WO2000026886A1

WO2000026886A1 - Fold out label and manufacture thereof

Info

Publication number: WO2000026886A1
Application number: PCT/US1999/025833
Authority: WO
Inventors: Scott A. Farkas; John P. Dwyer
Original assignee: HMS Label Specialties Inc
Current assignee: HMS Label Specialties Inc
Priority date: 1998-11-04
Filing date: 1999-11-03
Publication date: 2000-05-11
Anticipated expiration: 2001-05-04
Also published as: AU1339100A

Abstract

The present invention is a multi-layer label which includes a base (14), a piece (20) and an overlaminate (24). Adhesive is applied to the base in parallel strips (18) and the piece is placed on top of the base between the strips of adhesive. The overlaminate (24) is then placed on top of the piece and the base layer. The overlaminate has no adhesive of its own and is held in place only by the adhesive strips (18). The overlaminate thereby sandwiches the piece in place. By utilizing the method of the present invention, the label may be formed so that the overlaminate contains excess portions which allow the overlaminate to expand when the label is applied to a curved product. By including this excess material, the label is able to be placed onto a curved product without binding any of the associated layers.

Description

LABEL WITH UNSUPPORTED LAMINAR

Background of the Invention Field of the Invention

The present invention relates generally to label assemblies and more specifically to multi-layer laminate labels containing a removable piece.

Manufacturers and sometimes retailers increasingly require that additional information or premiums be placed on products sold to the public. Such additional information may be in the form of a coupon, rebate, warranty, or a supplemental instruction booklet. Premiums may include cards, pictures, holograms, lottery tickets, credit cards, small toys, or the like. By attaching this information (or premiums) in the form of a label to a preexisting product, the manufacturer can easily change the information presented, use shorter production runs, and even vary the information product by product. This is accomplished by varying the content of the printed matter and by controlling the quantity of labels applied. Furthermore, labels may be applied to selected products only (i.e., every one out of ten). Finally, a variety of different printed portions may be interchanged. That is, a single product line could have a plurality of different labels which may be applied to it.

When using such a label, the manufacturer or labeler is concerned with quickly, efficiently, and securely adhering the label to the product; protecting the printed portion of the label; and allowing the consumer easy access to the additional material when desired. For many products this is relatively easy (with varying degrees of success) and has become quite common. However, as the popularity of the use of such labels has increased so has the desire to label a wider variety of differently shaped products. There are many known labels which may easily be attached to a flat, planar surface such as a carton or box. Some difficulty arises however, when you try to attach these same labels to circular or cylindrical objects, such as a bottle or a can. Furthermore, even though these labels are easily attached, they do not facilitate the clean removal of the information or premium from the label structure.

The known label structure usually comprises a base sheet having an adhesive coating on its lower surface. The adhesive binds the base sheet, and thus the entire label structure to the product. A piece is then placed on top of this base sheet and an overlaminate with an adhesive on its lower surface is placed atop both the piece and the base sheet. The overlaminate is configured such that it has portions which extend beyond the edges of the piece. The adhesive on the overlaminate contacts both the upper surface of the piece and the base sheet bordering the piece, thereby holding the piece firmly in place. When the consumer wishes to access the printed portion of label, the overlaminate is peeled away, exposing the piece for review or removal. To facilitate the removal, the upper surface of the base sheet and the piece may include a release coating. This type of label structure works reasonably well on flat surfaces. However, if the same label is applied to a cylindrical object, some degree of binding or pinching would inevitably occur. The problem is increased as the radius of the product is decreased. As the base sheet is applied to the product, it curves to match the curvature of the product. The label attempts to follow suit, again trying the match the curvature of the product. However, because the underside of the overlaminate is coated with an adhesive and bonded flushly to both the base and the piece, the three separate components are not able to move separately and match the curvature of the product. The overlaminate is typically inelastic and thus does not stretch or give at all. Therefore, in order to get a smooth appearance on the overlaminate, the base sheet must pinch or bind. This creates a problem in that material is wasted and the adhesion to the product is diminished. Furthermore, the appearance of the label on the product may not be very appealing. Since the label structure does not lie flat, it may inadvertently be torn or pulled off due to unintentional contact. Finally, the cost of applying the label is increased accordingly to deal with these factors.

When such a label is applied to a curved surface, it becomes very difficult to remove the material from underneath the overlaminate. Because the overlaminate is stretched and adhered to both the base and the piece, it becomes difficult to separate the layers. As such, when removal is attempted, the printed piece will likely be damaged or torn, severely limiting the usefulness and desirability of using such a label structure.

Yet another problem exists when the piece is held in place by an adhesive bearing overlaminate. Generally, when removed the overlaminate must remain adhered to the piece. This is because separation of the piece from the overlaminate will usually result in damage to the piece. As a result, the consumer must deal with the piece while having the overlaminate still attached and having exposed adhesive portions. A similar problem will occur when the piece itself is coated with adhesive or an adhesive residue is transferred from the base to the piece. When the piece remains tacky after separation, problems arise in that the consumer cannot easily handle or store these items because they stick to other products. This is particularly a problem for stores that redeem coupons. These coupons must be stored with other coupons and will inevitably stick to them.

One solution to this problem would simply be to remove the overlaminate. In such a label structure, the piece simply has its underside coated with an adhesive, or alternatively the top side of the base sheet is so coated. This solution presents the additional problem of the label being exposed and possible worn. Additionally, adhesive must contact large portions of the underside of the piece, making it harder to remove without damaging it. There is a problem in that the use of a release layer to facilitate the removal of the piece necessarily limits the amount of adhesion holding the piece in place. In other words, in order to adequately hold the piece in place, it must be difficult to remove from the base. Another problem that exists is that the edges of the piece tend to be the weakest point of adhesion. The edges may even be left uncoated to facilitate removal. In either case, when such a label is wrapped around a radius, the edges tend to separate from the base. As a result, this causes the label to be damaged or inadvertently removed when contact with another item occurs. Therefore there exists a need to provide a laminate label containing a piece which may be applied to both planar and curved surfaces, wherein the piece is cleanly removable so that no adhesive or adhesive residue remains on the piece.

Summary of the Invention

The label of the present invention includes a base sheet having an adhesive backing which is ultimately applied to a product. On the upper surface of this base sheet an adhesive is applied. The adhesive is usually applied in two parallel regions along the width (as defined by a completed label) of the base sheet. Other patterns may be used for resultant labels of different shapes. The piece is then set atop the base sheet, (with either minimal or no contact with the adhesive) between the two parallel strips of adhesive. Finally, an overlaminate is placed across the base sheet to cover both the piece and the adhesive regions. The overlaminate has no adhesive of its own and is held in place solely by the adhesive deposited on the base sheet. Thus, the overlaminate serves to sandwich the piece between the overlaminate and the base sheet holding it firmly in place. There may be instances where it is desired to more securely attach the piece to the base. In those instances the adhesive may be applied so that a more substantial portion of the piece contacts the adhesive area, thus increasing the amount of adhesion. More overlaminate than base sheet is used in each label. This occurs because the overlaminate must account for the additional distance created by the height of the piece. The present invention provides a method of applying the overlaminate to provide for slightly more overlaminate than is just required to simply traverse the distance. The overlaminate contains this small excess of material, and has no adhesive of its own. Thus, when the product is applied to a curved surface the overlaminate has the ability to match the curvature of the product. Also, the piece is allowed to move freely between the base sheet and the overlaminate without either component binding.

In addition to the overlaminate holding the piece in place, the present invention contemplates having one or both edges of the piece contacting the applied adhesive. In uses where the sandwiching effect of the overlaminate is insufficient to hold the piece in place, this alternative allows the adhesive to prevent the piece from slipping, but does not hinder the removal of the piece once the overlaminate is removed. The amount of contact between the piece and the adhesive can vary depending on the particular characteristics of each. Preferably, only a small portion of one or both edges will be in contact with the adhesive.

During the process of forming the label, adhesive is deposited on top of the base sheet which will eventually hold the overlaminate in place. It may be desirable to vary the degree of adhesion, thus making it harder or easier to remove the overlaminate. To accomplish this, the present invention applies varied amounts and patterns of the adhesive. For example, adhesive may be applied in a continuous strip along both edges of the resultant label, creating a relatively strong adhesion. Alternatively, the adhesive may be applied in small patches, or even dots. This results in less adhesive contacting the overlaminate, and thus less adhesion.

When the materials have been laid in place, the assembly is die cut to form the completed label. It is at this point that the resultant shape of the label is determined. By leaving a portion of the overlaminate which extends past the applied adhesive area, a tab can be formed. This tab will facilitate the removal of the overlaminate, thus exposing the piece to the consumer.

The present invention is useful in making laminate labels which include a piece. The piece may be a single planar sheet, a plurality of sheets, or a booklet. Generally, any planar printed material could be utilized. Furthermore, a wide variety of "premiums" could be placed onto the base and formed into a label structure. Such premiums include, but are not limited to: sports cards, entertainment cards, credit cards, lottery tickets, magnets, pouches, product samples, pictures, holograms, condoms, seed packets or small toys. Basically, any product that can be placed onto the base and held in place by the overlaminate could be a piece. The present invention provides a superior means of packaging (and offering for sale or consumption) irregularly shaped objects, because the overlaminate bears no adhesive. As such it can easily conform to whatever shape is needed and hold the product in place. In addition, the overlaminate may bear its own printing or other indicia.

It is an object of the present invention to provide a multi-layer laminate label capable of being adhered to a curved product.

It is a further object of the present invention to provide a multi-layer label which has an overlaminate bearing no adhesive of its own.

It is yet another object of the present invention to provide a method of making a multi-layer laminate label which has a small excess of overlaminate to account for variations in the curvature of the product it is applied to.

It is still another object of the present invention to provide a method of making a multi-layer laminate label having various degrees of adhesion between the overlaminate and the base.

It is still yet another object of the present invention to provide a multi-layer laminate label having a tab portion to facilitate access to the piece.

It is another object of the present invention to provide a label structure which facilitates the easy removal of the piece, leaving no adhesive or adhesive residue on the piece.

It is still yet another object of the present invention to provide a multi-layer laminate label which may be resealable.

Brief Description of the Drawings

Figure 1 is a side planar profile of the multi-layer label of the present invention shown in separated form.

Figure 2 is a side planar profile of the multi-layer label of the present invention shown in a completed form.

Figure 3 is a top planar view of the multi-layer of the present invention shown attached to a supply web. Figure 4 is a perspective view of the multi-layer label of the present invention shown attached to a supply web. Figure 5 is a top planar view of a plurality of labels moving through the process of formation.

Figure 6 is a side planar view of a multi-layer label shown attached to a curved product. Figure 7 is a perspective view of the multi-layer label of the present invention wherein an excess amount of overlaminate is used.

Detailed Description of Preferred Embodiments

Turning to Fig. 1, a carrier web 10 is provided. The carrier web 10 provides a structure on which to create the label 22. By providing the carrier web 10 the various components of the label 22 can be applied in sequence and in bulk quantities in the manufacture of the finished labels. When the labels are complete, the carrier web 10 provides 'a convenient location for storing the labels and subsequently removing them for application to various end products. The upper surface 12 of carrier web 10 is coated with a release coating to allow for the easy removal of the label 22. Within the label structure 22, a base 14 is provided. Base 14 has an adhesive coating

16 on its underside. Preferably, the base 14 is a clear polystyrene base stock that is 2 mils thick having a pressure sensitive adhesive coating on one side. Deposited on the upper surface of the base 14 are various quantities 18 of an applied adhesive. Preferably the applied adhesive 18 is applied in two parallel strips along resultant edges of the label 22. (As shown more clearly in Fig. 3.) Any pattern or configuration of adhesive areas may be used, and is dependent upon the desired shape of the final label structure. By applying the adhesive 18 in this manner, substantial portions of the upper surface of the base 14 will remain uncoated. Various types of adhesive may be used in the applied adhesive 18.

Alternatively, the base may be an uncoated substrate. In such a case, the final "label" structure is simply a loose, unadhered item, with another item attached to it. For instance, a baseball card could serve as the base and a piece could be attached to the card by the overlaminate being bound to the baseball card via the applied adhesive.

Preferably, adhesive 18 will be a UN curable pressure-sensitive adhesive such as Radcoat UN12S-8K PSA. The advantage to using this type of adhesive is that it is applied in a liquid format that is not tacky when applied. Furthermore, during production runs the UN adhesive is generally more stable than other types of adhesive and can remain in the manufacturing line (in storage containers or on the labels themselves) for relatively long periods of time without breaking down. The adhesive will cure and set as it is exposed to ultra violet light. The rate at which it will set is dependent upon the quantity and intensity of the available UN light. Once the adhesive 18 is applied to the upper surface of the base 14, a piece 20 is laid down across base 14. The piece 20 can be any generally planar object, such as a single sheet or a commonly used booklet label as shown. Alternatively, the piece 20 could be a premium such as: sports cards, entertainment cards, credit cards, lottery tickets, magnets, pouches, product samples, pictures, holograms, condoms, seed packets, small toys or the like. Ideally, the piece 20 is dimensioned such that it will fit entirely within the applied adhesive 18 areas without contacting any of the adhesive, or only a small portion of the adhesive. However, in cases where more adhesive is required, the piece 20 could contact substantial portions of the adhesive 18.

Once the piece 20 is laid down, the overlaminate 24 is placed across the piece 20 and the adhesive areas 18. As the thickness of the piece 20 increases, so does the length of overlaminate 24 required. As shown by the Figure 1 , the overlaminate 24 is almost the same length as the base sheet 16. This is possible only because the piece 20 has a compressed height which will be less than the height of the adhesive areas 18. This will rarely occur in actual applications. Rather, as shown more clearly by Figures 4 and 7, the height of the piece 20 will be much greater than the height of the applied adhesive 18. As such, the length of the overlaminate 24 must be sufficient to lie flat across one patch of adhesive, span the height of the piece 20, cross the length of the piece 20, again span the height of the piece 20, reach and then lie flat across the second adhesive portion (and further if a tab 40 is utilized).

By increasing or decreasing the amount of overlaminate material, the tension imparted by overlaminate 24 can be controlled and varied. On one extreme, the overlaminate material may be stretched very tightly. In such a case, the transition area 30 (Figs. 4 and 7) approaches a horizontal orientation. On the opposite extreme, so much material may be used that the overlaminate material is simply loose and flapping. The embodiment as shown in Fig. 4, lies somewhere between these two extremes. The transition areas 30 have a smooth taper. If this label were to be attached to a curved surface there is some degree of excess in the overlaminate 24, which could compensate for the curvature. Figure 7 shows transition areas 30 approaching a more vertical orientation, thus allowing for more "stretch" when applied to a curved surface. (As shown in Fig. 6.)

To maximize the ability of the overlaminate 24 to compensate for curved surfaces, the greatest quantity of overlaminate material should be used, which still firmly holds the piece 20 in place. That amount of material would produce a transition area which is vertical (i.e., parallel to the height dimension of the piece) or even bowed out slightly from the piece 20. Such a configuration, when curved or bent, allows for the maximum amount of give in the overlaminate 24.

The overlaminate 24 is preferably a clear plastic (polypropylene) sheet which is held in place solely by the adhesive patches 18, thereby sandwiching the piece 20 between the overlaminate 24 and the base 14. Depending on the final product that the label 22 will be applied to, this sandwiching effect may be sufficient to hold piece 20 in place. For instance, if the label is applied to a curved product having a very small radius, the tension created by the curvature will effectuate a clamping action by overlaminate 24 upon piece 20. If, however, the final label will be used on a more planar product, the piece 20 may have a tendency to slide out from underneath the overlaminate 24. To avoid this problem, several alternatives are available. Piece 20 may be dimensioned, or the adhesive applied in such a manner, so that a small portion of one, or each, edge that is adjacent the adhesive 18 is actually in contact with a small portion of the adhesive 18; thereby holding the piece 20 in place. By contacting only a small portion of the piece 20, the adhesive will prevent slippage of the piece, but will not hinder its removal when the overlaminate 24 is removed. Alternatively, if piece 20 is dimensioned to fit within adhesive portions 18 without contacting them, a small quantity of adhesive may be applied to the base 14, so as to contact the middle portion of the piece 20. A small dot or patch of adhesive will serve to hold the piece 20 in place, without making it difficult to separate from the base when the overlaminate 24 is removed. When maximum adhesion is required, the piece may be caused to contact a larger portion of the adhesive 18. When so done, the adhesive 18 should be chosen to facilitate the clean removal of the piece 20 from the base 14. Finally, as described above, by varying the amount of overlaminate material used, the tension imparted by the overlaminate 24 to the piece 20 will vary, and can be adjusted based upon the desired end use of the label 22. The overlaminate 24 or the base 14 may bear additional printing of its own. Rather than being clear the overlaminate 24 may be opaque, either adding printed matter, aesthetic appeal or simply obscuring the contents of the piece 20.

Fig. 2 illustrates a complete label showing piece 20 sandwiched between overlaminate 24 and base 14. In this embodiment, piece 20 contacts no portion of the adhesive 18. Since the piece 20 is relatively thin, the overlaminate 24 simply lies flat above it, contacting each of the adhesive areas 18.

Turning to Fig. 3, a top view of the label 22 is shown. As is shown more clearly in this figure, adhesive areas 18 have been applied in strips across the resultant width of the label 22. An optional tab 40 is formed on the extreme most edge of label 22 by having a portion of the overlaminate 24 extend past the adhesive portion 18. Since this tab 40 does not contact any portion of the adhesive, the end user is able to grasp this tab and easily remove the overlaminate 24, exposing the piece 20. Alternatively, the label 22 may be cut so that both edges align with the adhesive areas 18 so that no tab exists. To facilitate the removal of the overlaminate 24, the adhesive 18 adjacent the tab 40 is applied in patches rather than a continuous strip. By applying the adhesive 18 in varying amounts, the adhesion between the overlaminate and the base 14 can be varied and controlled. The present invention contemplates using amounts ranging from complete coverage of the entire strip (as well as varying the size, number and location of the strips), for strong-adhesion, to the use of very small patches or dots to effectuate minimal adhesion.

Turning to Fig. 4, a perspective view of the label 22 is shown. In use, a plurality of the completed labels 22 will be adhered to the carrier web 10. The carrier web 10 will be placed within proximity of the products to which the labels 22 will be applied. The label 22 is then separated from the carrier web 10 by lifting the label 22 from the carrier web 10. Alternatively, in one possible method for automatic application by a machine, the supply web 10 is moved in a direction to meet the product that the label 22 will be applied to. Prior to contact, the supply web 10 is caused to turn sharply or bend (as much as 180°). Due to the rigidity of the label 22, when the supply web 10 bends, the label 22 is separated at the transition point. As the supply web 10 progresses, more of the label is exposed. At this point, some portion of the adhesive underside 16 of the label 22 is caused to contact the product and the label is then adhered to the product. The release coating on top of carrier web 10 allows for the removal or separation of label 22. The label 22 will then be fully applied to a product where the adhesive coating on the base 14 will adhere to the product.

Fig. 6 shows label 22 adhered to a curved product. The product P has a particular radius which results in the product P having a predetermined circumference. Base layer 14 is adhered to the product P by the adhesive coating on its underside. Adhesive areas 18 have been applied to the upper surface of base 14 and serve to hold overlaminate 24 in place. In this embodiment, piece 20 does not contact either of the adhesive areas 18, but could as described above. As can be seen from this perspective. The circumference that the overlaminate 24 must span is greater than the circumference that the base 14 spans. This simply results because the overlaminate 24 is farther from the center of the circular product than the base 14 is. Effectively, the overlaminate 24 must now span a greater distance than was required during the formation of the label 22, or than would be required if the label 22 were applied to a planar surface. Due to this increase in the distance required, the transition areas 30 have changed. Prior to the label's 22 application to the product, the transition areas 30 were near vertical (See Fig. 7). Now, to accommodate the greater distance, the excess overlaminate material, which was effectively "stored" in that vertical arrangement, is now pulled into a tapered configuration 30 to allow the overlaminate 24 to span the required distance, without binding or pinching the overlaminate 24, the piece 20, or the base 14. Fig. 6 shows the transition area 30 of overlaminate 24 as being tapered from the remainder of the overlaminate. If this same label were applied to a product having less of a curvature, the entire amount of excess overlaminate would not have been utilized. As such, the transition areas 30 would have had a more dramatic or sharper taper (remaining closer to vertical). It should be noted that the height of the adhesive areas 18 are shown greatly exaggerated in some of the figures, for illustrative purposes. In reality, even when all of the excess overlaminate material is utilized, there will generally be a tapered transition region from the terminus of the piece 20 to the appropriate adhesive area 18.

Turning now to Fig. 5, the process of forming the label 22 will be shown from left to right. Initially, a product consisting of the carrier web 10 with the base 14 releasably adhered to it is provided. In use, this combined product is supplied on a roll. This roll may be purchased as a prefabricated product, or independently made as a precursor step to the below described process. The material is pulled off that supply roll and guided along a series of rollers at a controlled rate. Alternatively, if the base 14 is to be replaced by some other product such as a baseball card, etc., the proper supply configuration is suitably arranged and that product replaces the base 14 in the steps described below.

On top of the base 14, the pattern adhesive 18 is applied. The adhesive 18 is applied at one or more stations along the traveling path of the supply web 10 / base 14. The adhesive 18 can be applied in varying quantities to affect the total adhesion of the final product. Printed material 45 is then placed on the web and positioned between adhesive areas 18. As shown in Fig. 5, the initial product is dimensioned to support three labels across its width, therefore the adhesive is applied accordingly.

The printed material 45 may be single sheets, stacked sheets or booklets. Any planar or suitably sized matter is acceptable. The actual number of pieces will depend upon the dimensions of the supply material as well as the desired dimension of the completed label. Of course, as described above, the printed material 45 could be replaced with any type of piece 20, including the premiums described. Because the overlaminate 24 bears no adhesive, the material conforms to the shape of the piece 20. For illustrative purposes only, piece 20 is shown as printed matter 45 in Fig. 5, but it is understood that whatever object is placed atop the base 14, is applied in a similar manner.

Printed material 45 containing a plurality of the eventual pieces 20 are placed on the base 14. To do so, the supply web 10, having the base material 14 with adhesive applied to the top is moved along the manufacturing line at a controlled rate of speed. Individual strips of the printed material 45 are taken from a supply area and placed atop the base 14 as it moves by the placer device. Any appropriate placer device could be used. The placer device shown in commonly assigned US Patent Number 5,431,274 is exemplary and is incorporated by reference in its entirety. Ideally, the speed of the placer device is matched to the speed at which the web product 10 is moving. By doing so, the printed material 45 is accurately positioned and smoothly placed. As shown in Fig. 5, the printed material 45 is printed having a width of three labels 22. Any number can be used, ranging from applying a single piece to a strip bearing as many printed portions as the dimensions of the product will allow.

Subsequently a sheet of overlaminate 24 is applied over the label pieces and the applied adhesive. The overlaminate 24 is also supplied in a roll. The overlaminate 24 is pulled from the supply roll and is moved along a series of rollers. At least near the point where the overlaminate will join the web, the two products are aligned, one above the other. Subsequently, the overlaminate is made to contact the base 14, and the two products are joined by the adhesive 18.

The amount of overlaminate 24 applied will depend upon the relative speeds at which the web and overlaminate are traveling when they are joined. If it is desired that the length of the overlaminate 24 exactly match the length of the supply web 10 and base 14 (as would be the case in a "normal" lamination process), the speed of the overlaminate 24 should match the speed of the supply web 10. In the present invention, however, it is necessary to add length to the overlaminate 24 to account for the height of the piece 20. To simply stretch the overlaminate 24 tightly about the piece 20, the speed of the overlaminate 24 is increased slightly. Often, however, it is desirable to provide a small excess of the overlaminate material 24. As such, the speed of travel of the overlaminate supply is increased even more, relative to the speed of the supply web 10.

To facilitate the understanding of this concept, assume that the first point of contact between the overlaminate 24 and the supply web/base 14 is at one of the adhesive areas 18. The overlaminate 24 contacts the adhesive area 18 and the two layers essentially begin to "sandwich" together. As the supply web/base moves along, more of the overlaminate 24 is distributed than is required to simply match the supply web/base. As such, this excess will either accumulate as it reaches the first edge of the piece 20, or it may even push the piece 20 towards the other adhesive patch. Subsequently, as the supply web 10 continues to move past the initial point of contact, the overlaminate 24 is lain across the upper surface of the piece 20 until its far edge is reached. Then, as the piece 20 continues to move away from the point of contact, excess overlaminate material 24 is again deposited between the edge of the piece 20 and the second adhesive area 18, due to the fact that the overlaminate 24 is being removed from its supply roll at a faster rate. Finally, the overlaminate 24 contacts the second adhesive area thus completing the assembling of components for that particular label section. At this point, if the piece 20 has been moved off center by the overlaminate 24, it will have a tendency to recenter itself. Thus, the excess overlaminate 24 will be located between the adhesive areas and the edges of the piece, equally on each side. The amount of this excess will depend upon the differential in speed between the supply web ase product and the overlaminate supply. By adjusting this differential, different tensions may be applied to the overlaminate and different amounts of excess overlaminate 24 may be provided to account for the curvature of the final product which the label 22 is applied to, as well as adjusting for the varying heights of the piece 20.

At this point, the composite product is then moved along a series of rollers into a die cutter which cuts through the overlaminate 24, the printed material 45 and the base 14 (including the adhesive on the underside of the base) but not the supply web 10. It is understood that if certain prepackaged premiums are used, the premiums are positioned so that the die cut does not damage the premium's package, but rather cuts around it. The same would be the case if the piece or premium would be damaged if die cut. Therefore the step of die cutting the composite includes avoiding the piece in its entirety, when necessary. Finally, the waste product is removed. Once completed, this leaves a carrier web having a properly dimensioned base supporting a piece wherein the base has an adhesive applied to portions of it and a similarly dimensioned overlaminate piece is adhered to the base by the applied adhesive. The final product as shown in Fig. 5 consists of a carrier web having a width supporting three completed labels 22 across it. This strip may then be divided so each resultant strip bears only a single row, or any appropriate numerical combination of labels 22. As shown, the die cut leaves the tab portion 40. The shape of the shown cut is not meant to be limiting and the die cut could simply eliminate the tab altogether, add a tab to any other side (by leaving material in place) or adding a tab to a plurality of the sides.

Also, Fig. 5 shows the strip of pieces having a width to fit between the applied adhesive areas 18. The adhesive 18 may be applied, or the pieces 20 dimensioned, so that one or both edges of the piece 20 contacts the adhesive to the desired degree.

Thus, the final label structure 22 provides a product containing a piece 20. Whether the label 22 is applied to a product or simply forms a completed product by itself, the construction of the label 22 facilitates the easy removal of the piece 20. To do so, the tab 40 (if used) or an edge of the overlaminate 24 is gripped. The overlaminate 24 is then pulled away from the base 14. At this point the piece 20 can be removed from the base 14. The base 14 may have printing of its own which would now be visible. The piece 20 may then be used or read. Piece 20 will have no adhesive or adhesive residue which otherwise may interfere in its use. If so desired, the piece 20 may be replaced on top of base 14, and the overlaminate 24 may be placed across piece 20 and readhered to the adhesive 18, thus making this a resealable label structure. Alternatively, as described above, the piece 20 may be adhered to the base 14 (with various degrees of adhesion) by having a portion of the piece 20 contact the adhesive 18. In certain applications, it may be desirable to have the piece 20 firmly mounted to the base 14, thus contacting a larger section of the adhesive 18. When so done, the user will simply uncover the piece 20 by removing the overlaminate 24. At this point the piece is read or otherwise utilized, but not removed from the base 14. Once read, the overlaminate 24 is resealed. This is particularly useful in applications where an extended instruction booklet is attached to a product, such as a pharmaceutical. By using this embodiment, extended information may be provided without fear that the information will become lost or accidentally replaced on a different product.

Those skilled in the art will further appreciate that the present invention may be embodied in other specific forms without departing from the spirit or central attributes thereof. In that the foregoing description of the present invention discloses only exemplary embodiments thereof, it is to be understood that other variations are contemplated as being within the scope of the present invention. Accordingly, the present invention is not limited in the particular embodiments which have been described in detail therein. Rather, reference should be made to the appended claims indicative of the scope and content of the present invention.

Claims

What is claimed is: 1. A label comprising: a base, the base including an upper surface and a lower surface, the lower surface including an adhesive layer; an adhesive pattern, the adhesive pattern being located on the upper surface of the base so that an uncoated area is defined; a piece, the piece being located on the upper surface of the base between portions of the adhesive area; and an overlaminate, the overlaminate covering the base and the piece, so that the adhesive pattern holds the overlaminate in place.

2. The label of claim 1, wherein the overlaminate has a length greater than the length of the base.

3. The label of claim 2, wherein all edges of the overlaminate align with all edges of the base.

4. The label of claim 1, wherein a portion of the overlaminate extends beyond at least a portion of the adhesive pattern so that a tab is formed.

5. The label of claim 1, wherein the adhesive pattern is UN curable adhesive.

6. The label of claim 1, wherein the adhesive pattern includes a plurality of continuous strips of adhesive.

7. The label of claim 1, wherein a portion of the adhesive pattern includes a plurality of discontinuous patches of adhesive.

8. The label of claim 1, further including: a supply web for supporting the base, the supply web having a release coating on an upper surface.

9. The label of claim 1 , wherein the piece is a booklet.

10. The label of claim 1 , wherein the piece is a single sheet.

11. The label of claim 1 wherein the piece is a plurality of sheets.

12. The label of claim 1 wherein the piece is a premium.

13. The label of claim 1 wherein at least one edge of the piece contacts one of the adhesive areas.

14. The label of claim 1 wherein the label is resealable.

15. The label of claim 1 wherein the piece is removable.

16. The label of claim 15 wherein the removed piece contains no adhesive or adhesive residue.

17. The label of claim 1 wherein the base bears printed indicia.

18. A label comprising: a base, the base having an upper surface and a lower surface, the lower surface coated with an adhesive; a first adhesive strip, the first adhesive strip located on the upper surface of the base adjacent a first edge of the base; a second adhesive strip, the second adhesive strip being discontinuous and located on the upper surface of the base adjacent a second edge of the base; a booklet, the booklet including a single sheet, folded to form a plurality of sections, the booklet bearing printed indicia, the booklet being located between the first adhesive strip and the second adhesive strip atop the base; and an overlaminate, the overlaminate held in place by the first adhesive strip and the second adhesive strip while covering the booklet and the base.

19. The label of claim 18, wherein the overlaminate has a length greater than a length of the base.

20. The label of claim 19, wherein all edges of the overlaminate align with all edges of the base.

21. The label of claim 18, wherein a portion of the overlaminate extends beyond the first adhesive area or the second adhesive area so that a tab is formed.

22. The label of claim 18, wherein the first and second adhesive areas are UN curable adhesive.

23. The label of claim 18, further including: a supply web for supporting the base, the supply web having a release coating on an upper surface.

24. A method of forming a label comprising: providing a supply web; releasably adhering a base to the supply web; applying an adhesive in a predetermined pattern in at least two areas to an upper surface of the base; placing a piece between the two areas of adhesive; placing an overlaminate strip on top of the piece and the base so that the adhesive areas hold the overlaminate in place; die cutting through the overlaminate and the base, but not the supply web; and removing the waste material.

25. The method of forming a label according to claim 24, further including: adjusting the speed of the overlaminate to be greater than the speed of the of the base and the supply web.

26. The method of claim 24, wherein the step of applying an adhesive includes applying the adhesive in discontinuous patches for at least one of the areas.

27. The method of claim 24, wherein the step of placing the piece includes contacting at least one edge of the piece with one of the adhesive areas.

28. The method of claim 24 wherein the step of die cutting includes cutting through the piece.

29. The method of claim 24 wherein the step of die cutting includes cutting around the piece without contacting any portion of the piece.

30. A label comprising: a base, the base including an upper surface and a lower surface; an adhesive pattern, the adhesive pattern being located on the upper surface of the base so that an uncoated area is formed; a piece, the piece being located on the upper surface of the base between portions of the adhesive area; and an overlaminate, the overlaminate covering the piece and at least a portion of the base, so that the adhesive pattern holds the overlaminate in place.

31. The label of claim 30, wherein the overlaminate has a length greater than the length of the base.

32. The label of claim 30, wherein all edges of the overlaminate align with all edges of the base.

33. The label of claim 30, wherein a portion of the overlaminate extends beyond at least a portion of the adhesive pattern so that a tab is formed.

34. The label of claim 30, wherein the adhesive pattern is UV curable adhesive.

35. The label of claim 30, wherein the adhesive pattern includes a plurality of continuous strips of adhesive.

36. The label of claim 30, wherein a portion of the adhesive pattern includes a plurality of discontinuous patches of adhesive.

37. The label of claim 30, wherein the piece is a booklet.

38. The label of claim 30, wherein the piece is a single sheet.

39. The label of claim 30 wherein the piece is a premium.

40. The label of claim 30 wherein at least one edge of the piece contacts a portion of the adhesive portion.

41. The label of claim 30 wherein the label is resealable.

42. The label of claim 30 wherein the piece is removable.

43. The label of claim 30 wherein the removed piece contains no adhesive or adhesive residue.

44. The label of claim 30 wherein the base bears printed indicia.

45. The label of claim 30 wherein a lower surface of the base is coated with adhesive.