BOX-FREE PRINTING BLANK PACKAGING
Field of the Invention The present invention relates to assemblies of printable blanks and, in particular, to a self-contained printable blank assembly that may be displayed and sold without a box or similar packaging.
Background of the Invention Sheets of blank labels are typically sold in rectangular boxes. The rectangular boxes may be about 4 1/4 inches wide by 7 1/8 inches long by lλ inch thick. The labels are visible through a transparent window . The top of the box or a flap extending therefrom may be provided with a hole to receive a support rod for mounting the label box in a display. In an office supply store, a series of boxes of different types of labels may be mounted side-by-side on rods extending outwardly from a peg board or other similar support. Unfortunately, there are some disadvantages to selling labels in boxes.
First, the cost of the box must be added to the price of the labels, making the labels more expensive. Secondly, millions of the boxes are sold, and tons of trash are generated when the users throw away the boxes. Thirdly, the boxes are typically cardboard, and trees must be cut down to provide the pulp to make the boxes. Additionally, the boxes add weight to the product, thereby increasing the cost of shipping the product.
Many other products are mounted on rods for display in a manner similar to the label boxes as described above. Toys and stationary products are often mounted on such rods in stores. In this regard, attention is directed to U.S. Patent No. 5,161,687, which discloses a package of labels having a die-cut hanger hole, and to U.S. Patent No. 5,064,060, which discloses a kit having a hook-receiving opening 30. In Canada, special double thickness stamp sheets with die-cut stamps having pressure-sensitive adhesive, mounted on a backing sheet, are mounted in this way. Before folding, the sheet is 17 1/4 inches long by 4 1/8 inches wide and is folded twice and tacked closed to form an assembly
6 inches by 4 1/8 inches with a mounting hole at one end. This Canadian stamp product also includes circular die-cut greeting images which can be added to the basic stamp, but the stamp assembly does not provide blank labels that a user may print in the office. Returning to the boxed blank labels, the box serves several purposes. It protects the printing surface of the labels from dirt, and it protects the sheets from being bent or deformed. The box keeps all of the sheets of labels together and allows the user to store the labels. The boxes also display company identification information and advertising, as well as label product specifications. Additionally, a pamphlet or instruction sheet may be placed inside the box to instruct the user on the proper use of the labels.
Summary of the Invention Broadly speaking, a method for storing printable blanks, such as labels or cards, in a booklet without the need for a box includes a number of steps. A sheet of removable printable blanks is prepared. The sheet is divided into two or more separable sections by lines of weakness, at which a user may later individually separate the sections from the sheet for individual printing in a printer. The sheet is folded into a booklet, with the printing surface of the labels on the interior of the booklet, and indicia such as product identification and/or instructions on the exterior of the booklet.
The present invention overcomes the drawbacks of the prior art in a number of ways. The printable blanks are stored in a booklet, thereby eluTiinating the need for a box. The printing surface of the printable blanks are on the inside of the booklet, thereby protecting the printing surface from dirt and dust. The booklet is lightweight and compact, and can therefore be inexpensively shipped and stored in a minimum of space.
In accordance with particular embodiments of the present invention, the printable blanks may be labels that are cut from a double-thickness assembly that includes an adhesively-coated label sheet and a release-coated backing sheet. Alternatively, the printable blanks may be cards, such as 2" by 3 v " business cards. The cards and/or labels may be defined by closed patterns of lines of weakness, such as microperforations, scoring, partial die cuts and/or other known types of lines of weakness, that are formed on the sheet. Additionally, the booklet may be provided with instruction indicia explaining how to print onto the individual sections. Generally speaking, a method for storing double-thickness labels in a booklet without the need for a box includes a number of steps. A label sheet having an entirely blank printing surface is prepared. The sheet is backed with a pressure-sensitive, temperature-stable adhesive. A release-coated backing sheet or liners is attached to the sheet of blank labels. The label sheet is then folded into a booklet, with the printing surface of the labels on the interior of the booklet, and advertising and instructions on the outer surface of the backing sheet.
The present invention overcomes the drawbacks of the prior art in a number of ways. The labels are stored in a booklet, thereby eliminating the need for a box. The printing surface of the labels are on the inside of the booklet, thereby protecting the printing surface from dirt. The booklet is lightweight and compact, and can therefore be shipped easily and inexpensively.
In accordance with a particular embodiment and method of use of the present invention, a method for custom-printing double-thickness labels that are stored in a booklet without the need for a box includes several steps. The first step is to prepare a die-cut, double-thickness label assembly. The assembly has a label sheet with a printing surface and a back surface. The back surface is coated with a pressure-sensitive, temperature-stable adhesive. The assembly
also has a release coated backing sheet, with the back surface of the label sheet being adhesively mounted onto the release coated backing sheet. The label sheet and the backing sheet are substantially coextensive, the printing surface is entirely blank and the label sheet includes one or more removable labels. The label sheet is perforated into individual sections, at least some of the sections being sufficiently large for printing in office printers, such as laser and ink-jet printers, copiers and/or other printers, without jamrning. The label sheet is folded into a booklet, with the backing sheet or liner outside, and the booklet is secured shut. The user may separate one or more sections from the label sheet. The user feeds the section or sections into a personal office printer, such as a laser or inkjet printer or copier, for printing onto the printing surface of the section or sections. The user removes a label from the sheet and applies the label to a substrate. Embodiments of the present invention may have various additional features. In embodiments having separable sections, each of the sections may have dimensions of at least 3 inches by 5 inches, to ensure that each section is large enough to be fed through an office printer without jamming. At the same time, the sections of some of the embodiments may be limited to dimensions no greater than 4.5 inches by 6.5 inches, which provides a small number of labels on each section and which reduces the number of unused labels that would otherwise be wasted when a large sheet is used for a small job.
The label booklet may include printing on the outer backing sheet, with company and product infoimation, and explaining how to print onto the labels with a personal office printer, thereby eliminating the need for a separate instruction sheet or pamphlet. The labels may be made of substantially transparent paper to allow a user to see the color and texture of the substrate through the label.
The booklet may be secured shut with an adhesive, such as a temperature- stable dry tack adhesive known in die art, or with other means such as staples or other common securing methods. An aperture may be provided at one end of the folded label sheet for hanging the booklet on a display hook or rack, taking up substantially the same area on the display as die box of labels.
Other objects, features, and advantages of the invention will become apparent from a consideration of the following detailed description and the accompanying drawings.
Brief Description of the Drawings
Figure 1 is a perspective view of a prior art box of labels; Figure 2 is a front view of a box-free label assembly; Figure 3 is a rear view of die box-free label assembly of Figure 2; Figure 4 is a sectional view taken at line 4-4 of Fig. 3; Figure 5 is a perspective view of the box-free label assembly of Figure
2 after having been folded into a booklet;
Figure 6 is a front view of an alternative embodiment of a box-free label assembly;
Figure 7 is a rear view of d e box-free label assembly of Figure 6; Figure 8 is a rear view of a second alternative embodiment of a box-free label assembly having three separable sections divided by lines of perforations; Figure 9 is a front perspective view of d e embodiment of Figure 8 folded into a booklet;
Figure 10 illustrates a user laser printing individual sections that have been separated from me assembly of Fig. 9;
Fig. 11 is a front view of a business card embodiment of the present invention; and
Fig. 12 is a rear view of the business card embodiment of Fig. 11.
Detailed Description of the Preferred Embodiments Referring more particularly to the drawings, Fig. 1 illustrates labels 20 stored inside of a prior-art box 22. The labels 20 are visible dirough a transparent window 24 on the front of die box. An upwardly-extending portion 26 includes a hole 28 for mounting die box on a display hook or rod.
Fig. 2 illustrates die front side of an embodiment of a three-part boxless label assembly 30 in accordance widi d e present invention. The assembly 30 has a first section 32, a central section 34 and a narrow section 36. Fold lines 38 and 40 separate me sections from one anoύier. The fold lines 38 and 40 are perforated so that d e sections may be separated from each odier. The perforations are preferably closely spaced "microperforations" which leave a relatively smootii edge when me subsections are separated. "Microperforations" generally have at least tiiirty five cuts per inch, almough many more cuts per inch may be used. It should be understood, however, d at die term "microperforations" is intended to encompass all constructions in which die edges of d e backing sheet are smooth and substantially free of coarse irregularities following separation.
Generally speaking, as an alternative to microperforations, odier types of lines of weakness, such as standard perforations, scoring, partial die cuts and/or other known types of lines of weakness, may be used in various embodiments of me label assembly.
The ttiird section 36 includes indicia 42, which may instruct me user as to d e proper use of die label assembly 30.
Fig. 3 is a rear view of me label assembly of Fig. 2. The rear side 48 includes a plurality of labels 50a and 50b. The labels 50a and 50b are printing areas that are entirely blank prior to printing. The rear side 48 is typically a paper layer that is backed widi a pressure sensitive adhesive.
Fig. 4 is a cross-sectional view taken about line 4 - 4 of Fig. 3. Fig. 4 shows diat d e upper paper label layer 48 is backed wid a pressure sensitive adhesive layer 51. The Hewlett Packard LaserJet 4 and 4M Printers User's Manual, Second Edition, March 1993, specifies diat materials inserted into die printer must be stable in die presence of temperatures up to about 200° C for at least 0.1 second to wid stand die significant heat encountered in die printer's fusing process. Consequentiy, as a miriimum requirement, d e adhesive of embodiments of the present invention may be selected to be temperature stable to a temperature of 200° C for at least 0.1 second for tiiese types of laser printer. If die adhesive is not temperature-stable, die adhesive may ooze out from the assembly and damage me interior of die printer or copier. Suitable temperature-stable adhesives are known in die art.
One temperature-stable adhesive tiiat may be used is die P09 acrylic adhesive sold by Avery Dennison Corporation. A rubber-based adhesive of styrene butadiene and ABA block copolymers compounded wid tackifying resins may also be used. However, it is important to note mat any suitable stable, pressure sensitive adhesive may be used which facilitates printing at high temperatures and peeling die labels from d e backing layer.
The upper label layer 48 and die pressure sensitive adhesive 51 adhere to d e backing sheet 31, which has a release coating 52 to facilitate easy removal of labels 50a and 50b from off of die backing layer 31. The release coating 52 is typically silicone, altiiough it may be fluorinated or amine-based ratiier man silicone, or may be any otiier suitable coating.
The paper label layer 48 is typically coextensive wid me backing layer 31, widi die labels 50a and 50b being die cut from die paper label layer 48. Alternatively, d e labels may be cut widi laser cutters or water jets.
When d e first section 32 and d e tiiird section 36 are folded about die perforated fold lines 38 and 40, respectively, me assembly 30 becomes a label
booklet 54, as Fig. 5 shows. The booklet 54 includes an aperture 56 for hanging die booklet 54 on a display hook or rod. The aperture 56 is formed when die apertures 56a, 56b and 56c (Fig. 2) are aligned when die assembly is folded. In ti is booklet configuration 54, d e printing surface of die label layer 48 is on me interior of me booklet 54 and is protected from dirt and odier contaminants. Furthermore, because die booklet 54 is three layers tiiick across a major portion of me widtii, and is two layers thick for me remainder of d e widti , die booklet is structurally strong and ti ereby protects the labels from damage.
Fig. 6 illustrates a first alternative embodiment 60 of die present invention. Fig. 6 is a front view showing die exterior surface of a backing layer 62. The assembly 60 is divided into die sections 64 and 66, which are separated from each other by me perforated fold line 68. The assembly 60 includes apertures 70a and 70b, which form a display aperture 70 (not shown) when d e assembly 60 is folded about line 68. 5 Fig. 7 is a front view of me label assembly 60. Fig. 7 shows e label layer 72, which includes die cut label sets 74a and 74b. Each of d e sections 62 and 64 have dimensions sufficientiy large such diat each of die sections may be individually fed into common office printers, such as ink-jet printers, common laser printers, such as me Hewlett-Packard LaserJet 5 series of printers, or any o odier printers. A user may then divide me assembly 60 along me perforated fold line 68 to separate sections 62 and 64 from one anotiier. The user may tiien run one of he sections 62 or 64 individually d rough die office printer to print only a small number of labels. Alternatively, me user may feed the entire assembly 60 through d e office printer to print a larger number of labels, or to meet the 5 minimum dimension requirements for older office printers, such as me Hewlett-Packard LaserJet 2 series of printers, which require greater minimum sheet dimensions than me newer models of office printers.
Fig. 8 is a front view of a second alternative embodiment 80 of me present label assembly invention. This second alternative assembly 80 includes diree relatively long sections 82, 84 and 86. Each section includes a plurality of labels 88a, 88b and 88c. The sections 82, 84 and 86 are separated from one anotiier by he perforated fold lines 90a and 90b. The assembly 80 also includes display apertures 92a, 92b and 92c, which form an aperture 92 (Fig. 9) when die assembly 80 is folded about perforated fold lines 90a and 90b to form a booklet 94. The booklet 94 is initially secured shut widi a pattern of adhesive 95 diat is applied along die outer edge of die tiiird section 86. This securing adhesive may be a temperature-stable, dry tack adhesive diat has no residual tackiness once d e booklet has been opened and d e adhesive bond broken. Such dry tack adhesives are known in the art. Normal pressure sensitive adhesives could also be employed. The booklet 94 may be secured in ways other tiian an adhesive, such as by staples. Fig. 10 illustrates die process for printing the individual sections of die embodiment of Fig. 2. A printed section 32 is illustrated bearing customized printing thereon. A user is feeding anotiier section 84 dirough die laser printer at adjustable manual feed guides 96a and 96b. The user may adjust tiiese guides to input sheets of various widtiis into the printer for printing. Consequently, a user can adjust die feed guides to accommodate one or more subsections of die box-free label sheet 10 for printing.
Once the individual sections have been printed, me user may remove individual labels from off of the label sheet, and apply the individual labels to substrates, such as for applying address labels to envelopes. Figs. 11 and 12 illustrate a further embodiment of the present invention, in which a divisible box-free booklet 100 of sheets of blank business-sized cards 102 is provided. The booklet 100 is divided by lines of weakness 104 and 106, which are typically microperforations, into diree individually printable sections
108, 110 and 112. The section 108 includes two blank business cards defined by lines of weakness 114, while d e sections 110 and 112 include three blank business cards defined by lines of weakness 116 and 118. The various lines of weakness may be formed by a variety of known means, although die inventors presently prefer to use microperforations.
The box-free packaging 100 includes apertures 120a, 120b and 120c which, when die booklet is folded, togedier form a single aperture 120 for hanging me packaging 100 on a display rack. The front of the booklet 100 includes indicia 122, which may identify die manufacturer and include product information (Fig. 11), while the back of die booklet may include odier indicia 124, which may be instructions for die metiiod of using the product.
When folded, die booklet 100 is held togedier widi areas of a dry-tack adhesive 126 applied along an inner edge of die booklet. When d e user opens the booklet, die bond of d e adhesive is permanentiy broken, and tiiere is no residual tackiness. Alternatively, odier types of adhesives, such as pressure sensitive adhesives, may hold die booklet togedier.
In use, die user first opens die folded booklet 100 and separates at least one of d e sections 108, 110 and/or 112 from die booklet. The user feeds one or more of d e sections dirough a personal printer, such as a laser or ink-jet printer or photocopier, which prints information onto d e blank business cards. After printing, d e user removes the section or sections from d e printer and separates die newly-printed individual business cards from die section or sections.
The booklet 100 may be made from a variety of heavy papers and cardstocks. In general, d e sheet should be less than approximately 10 mils to prevent me sections from jamming in d e printer, altiiough d e specific tiiickness limitation will depend on the requirements of the particular printer being used.
The following exemplary dimensions are given for purposes of illustration only and not for limitation. Referring to Fig. 2, me assembly 30 may be approximately 6-1/4 inches high. The first section 32 may be 4-1/8 inches wide, d e second section 34 may be 4-1/4 inches wide and die tiiird section 36 may be 2-15/16 inches wide.
The assembly may be approximately 5 to 10 mils thick, wid die label layer having an approximate thickness of 4 to 6 mils, the adhesive layer being on die order of 1 mil tiiick, die release coating on d e backing sheet being less man 1 mil thick, and d e backing sheet being approximately 2 or 3 mils thick. In general, the assembly should be no more tiian 15 mils tiiick to properly print in a laser printer. The foregoing dimensions are merely illustrative and greater or lesser tiύcknesses may be employed for particular applications, and d e backing sheet may be of the same material as die top sheet.
In conclusion, it is to be understood diat me foregoing detailed description and die accompanying drawings illustrate preferred embodiments of die invention. However, various changes and modifications may be made witiiout departing from die spirit and scope of d e invention. For example, d e upper paper label layer may be a transparent paper. One suitable transparent paper is
Gateway Natural Tracing Paper, manufactured by Chartiiam Paper Mill, Canterbury, Kent, England. Alternatively, the upper label layer may be a transparent polymer film having a print-receptive surface. Suitable plastic films are available from Protect-All, Inc. of Darien, Wisconsin. Coatings to enhance print receptivity are available from Precision Coatings, Inc. of Walled Lake,
Michigan. Further, the upper layer may be formed of card stock suitable for business cards or odier card stock products.
Altiiough it is preferable to use microperforations for the perforated fold lines, odier types of lines of weakness may be used in some embodiments.
Examples of lines of weakness that may be used include ordinary perforations, scoring, partial die cuts, and odier known types of lines of weakness.
It is noted d at d e embodiments of the assembly described above are substantially uniformly flat, which helps to prevent jams in a printer or photocopier. However, for embodiments diat are not intended to be run dirough a printer, die label layer and die backing layer need not necessarily be coextensive, although coextensivity is preferred. Altiiough the present and preferred embodiments have individual sections that are considerably smaller than a regular 8-1/2 by 11 inch sheet, embodiments may be made in which d e individual sections have dimensions of 8-1/2 by 11 inches or greater, or A-4 size paper, for specific example. These larger dimensions are preferred where d e user wishes to print a large number of labels all at once.
The upper label sheet is typically one of several known materials that are suitable for laser and/or inkjet printers, and/or copiers. For example, suitable materials for use witii inkjet printers include Chartiiam Papers Computa Plot Opaque 90, Hewlett Packard Coated Ink Jet Paper, InkJet Technology Ink Jet Paper, Stratiimore 28# Ultimate White Wove Text, and odier materials known in me art. The upper label sheet may alternatively be made of transparent mylar or other suitable polymer material or composite, such as metalized polyester. As an alternative to small-sized subsheets of labels and/or business cards, each subsheet may have an upper label layer that is not die-cut or otiierwise cut into individual labels, but serves as one large label covering die entire upper surface of the subsheet. As a further alternative, die subsections need not be separated by lines of weakness, but instead may form an integral whole, for printing a single large label that extends the full widtii and lengti of the upper surface of die assembly. Similar embodiments for printing cards may also be employed.
Rather than being a label assembly, the present invention could have an upper lamination layer and a lower paper or card layer, which has an identification card or odier shaped card die cut therein. The user runs a single section dirough a printer to print on the card, tiien removes the card and a die cut portion of lamination from he assembly. The user then folds the lamination over die card to laminate it, resulting in a custom printed laminated card.
It will be appreciated that all of die current embodiments of me present invention may be sold without the packaging typically required by present day label assemblies. The applications of die present invention are wide-ranging, and may include embodiments for address labels, shipping labels, filing labels and tabs, labels for CD-ROMS, information labels, and numerous other applications.
It is noted diat new types of printers other tiian laser printers, ink jet printers and copiers may be developed in the future. Accordingly, die assemblies of the present invention are not limited to use in presently popular printers, but may be used in suitable new types printers in die future.
Accordingly, die present invention is not limited to die specific embodiments shown in die drawings and described in die detailed description.