U.S. patent application number 11/358199 was filed with the patent office on 2006-09-14 for reinforced tag and method of manufacturing.
Invention is credited to John Garber, F. Paul Valenti.
Application Number | 20060204715 11/358199 |
Document ID | / |
Family ID | 31186959 |
Filed Date | 2006-09-14 |
United States Patent
Application |
20060204715 |
Kind Code |
A1 |
Valenti; F. Paul ; et
al. |
September 14, 2006 |
Reinforced tag and method of manufacturing
Abstract
A method of manufacturing reinforced tags using a press is
disclosed which includes providing a continuously moving web of tag
material. A web of reinforcing material is also provided and die
cut into reinforcing patches. The reinforcing material has a
pressure sensitive adhesive thereon. A first portion of the patches
is adhered to a first major surface of the continuously moving web
of tag material so it extends beyond said first major surface. A
second portion of the patches is contacted with a stationary curved
surface which folds the patches as they move along the folder so
that the second portion is folded around an edge of the tag
material and adheres to a second major surface of the web of tag
material. A hole is then cut in each tag unit at a location such
that it extends through the patch at a point where it is adhered to
two major surfaces of each tag unit. The web of tag material is
then cut into the individual tag units. The patches and the tags
both have a transverse dimension which is smaller for the patches
than for the tags.
Inventors: |
Valenti; F. Paul;
(Barrington, IL) ; Garber; John; (Fenton,
MO) |
Correspondence
Address: |
ICE MILLER LLP
ONE AMERICAN SQUARE, SUITE 3100
INDIANAPOLIS
IN
46282-0200
US
|
Family ID: |
31186959 |
Appl. No.: |
11/358199 |
Filed: |
February 20, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10209069 |
Jul 30, 2002 |
7005027 |
|
|
11358199 |
Feb 20, 2006 |
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Current U.S.
Class: |
428/121 ;
428/131 |
Current CPC
Class: |
Y10T 156/1026 20150115;
B31D 1/025 20130101; Y10T 156/1075 20150115; Y10T 428/2419
20150115; Y10T 156/1034 20150115; Y10T 428/24273 20150115; Y10T
428/24322 20150115; Y10T 156/1097 20150115; Y10T 156/1077 20150115;
Y10T 156/1011 20150115; Y10T 156/1057 20150115; Y10T 156/1015
20150115; B42F 3/006 20130101; Y10T 428/24215 20150115 |
Class at
Publication: |
428/121 ;
428/131 |
International
Class: |
B32B 3/04 20060101
B32B003/04 |
Claims
1. A reinforced tag comprising; a tag material having a first and
second major surface and at least one edge; a reinforcing patch
having a first and second portion and wherein the first portion is
adhered to cover an extent of the first major surface, and the
reinforcing patch extends along a fold line over an extent of said
edge with the second portion adhered to cover an extent of the
second major surface; wherein the first and second portion are
positioned to substantially cover coextensive and aligned areas on
the first and second major surfaces; and an opening extending
through the tag material and the first and second portions of the
reinforcing patch.
2. The reinforced tag of claim 1 wherein the reinforcing patch is
weakened along the fold line to allow for easier folding during
manufacture.
3. The reinforced tag of claim 1 wherein the reinforcing patch
comprises a synthetic material.
Description
RELATED APPLICATION
[0001] This application is a continuation of U.S. Ser. No.
10/209,069, filed Jul. 30, 2002.
FIELD OF THE INVENTION
[0002] The present invention relates to tag manufacturing, more
specifically, it relates to a method of manufacturing a reinforced
tag in a continuous process and a tag manufactured by the
continuous process.
DESCRIPTION OF THE RELATED ART
[0003] The manufacturing of tags is a multi-step process which
typically includes the steps of printing the tag, making a hole in
the tag, reinforcing the hole, and trimming the tag to the proper
size. While tags may be manufactured using a sheet press, they are
predominantly manufactured on a web press which allows for a web of
feed stock to be transformed into the final product of individual
tags by undergoing a variety of processes.
[0004] Typically, the web is printed in one part of the press, a
hole punched and reinforced in another part of the press, and the
tag die cut to the desired shape in another portion of the press.
Of these steps, the step which most limits the manufacturing speed
and the materials which may be used is the punching and reinforcing
of the hole, as this is generally done using a reciprocating press
which simultaneously punches a hole through the tag and puts down a
reinforcing patch around the hole. It is desirable to have the hole
reinforced so it functions effectively when a string or other
flexible member is threaded through the hole and attached to a
tagged object. An unreinforced hole is more likely to tear during
use, rendering the tag useless. Therefore, even though this portion
of the manufacturing process slows down the overall rate of
manufacture, it remains a necessary step for making high
performance tags.
[0005] The reciprocating press for punching and reinforcing the
hole generally includes a male and female portion which together
close unto the tag surface. In between the tag and the press is the
reinforcing material. The reinforcing material is generally a web
of material unto which is coated an adhesive. The press cuts out a
section of reinforcing material and adheres it securely to the tag,
while a punch simultaneously makes a hole in the both the tag and
the reinforcing patch near to the center of the patch. This method
may be used to simultaneously adhere reinforcing patches to both
the top and bottom surfaces of the tag if additional strength is
required.
[0006] This method of manufacturing tags remains effective, but it
has numerous drawbacks. One drawback, as discussed above, is the
relatively slow rate of manufacture of the tags which is limited in
that the web of material must come to a stop while the hole is
punched and the reinforcing material applied. Another drawback is
in the materials which may be used. Typically, material used in
manufacturing tags and patches is paper. The press described above
does not operate well when certain materials, including synthetic
materials having high strength and flexibility, are used. Finally,
the use of a male and female type die makes it expensive to apply
reinforcing patches of different shapes due to the cost of
procuring different shaped dies. These problems and others have
been addressed to create the tags and the method of manufacturing
said tags which are the subject of the present invention.
BRIEF SUMMARY OF THE INVENTION
[0007] A first aspect of the present invention provides a method of
manufacturing reinforced tags. The method includes providing a web
of tag material having first and second major surfaces moving
continuously through a press. A reinforcing material is adhered
onto the first major surface of said continuously moving web so
that a first portion is adhered to said first major surface and a
second portion extends beyond said first major surface. The
reinforcing material adhered to said continuously moving web is
folded along a fold line so that at least a part of said second
portion is adhered to said second major surface. A hole is cut in
the continuously moving web of material which extend through the
reinforcing material. The web is then cut into individual tags
having a hole in each.
[0008] According to another aspect of the invention, a method of
manufacturing reinforced tags includes providing a continuously
moving web of tag material having a first and a second major
surface. A feed of reinforcing patches, each individual patch
having a transverse and longitudinal dimension is also provided.
The patches are intermittently adhered onto the first major surface
of the continuously moving web of tag material so that a first
portion of the patch is adhered to the first major surface and a
second portion of said patch extends beyond the first major
surface. The second portion of the patch on the continuously moving
web of material is folded and adhered to the second major surface.
Individual tags are then formed from the web of tag material so
that each has a transverse and longitudinal dimension, and each has
a folded patch thereon. The transverse and longitudinal dimensions
of individual patches are less than the transverse and longitudinal
dimensions of individual tags.
[0009] According to another aspect of the present invention, a
continuous process for the manufacture of reinforced tags includes
supplying a first web of a reinforcing material stock. The
reinforcing material is cut to define discrete patch units. A
continuously moving second web of tag material stock is also
supplied. The discrete patch units are adhered at intervals to said
continuously moving second web of tag material such that a first
portion of each said patch unit is adhered to a first major surface
of the tag material and a second portion extends beyond the first
major surface of said tag material. The second portion of each
patch unit is folded along a fold line over an edge of the tag
material and adhered to a second major surface of the tag material.
The second, web of tag material is than formed into individual
tags, each having a folded patch thereon.
[0010] According to another aspect of the present invention, a
reinforced tag includes a first and second major surface and at
least one edge. A reinforcing patch has a first and second portion
wherein the first portion is adhered to cover an extent of the
first major surface, and the second portion is adhered to cover an
extent of the second major surface. The first and second portion of
the tag are aligned to cover co-extensive and aligned areas on the
first and second major surfaces. A hole extends through the tag and
the first and second portions of the reinforcing patch.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0011] FIG. 1 is an elevation view of a press manufacturing tags
according to one embodiment of the present invention;
[0012] FIG. 2 is a plan view of a reinforcing patch being folded
during the manufacture of reinforced tags according to one
embodiment of the present invention;
[0013] FIG. 3 is a cross-sectional view along line 3 of FIG. 2;
[0014] FIG. 4 is a cross-sectional view along line 4 of FIG. 2;
[0015] FIG. 5 is a cross-sectional view along line 5 of FIG. 2;
[0016] FIG. 6 is a cross-sectional view along line 6 of FIG. 2;
[0017] FIG. 7 is a cross-sectional view along line 7 of FIG. 2;
[0018] FIG. 8 is a cross-sectional view along line 8 of FIG. 2;
[0019] FIG. 9 is a cross-sectional view along line 9 of FIG. 2;
[0020] FIG. 10 is a perspective view of a reinforced tag according
to one embodiment of the present invention; and
[0021] FIG. 11 is a perspective view of a reinforced tag according
to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0022] While the invention is susceptible of embodiment in may
different forms, there is shown in the drawings and will herein be
described in detail preferred embodiments of the invention. It is
to be understood that the present disclosure is to be considered as
an exemplification of the principles of the invention. This
disclosure is not intended to limit the broad aspect of the
invention to the illustrated embodiments.
[0023] FIG. 1 discloses generally an in-line press with reference
numeral 10 according to a preferred embodiment of the present
invention. The press is preferably a rotary flexographic printing
press. However, any of the presses which are well known in the art
which provide for the continuous movement of a continuous web of
material through the press during operation may be used. Preferably
the press is an in-line press which can accomplish all of the steps
of manufacturing a tag in a single pass through the press so that a
feed stock can be fed to the press, and a finished tag will be
produced.
[0024] A first roll 12 of a continuous web of tag material 14 is
provided. The first roll 12 has a width and a roll radius. The
width of the rolled material is typically in the range of from
about one to about eighteen inches. Preferably, the width of the
web coming off the first roll 12 defines the longitudinal dimension
11 of the tag 26 shown in FIG. 10. However, in other embodiments,
the finished tag 26 may be trimmed, thereby decreasing its
longitudinal dimension 11 from the original width of the first roll
12. The width, or transverse dimension 13 of the tag 26 is
determined by cutting individual tags from the roll 12 at the
desired tag width. Any material which can be run through the press
is suitable for use as a tag material 14, and considerations such
as printablility, strength, flexibility, weatherability, and cost
generally determine what material is used. Preferably, the tag
material used is a paper or synthetic material. Synthetic materials
may include such materials as polyester, vinyl, polypropylene, and
many others which are well known in the art. The thickness of the
tag material is generally in the range of from two to twenty mils,
preferably in the range of from about seven mils to about fifteen
mils.
[0025] From the first roll 12, tag material 14 is preferably fed to
a printing apparatus 16. The printing apparatus 14 repetitively
prints the desired design or writing onto the tag material 14 so as
each tag will have the desired design or message printed thereon.
The desired design or message may be the same on each tag, or it
may be different as in consecutively numbered tags. The printing
apparatus 16 may optionally be adapted to print on both sides of
the tag material 14. Printing apparatus 16 may also be adapted to
perform other manipulations to the tag material 14, for example,
applying a coating of a material to improve the printability or
weatherability of the tag material. Many other treatments and
manipulations of the tag material 14 which are well know in the art
may be performed by the printing apparatus 16. In this embodiment,
the tag material 14 is printed and then proceeds along through the
press. However, in other embodiments, it may be desirable to not
print on the tag material 14 at all.
[0026] In this embodiment, a second roll 18 of a reinforcing
material 20 is provided. The second roll 18 includes a reinforcing
material 20 and a release liner material 30 with a pressure
sensitive adhesive layer between the two materials. The reinforcing
material 20 and the release liner material 30 are provided in this
embodiment as continuous webs removably bonded to one another. The
reinforcing material 20 of the second roll 18 is preferably chosen
for its ability to provide reinforcement as a reinforcing patch 32
to the hole 24, or opening, of tag 26 as shown in FIG. 10.
Materials suitable for this purpose include numerous natural and
synthetic materials. Preferably, the material used is a paper or
synthetic. The thickness of the reinforcing material is also
generally in the range of from about two to about twenty mils,
preferably in the range of from about nine mils to about eleven
mils.
[0027] The reinforcing material 20 in this embodiment is fed to a
die cutting apparatus 28 where the continuous web of reinforcing
material is cut into distinct patches 32 as shown in FIGS. 1 and 2.
When the reinforcing material is die cut into rectangular or square
patches, the width of the second roll 18 defines the longitudinal
dimension 34 of the individual patches 32, and the transverse
dimension 36, or patch width, is determined by die cutting the
continuous web. However, a benefit of this process is that various
shapes can be inexpensively and easily die cut out of the
reinforcing material by simply changing the die used. Whatever
shape the patches are cut into, the patches still have a transverse
and longitudinal dimension. The transverse and longitudinal are
then determined by their orientation to the corresponding
transverse and longitudinal dimensions on the tags to which they
are applied. In the die cutting apparatus 28, the continuous web of
reinforcing material 20 is optionally and preferably also scored or
perforated along a fold line 38. The scoring or perforating weakens
the reinforcing material 20 along the fold line 38 so that it may
be more easily folded. The release liner material 30 is preferably
not die cut or scored.
[0028] The reinforcing material 20 and the release liner material
30 continue moving through the press 10 to an edge 40 where the
patches 32 are removed. The release liner material 30 is pulled
back over the edge 40 by a rotary pull and collected on a
collection roll 42. Pulling the release liner material 30 back over
the edge 40 causes the patches 32, which have been die cut out of
the reinforcing material 20, and have a pressure sensitive adhesive
thereon, to separate from the liner material 30. The patches 32
intermittently contact the tag material 14, which is in continuous
movement through the press 10. Preferably, when the leading edge of
the patches 32 contacts the tag material 14 it becomes adhered to
the tag material 14 by the pressure sensitive adhesive on the
patches 32. A nip 43 simultaneously pushes the patches 32, having
the pressure sensitive adhesive, into close contact with the
continuously moving tag material 14 to ensure a good bond is
formed.
[0029] The position of the patches 32 on the tag according to one
preferred embodiment is shown in FIG. 2, which is a plan view of
the web of tag material 14 passing through the press 10. The
patches 32 are applied to the tag material 14 at intervals to
correspond to the individual tags 26 which will subsequently be
formed from the web of tag material 14 at locations as indicated by
lines 44, typically by cutting or perforating the tag material. In
a preferred embodiment, a first portion of preferably one half of
each patch 32 along the longitudinal dimension 34 is adhered on a
first major surface 46 of the tag material 14. The second portion
extends beyond the first major surface 46.
[0030] The manner in which the patches 32 of a reinforcing material
20 are intermittently applied to the continuously moving web of tag
material 14 is preferably based on the difference in the relative
rates of travel of the web of tag material 14 and the web of
reinforcing material 12. The web of reinforcing material 12 travels
at a slower rate of speed, allowing the patches 32 to be
strategically placed to reinforce only the desired portion of the
tags 26. The ratio between the desired transverse dimensions of the
individual tags and the individual patches determines the relative
rates of travel of the web of tag material 14 and reinforcing
material 20. Preferably the rate of travel of the web of tag
material 14 remains constant, and a feed back loop in communication
with a servo motor adjusts the rate of travel of the reinforcing
material 20 as required to maintain the desired placement position
of the individual patches on the individual tags while the press is
operating. The web of reinforcing material 20 in this embodiment
preferably moves at a substantially constant rate of speed with
minor variations as required to insure correct placement of the
patches 32.
[0031] Placement of the patches 32 on only the required portion of
the tag 26, namely that portion through which the hole 24 will be
cut, allows less reinforcing material 12 to be used with the same
benefits as if the reinforcing material 12 were continuously
applied to the tag material 14 along an edge 47. This results in a
material and cost savings, the cost portion of which is multiplied
when relatively expensive synthetic materials are used instead of
paper stock as a reinforcing material.
[0032] In another embodiment, reinforcing patches are provided to
the continuously moving web using a vacuum cylinder. Preferably, a
pressure sensitive adhesive hot melt glue is first coated onto a
web of patching material. The web then travels to the hardened
vacuum cylinder where it is cut into the proper patch size. The
reinforcing patches are picked up by the vacuum effect of the
cylinder with the pressure sensitive adhesive facing away from the
vacuum cylinder. They are then rotated and intermittently placed
onto a first major surface of the continuously moving web of tag
material.
[0033] In another embodiment of the present invention, a roll of
reinforcing material is not provided. Rather, preformed patches of
a reinforcing material are provided to the press 10 for use as
reinforcing patches. If the preformed patches are provided on a
continuous release liner they may utilize a rotary pull, an edge,
and a collection roll as described above. If they are provided
individually they may utilize a vacuum cylinder to properly
position the patches on the individual tags.
[0034] The tag material 14 having patches 32 adhered to the first
major surface 46 continues through the press 10 to a folding
apparatus 48. In this embodiment, the folding apparatus 48 includes
a first base member 50 and a second base member 52. Between the
first and second base members 50, 52 is a belt 54. The first and
second base members 50, 52 are preferably stationary bases between
which the belt 54 is tautly strung. The belt 54 is twisted as
indicated in FIG. 2. The twisted belt 54 presents a continuous
curved surface along which the tag material 14 having patches 32
adhered thereto can be moved. As shown in FIG. 1, the belt 54
extends from the first base member 50, which is above the
continuously moving web of tag material 14, to the second base
member 52, which is below the continuously moving web of tag
material 14.
[0035] FIGS. 3 through 9 show a patch 32 passing through the
folding apparatus 48 according to one embodiment of the present
invention. The patch 32 is first adhered to the first major surface
46 of the tag material 14, as shown in FIG. 3, which is a
cross-sectional view taken along line 3 of FIG. 2. The patch 32
contacts the belt 54 and begins to fold along a fold line 38. As
the patches 32 move along the folding apparatus 48, they are folded
progressively further by the belt 54 until the second portion of
the patch 32 is contacted to the second major surface 56 of the tag
material 14 as shown by FIGS. 4 through 9, which are
cross-sectional views taken along lines 4 through 9 of FIG. 2. The
use of a stationary curved surface, such as the belt 54, to fold
the patches 32 is beneficial because it allows the web of tag
material to move continuously while the folding of the patch 32 is
being accomplished. The belt 54 can be replaced in other
embodiments by another curved surface, such as curved plastic,
metal, or wood surface. It is appreciated that the list of
materials from which the curved surface could be formed is nearly
unlimited. The folder is preferably stationary, and the tags in
constant motion through the press.
[0036] While one preferred embodiment of a folding apparatus 48
utilizing first and second base members 50, 52 and a twisted belt
54 has been shown in the accompanying figures, it is appreciated
that other types of folding apparatuses could be used to achieve
the same beneficial results within the scope of the present
invention. For example, the patch 32 may be folded along the fold
line 38 using streams of directed air (not shown) to fold the patch
32 over the edge 47 of the tag 26. Another example may utilize a
folding apparatus which moves alongside of the web of continuously
moving tag material 14 and includes a jaw (not shown) which grasps
and folds the patch. A movable folding apparatus or streams of
directed air would allow for the tag material 14 to move along
continuously through the press without necessitating stops and
starts of the web, thereby preserving the rapid rate of
manufacturing which is one benefit of the present invention.
[0037] In the embodiment shown in FIG. 1, after the patch 32 has
been folded, holes are formed in the continuously moving web of tag
material 14. As shown in FIG. 10, the hole 24 is cut so that it
extends through the reinforcing patch 32. The tag material 14
passes through a cutting apparatus 58. The cutting apparatus 58
preferably includes an engraved rotary die with air eject, or a
male and female punch die set for cutting a hole through the tag 26
and reinforcing material 12. While a hole is preferably cut through
the reinforcing patch and the tag material, in another embodiment,
a patch could be folded such that a portion of the folded patch
extended beyond the boundaries of the tag material. In such an
embodiment, a hole could be formed through only the patch material
with similar beneficial results.
[0038] In one preferred embodiment, the final finishing step in the
manufacture of the reinforced tags 26 is die cutting the tags 26 to
the correct size. This includes die cutting the continuous web into
individual tags, and may additionally include further trimming of
the corners of the tags, or otherwise trimming the tags to the
desired size. Finishing apparatus 60 preferably includes an
engraved rotary die cutter which makes the appropriate cuts and
collects the finished tags 26.
[0039] A finished tag according to one embodiment of the present
invention is shown in FIG. 10. The tag 26 has a longitudinal
dimension 11, a transverse direction 13 or width as measured at
it's widest point, and an edge 47. It further includes a first
major surface 46 and a second major surface opposite to the first
major surface 46. A reinforcing patch 32 is adhered to the first
major surface 46 and extends over the edge 47 and unto the second
major surface. The reinforcing patch 32 covers substantially
co-extensive and aligned areas on the first and second major
surfaces. In other words, approximately one half of the patch is
covering an extent of the first major surface 46, and the other
half is covering the corresponding area on the second major
surface. This is a result of the way in which the tag is
manufactured by folding the patch 32. A hole 24 extends through the
first and second major surfaces of the tag 26 and also through the
first and second portions of the patch 32 which cover the major
surfaces.
[0040] Another embodiment of the present invention is shown in FIG.
11. In this embodiment, the finished tag 70 has been trimmed along
an edge 72 which is proximate to a reinforcing patch 74 through
which a hole 76 extends. Prior to trimming, the reinforcing patch
74 is folded over the edge 72 so that substantially co-extensive
and aligned areas on a first major surface 78 and a second major
surface opposite to the first major surface 78 are covered by the
reinforcing patch. The tag 70 is therefore reinforced on both the
first major surface 78 and a second major surface for additional
strength, but has a substantially smooth edge proximate to the
reinforced hole 76.
[0041] While the specific embodiments have been illustrated and
described, numerous modifications come to mind without
significantly departing from the spirit of the invention, and the
scope of protection is only limited by the scope of the
accompanying claims.
* * * * *