabout. Alternatively, the cutting step may take place prior to the ~ of the outsert. The resultant waste matrix 280 is removed at remoYal station 580. The resulting labels 210 and liner 248 may then be rolled onto a roll by winding station 590.
It will be ap~ t~l from the foregoing that the method as described provides a 15 margin of error for locating the outserts and the cut lines.
It will be appreciated that in each of the methods described aboYe, if a double coated tape of the type having a second release liner is used, the secondliner will be remoYed as a part of the unwinding step.
In each of the a'vv.~ d~.~;bed methods, a plurality of individual outserts 20 may be placed across the web using a co~ vnling number of outsert applying stations (not shown) spaced across the web. The web may thereafter be slit into individual webs, each having labels thereon.
~ Multiple up" books g0, as shown in FIGURE 13, for example, are books which may be placed on the double coated tape, and :...v . l~ cut into more 25 than one complete individual outsert 92 such that a plurality of indlvidual outserts will then extend across the web, which may or may not thereafter be slit into individual webs. Each outsert 92 will be r h5t~nti:~lly identical to outserts 50,150, 250 as described aboYe. Typically, a margin of about one-half inch is provided between indiYidual outserts 92 so that, once the multiple up book is cut, 30 there remain one or more waste portions of outsert material 96 between cut lines 94 that must be removed along with the other waste matrix materials. In each of the above-described methods, if multiple up books are used, the outsert waste ' portions will be removed along v~ith the other ~vaSte matrix without further provlsion because of ehe ~ L._iiO~I of the double coated tape. More speclfically, the outsert waste portions are disposed outside the diecut region of the labels. As the waste matrix is removed, the outsert waste portions 96 are pulled away from ~ ` ' by the adhesive and carrier layers which form a substrate i' ~ .. That is, as ehe adjacent portions of the carrier and adhesive layers are pulled up, the portion beneath the outsert waste portioncomes up as well, bringing the outsert waste portion with it.
Referring now to FIGURES 9,11, and 12, fourth, rlfth, and sixth ; l c of the present invention, ~ , are shown therein, each being formed from adhesive transfer tape rather than the double coated tape of FIGURES 1-8. Label 310 of FIGURE 9 includes a film laminate cover. Label 410 of FIGURE 11 is, ' ' ~Pr~ and is forlned without a border surrounding the outsert. Label 510 of FIGURE 12 is likev~ise ~ r~l but includes a border 964 aU~ ,, the outsert in which the adhesive has been removed.
The transfer tape 540 Is best seen in FIGURE 10. Tape 540 ~ncludes liner 548 and adhesive layer 546. Preferably, liner 548 includes a sllicon coating on both sides. Adhesive layer 546 is preferably formed from pressure sensitive adhesive. Transfer tape such as 3M Product #9447, 1 mlllimeter high tenacity tape with 320 adhes~ve is exempiary of one product which may be used. Transfer tapes having a second release liner laYer located on adhesive layer 546 may alsobe used. Note that the relative size of the tape and thicicness of the adhesive layer have been ~ ~ d in the drawings for the sake of clarity. Preferably, layer 546 which remains with label 310 vYhen the same is removed from liner 548 will appear as a thin adhesive film on the lower surface of the bottom panel of the outsert.
Referring now to FIGURES 9 and 10 in general and to FIGURE 9 in particular, a fourth: ' L ~r ' of the label Or the present invention, generally denoted 310, is shown therein. The numerals 558, 554, 550, 559, 555, 552, 556, and 557 indicate elements which ~olL~Inn.d to elements 58, 54, 50, 59, 55, 52, 56, and 57 of the first PlnhoAi~nPnt Ir~Ll..~i~.l). Label 310 includes a au~,G.Li-l~ patch 522 formed from adhesive 546 which is releasably secured to --- 2 ~ 928~ ~
release liner 548, and outsert 550 which is secured to the top of patch 522.
Laminate cover 560 covers both outsert 5~0 and its Support patch 522.
Patch 522 is somewhat larger than outsert 550, thereby forming borders 562. Film layer 560 is tormed by a preferably clear film secured to patch 522 along the peripheral portion of adhesive layer 546 located in borders 562. Film layer 560 preferably includes adhesive on its inner surface. Laminate 560 servesto protect outsert 550 from damage during handling of the package. Laminate 560 is provided with a perforation 561 to facilitate access to the outsert.
Preferabiy, laminate 560 has a thickness in the range of 2-3 mil to facilihte al.~,li~t:c.1 of labels 310 from the release liner to packages. The increased thickness helps to reduce buckling of the laminate due to the thickness of the outsert and the large amount of adhesive present on the transfer tape.
Label 310 according to the fourth . im.-nl may be ~o...l-u~t~i using the same apparatus as used to construct label 10 as shown in FIGURE 4, and by the same method except that tape 540 is ~ui~ ul~i for double coated tape 40.
In this case the cut line formed by diecutter 570 extends down through adhesive layer 546 to release liner 548. Simllarly, the release liner and labels may be wound onto take-up roller winding station 390 or fan folded into a stack.
Mu~tiple individual outserts may be placed across the web by multiple outsert 20 applying stations (not shown) spaced across the web. The web may thereafter be slit into a plurality of individual webs having labels thereon. It will be appreciated that because all of adhesive layer 546 has been either removed or covered by laminate 560, the liner and labels may be ~ y~ lly unwound for use without binding. Again, it will be appreciated that the method as described 25 allows a margin of error for placement of the outsert and location of the diecut.
If multiple up books 90, as best seen in FIGURE 13, are used to produce labels according to the fourth, fifth, or sixth ~mho~im~nt~ (discussed below) removal of the outsert waste portion 96 (the margin of book material between respective individuai outserts) will be more diflicult. This is because the transfer 30 tape lacks the carrjer layer and the integrity provided thereby which aided in the removal of this waste in the production of labels according to the first, second, and third embodiments. With this draw-back of transfer tape in mind, the ~ .

21 9284 t 1~ following method may be used for forming labels according to the fourth ~imPnt using multiple up books.
With reference to FIGURES 13 and 14, labels 310 according to the fourth ' may be formed by first ul...;..ljl b the transfer tape 540 from 5 unwinding station 640. A multiple up book 90 is then placed on the adhesive layer by booklet applying station 650. A clear laminate 561 having adhesiYe on the side facing the transfer tape is then applied by laminate unwind station 660over the transfer tape and the multiple up books. Tape 540, books 90, and laminate 561 are then passed through nip rollers 662. The laminate and books 10 are face cut down to the release liner by diecutter 670, creating two or more side-by-side Individual outserts 92 from each multiple up bool~ The waste matrix 681 including the adhesi~e between the individual outserts and the outsert waste portion between the Endividual outserts is then removed by rewinding station 680. Labels 310 may then be wound onto a take-up roll by winding station 690.
15 Optionally, the web may be slit into a plurality of webs having labels thereon prior to winding.
A label 410 according to a fifth embodiment of the present invention, best seen in FIGURE 11, is formed without the use of a laminate cover. The numerals 758, 754, 750, 759, 755, 746, 756, 748, and 757 indicate elements which~UIII~ JO. ~ to eleme[lts 558, 554, 550, 559, 5~5, 546, 552, 556, 548, and 559, m~Li.~ly~ of the fourth Pm~oA~ Label 410 includes a patch 720 identical to patch 522 of the fourth Pmho~ 1 except that patch 720 is sized and shaped to fit at or within the periphery of outsert 750. It will be appreciated that because outsert 750 covers all of the adhesiYe layer 746 of patch 720, the linerand labels may be rolled and unrolled without binding.
` Labels 410 of the fifth; ' ~ " may be constructed uslng the same apparatus as used to construct label 110 as shown in FIGURE 6 and by the same method except that tape 740 is s~-hstit--tPA for double coated tape 140.
Removal of the waste adhesive may be accomplished by applying a laminate to the construction, passing the construction with laminate through a nip roller, and removing the laminate and excess adhesive along with it. Multiple, individual outserts may be placed across the web by multiple outsert applying 2 1 9284 ~
stations ~not shown) spaced acroSs the web. The web may thereafeer be slit into a plurality of individual webs having labels thereon.
With reference to FIGURE 15, labels 410 according to the fifth I ~ t may be produced using multiple up books using the following method. First, the transfer tape web 740 is unwound from winding station 840 and multiple up books 790 are placed thereon by booklet applying station 8S0.
The multiple up books are then face cut by cuKer 870, creating the foot print ofthe individual outserts and the respective labels 410. Next, a second web of clear laminate material 7~1 having no adhesive is unwound. The clear laminate is run L0 through a print station 871 which applies band or bands of adhesive in the web direction. The bands are slzed and collfigured to run between each of the individual outserts and adjacent the outer edges of the end outserts if outsert waste portions are present there. Next, the clear laminate material with the adhesiYe bands is laminated by laminate unwind station 739 to the transfer tape 15 and outserts. The, ~ )is then passed through a nip roller 735 and the laminate material is removed by removal station 743. Removal of the laminate material will pull up the exposed adhesive between the multlple outserts and pull away the outsert waste portion between the outserts (coll..li..l~, waste matrix 742). Only the indi-idual outserts 792 and their respective adhesive patches 720remain on liner 748. The liner with labels thereon may then be slit into two or more webs andlor wound onto a roll by winding station 890.
Labels 510 according to a sixth P~n~m~" of the present invention, as best seen in FIGU~E 12, may be formed without a laminate cover while still providing a patch 922 which extends beyond the periphery of outsert 950. The numbers 958, 954, 950, 959, 955, 956, 946, 948, 952, and 922 indicate elements which c~ d to elements 558, 554, 550, 559, 555, 556, 546, 548, 552, and 522, respectively, of the fourth P-nho.' Label 510 includes patch 922 which is larger than outsert 950 such that borders 964 extend beyond the edges of outsert 950. The portions of adhesive layer 946 which make up borders 964 are treated with a deadening agent such that they are no longer adherent. It will beappreciated that labels 510 mounted on release liner 948 may be rolled and unrolled without binding because no adherent adhesive is exposed.

' Labels 510 accor~iing to the sixth; ~ may be formed using the same npparatus as used to construct label 210 as shown in FlGUi~ 8, and by the same method except that tape 940 is, ~ l for double coated tape 240.
Multiple individual outserts may be placed across the web by multiple outsert 5 applying stations (now shown) spaced across the web. The web may thereafter be slit into a plurality of individual webs having labels thereon. Agaln, it will be appreciated that the method as descAbed provides a margin of error for locating tbe outserts and the cut lines.
With reference to FlGUi~E 16, labels 510 according to the sixth 10 i '~ " may be produced us~ng multiple up book5 990 using the following method. First, adhesive deadener is applied to the unwound transfer tape web 940 at areas where no books are to be applied by means of coating station 1095.
Next, the multiple up books 990 are placed on the web by book applying station 1050. The multiple up books are then face cut down to the release liner by cutter 1070 to form individual outserts 992. As in the previous method, bands otadheslve are applied to a clear laminate material 981 by print station 1081 and the laminate mateAal is then laminated to the transfer tape using nip roller 935.
Thereafter, the laminate material is remoYed by removal station 1079, taking up the outsert waste portions and any exposed, non-deadened adhesive therewith.
20 Optionally, the iiner with labels thereon may be slit into two or more webs and/or wound onto a roll by winding station 1090.
As an alternative to unrolling prefabricated transfer tape as disclosed above, the transfer tape may be formed as part of the label forming process.
Flrst, a release liner is unwound and the upper surface thereor is coated by a 25 coating station with an adhesiYe as discussed above. The transfer tape thus formed is thereafter li l~t~(~ as descAbed above.
It will be dpy~ i that labels according to any of the above-described methods can be paci~aged by winding or fan-folding without exposing the title panel to exposed, actiYated adhesive, because all of the adhesive not covered by30 the bottom panel is either covered, deadened, or removed.

2 1 9284 ~
' It v~ill be ~ t~d that in each of the methods described abo-~e, ~f a transfer tape of the type having a second release liner is used, the second liner v~ill be removed as a part of the unv~inding step.
In any of the methods discussed above, it may also be ad~ Lh~..~ to 5 apply adhesive deadener to the double coated tape or to the transfer tape prior to applying the outserts. In particular, one may vish to apply adhesive deadenerIn areas '' '~ adjacent to the folded edge side of the outserts. The reason for this is that the folded outserts tend to create a certain amount of buli~iness, and it may be difficult to remove the exposed adhesive - ' 'y 10 next to these locations. In each of the above-described methods, It may be necessary to bring the exposed adhesive layers of the double coated tape or the transfer tape into contact v~ith rollers. Preferably, these rollers are coated with a teflon coating to repel the adhesiYe and avoid gumming.
In: ' c' one and four discussed above, it may be desirable to add 15 a second tear line in the laminate cover adjacent the edge of the outsert oppos~te the first tear line. With such provision, a user may tear the first tear line, remove the outsert, and then remove the fiap of laminate cover by tearing along the second tear line. It v~ill be ~ .h.t.l that only the remnants of the l~mi ]te c~ver will rcmain ~ the p~c mg~.

Claims

What Is Claimed Is:

1. A label product, comprising:
(a) a web of transfer tape, said web including a release liner having an upper surface and a layer of adhesive thereon;
(b) a plurality of outserts affixed at spaced positions along said web, each of said outserts having a bottom panel;
(c) said adhesive layer interposed between said upper surface and each of said outserts; and (d) wherein each of said outserts is releasably secured to said upper surface of said release liner by said adhesive layer.

2. The label product of Claim 1 further including a laminate cover covering each of said outserts and secured to said upper surface of said releaseliner by said adhesive layer.

3. The label product of Claim 2 wherein said laminate is secured to said adhesive layer by a border of adhesive formed about each of said outserts.

4. The label product of Claim 1 further including a border formed about each of said outserts and wherein said border comprises deadened adhesive.

5. The label product of Claim 1 wherein substantially all of said adhesive layer is covered by said outserts.

6. A method for manufacturing labels, comprising the steps of:
(a) unwinding a transfer tape, the tape comprising a release liner having an upper surface and the upper surface coated with an adhesive layer, the adhesive layer releasably secured to the upper surface; and (b) placing an outsert having a bottom panel on the upper surface of the release liner such that the bottom panel is releasably secured thereto by the adhesive layer; and (c) packaging the labels.

7. The method of Claim 6 further including the step of cutting the tape through the adhesive layer to form a patch, wherein said step of placing an outsert includes placing the outsert on the patch.

8. The method of Claim 7 wherein said step of cutting precedes said step of placing an outsert.

9. The method of Claim 7 further including the step of applying a laminate cover over the outsert and the upper surface of the release liner, wherein the laminate cover is secured to the release liner by the adhesive layer.

10. The method of Claim 9 wherein said step of laminating precedes said step of cutting.

11. The method of Claim 7 further including the step of applying a deadening agent onto a portion of the adhesive layer not covered by the outsert.

12. The method of Claim 11 wherein said step of applying a deadening agent precedes said step of placing an outsert.

13. The method of Claim 6 wherein said step of packaging includes rewinding the transfer tape with the outserts thereon.

14. The method of Claim 6 wherein said step of packaging includes fan-folding the transfer tape with the outserts thereon.

15. The method of Claim 6 wherein the step of placing an outsert includes placing a multiple up book on said upper surface of said release liner,and further including the steps of cutting the multiple up book to form a plurality of individual outserts and at least one outsert waste portion disposedbetween respective individual outserts, and removing the outsert waste portion.

16. The method of Claim 15 further including, prior to the step of cutting, the step of applying a laminate cover having adhesive on its lower surface onto the upper surface of the transfer tape and the multiple up book, and wherein the step of cutting includes cutting the laminate cover, the multiple up book, and the transfer tape down to the liner, thereby defining a plurality of labels, the outsert waste portion being disposed between the labels, and whereinthe step of removing the outsert waste portion includes removing the portion of the laminate cover outside the plurality of labels from the transfer tape, whereby the outsert waste portion and a portion of the adhesive layer not within the plurality of labels is removed therewith.

17. The method of Claim 15 wherein said step of removing the outsert waste portion includes applying a laminate having an adhesive band on its underside onto the upper surface of the transfer tape and the multiple up book such that the adhesive band adheres to the outsert waste portion, and thereafterremoving the laminate whereby the outsert waste portion is removed therewith.

18. A label product, comprising:
(a) a web of double coated tape, said web including:
(i) a carrier having a thickness of between 0.5 mil and 4.5 mils and an upper surface and a lower surface;
(ii) a release liner having an upper surface;
(iii) said lower surface of said carrier coated with a first adhesive layer and said upper surface of said carrier coated with a second adhesive layer, (Iv) said carrier releasably secured to said upper surface of said release liner by said first adhesive layer; and (b) a plurality of outserts affixed at spaced positions along said web, each of said outserts having a bottom panel, said outsert secured to said upper surface of said carrier by said second adhesive layer.

19. The label product of Claim 18 further including a laminate cover covering each of said outserts and secured to said upper surface of said carrierby said second adhesive layer.

20. The label product of Claim 18 wherein said laminate is secured to said second adhesive layer by a border of adhesive formed about each of said outserts.

21. The label product of Claim 18 further including a border formed about each of said outserts and wherein said border comprises deadened adhesive.

22. The label product of Claim 18 wherein substantially all of said second adhesive layer is covered by said outserts.

23. A method for manufacturing labels, comprising the steps of:
(a) unwinding a double coated tape, said tape comprising a release liner having an upper surface and a carrier having an upper surface and a lower surface, said lower surface coated with a first adhesive layer, and said upper surface coated with a second adhesive layer, said carrier releasably secured to said upper surface of said release liner by said first adhesive layer, and (b) placing an outsert having a bottom panel on said upper surface of said carrier such that said bottom panel is secured thereto by said second adhesive layer.

24. The method of Claim 23 further including the step of cutting said tape through said first adhesive layer, said carrier, and said second adhesive layer to form a patch, wherein said step of placing an outsert includes placing said outsert on said patch.

25. The method of Claim 23 wherein said step of cutting precedes said step of placing an outsert.

26. The method of Claim 23 further including the step of applying a laminate cover over said outsert and said upper surface of said carrier, whereinsaid laminate cover is secured to said carrier by said second adhesive layer.

27. The method of Claim 23 wherein said step of laminating precedes said step of cutting.

28. The method of Claim 23 further including the step of applying a deadening agent onto a portion of said second adhesive layer not covered by saidoutsert.

29. The method of Claim 23 wherein said step of applying a deadening agent precedes said step of placing an outsert.