CA2256580A1 - Method and apparatus for adhering linerless repositionable sheets onto articles - Google Patents

Abstract

A method and apparatus for sequentially and precisely registering cut sheets for application onto advertising signatures at high speeds employs an initial roll of sheeting material. The sheeting material is unwound to track a process path, where eyemarks on the sheeting material are detected for use in registering the sheeting material to be cut into discrete sheets and to be aligned with a moving advertising signature for affixation thereto. The sheeting material has a repositionable pressure sensitive adhesive along one side edge thereof for use in adhering the cut sheet to the advertising signature. In one embodiment, the sheeting material is generally opaque adjacent one side edge and is sufficiently transparent adjacent its other side edge so that when a sheet cut from the sheeting material is adhered to an advertising signature, images on the advertising signature are visible through at least a portion of the sheet.

Description

CA 022=,6=,80 1998-11-30 METEIOD AND APPARATUS FOR AD~IERING
~ LINERLESS REPOSIl IONABLE ~ ONTO ARTICLES

BACKGROUND OF THE INVENTION
5It is well known to inçlurling advertising insert cards ("blow-ins") with no adhesive in m~g~7ines for promotional purposes. These insert cards simply sit between pages loosely and may fall out when the m~7 ne is read. Typically, such insert cards are in the fomm of a postcard for the reader to complete and retum.
Repositionable sheets, such as the type available from Minnesota Mining and 10 M~mlfac~-ring Company of St. Paul, Minnesota under the trade decign~tion "Post-It,"
are quite common and in every day use. Such sheets in familiar form are available in stacks or pads of sheets, one adhered to another. Such repositionable sheets have a first side which is partially coated with a repositionable pressure sensitive adhesive (RPSA) and a second side which is either plain (no printing) for writing a note, or which may 15 have a preprinted message or design thereon. Such repositionable sheets are useful for calling attention to a particular section of a docl.ment for m~ L..g pages in docl.mente or books, or for leaving removable and repositionable notes that can be adhered to just about any clean surface.
The utility of placing a repositionable sheet on an advertising signature, flyer, 20 new~al)er, mag~7inÇ, etc. has also been noted. An advertising signature is an insert that is placed in a m~g~7ine and comprises a plurality of pages, typically rect~n~ r pieces of paper having advertising printed thereon and being folded over to form a registration edge. When placed in a m~7in~, the advertising signature is bound to the other m~g~7ine pages along the I~;gi~ ion edge. Advertising signatures have been provided 25 with repositionable labels that contain information such as the name and telephone ~ number of the advertiser or a coupon for a price discount. The labels are repositionable so that they can be removed from the advertising signature and adhered at another location (for example, a desk or refrigerator) to remind the reader to call the advertiser or to use the coupon at a later date.

CA 022~6~80 1998-11-30 WO 97/48608 PCT/U$97109333 Many of such labels that have been placed on advertising signatures have a repositionable pressure sensitive adhesive (RPSA) coated over the entire back side of the label. Labels that have RPSA coated over their entire back side are typically carried on a liner before being adhered to an advertising signature. The labels on the liner are 5 supplied to an apparatus which sep~ ~les the label from the liner and adheres the label to an advertising signature. The label is typically separated from the liner by a peeler bar, and the label is subsequently adhered to a substrate (that could be an advertising signature), typically by a blast of air. The liner which previously supported the label, often is rewound on a take-up reel and subseq~lPntly discarded as waste. These mP.thodc 10 and apparatus have drawbacks in that they generate waste in the form of a useless liner require ~lrlition~l equipment on the apparatus to remove the label and store the liner (for c ~ plc, a peeler bar and take-up reel) and use excess quantities of adhesive by having the entire back side ofthe label coated with RPSA.
In another approach to promote an adverlisennPnt in an advertising signature, a 15 backer card is employed to secure a reposi~ion~hle ;l~"~lalion-containing sheet to an advertising signature, as in U.S. Patent 4,842,303. The backer card has a l~i~ lio edge which is aligned with the I~gi~ lion edge ofthe advertising ~;~lalu~e. The repo.sition~h'e sheet of paper has a narrow band of RPSA coated on one surface nt to an edge ofthe repositionable sheet. The repositionable sheet is adhered 20 along the registration edge ofthe backer card by the narrow band of RPSA. Thec~ l,;n~ion backer card and repo~itiorla~le sheet is secured to an advertising signature by gluing the backer card to the advertising signature using for el 'e, a tipping m~.hin~
~hhough the approach dis~losed in U.S. Patent 4,842,303 elllploy~ an 25 il~llllalion-co..l;-;..;.~g sheet which only uses a narrow band of RPSA, it too has a number of drawbacks. One drawback is the need to employ a backer card to secure the repositionable sheet to an advertising signature. Another drawback is the need for a number of ~d-iition~l process steps to assc~u,l;le the co",l,i"alion backer card/repositionable sheet before it is ~ttached to an advertising signature. The ~cklition~

CA 022~6~80 1998-11-30 process steps that have been used include~ g the adhesive bearing sheet andbacker card toeether in registry; cutting the l~min~ted webs to a master sheet si_e (typically, 8.5 by l2 inches); ~t~ ng the cut master sheets; jogging the master sheets;
cutting them into conventional sizes (for eY~mp'e, 4 inches by 6 inches); st~c~ing the cut S l~min~ted sheets; and then ~lu~p;ng them to an inserter for att~çhm.ont to an advertising signature.
It is believed that the only publicly known method for directly applying linerless repo~;l;oll~h'e preprinted sheets having a band of adhesive thereon directly onto articles such as m~g~7ines or advertising signatures is by manual means. A previous method 10 and apparatus for an automated application of such sheets is ~lisc1osed in co-pending U.S. patent applic~ti()n 08/095,722, co--ll--ollly owned by the Ac~;g~ee ofthe instant appli~tion, Minnesot~ Mining and M~nuf~ct-.ring Company of St. Paul, Minnesota. In that di~closl.re, a supply roll of paper for forming such sheets is incrPmPnt~lly d;s~~nsed, cut by a reciprocating knife, and then ll~lslJo- led to a flat vacuum plate, which first held 15 the cut sheet by forming a vacuum and then blew the RPSA side of the cut sheet onto an advertising signature. In this arr~ng~me.nt, a series of indicia (i.e., "eyemarks"~ printed on the RPSA side of the sheet material were detected to control the movement of the sheet material through the apparatus and its alignment relative to its respective advertising signature. The locational placemPnt of the cut sheet relative to the20 advertising signature is referred to as its registration. At the highest speeds possible with this eq~irm~Pnt (e.g., 3,000 articles processed per hour), this prior art apparatus did not provide as precise a pl~~P.ment or regi~L, ~lion of the cut sheet on sequpnti~l advertising signatures as desired.

SUMMARY OF l~E rNVENTION
The present invention relates to a new method and apparatus for applying adhesive sheets directly to an advertising signature or other article. Initially, the sheets are provided in roll form for processing and appli~tion In one embodiment, a roll of sheet material is elong~ted longit~l-lin~lly, has first and second opposed sheet surfaces CA 022~6~80 1998-11-30 and first and second opposed side edges. A pressure sensitive adhesive extends in a predetermined pattern on only a first adhesive portion of the first surface of the sheet material, ~dj~c~nt the first side edge thereof. The sheet material, ~(ljac~nt its first side edge and in~ li~ the first adhesive portion, is formed from a material that is 5 s~ ç:r-,lly l.~l~a.~..L when adhered to a substrate that underlying images on the substrate are subst~nti~lly visible through the sheeting material. The sheet material also has a plurality of longit ldin~lly spaced and delecl~hle images disposed in predeterrnined locations on the first adhesive portion thereo~ In an alternative embodiment, the sheet material in roll form is entirely opaque and has a plurality of equally-spaced, 10 longit~l-lin~lly disposed images printed on both sides thereof, with the images on the side bearing the pressure sensitive adhesive serving as registration means for use inprocessing the sheet material.
A method of sequ~nti~lly adhering linerless sheets to a corresponding seqU~nre of articles comprises supplying (a) an elon~e~ted linerless sheetin_ in wound roll form, 15 with the ~l~e~ g having a first major side and an opposed second major side. A
pressure sensitive adhesive coating partially covers the first side ofthe .chee~ p while the second side of the ~I.e~ g is free of adhesive. (b) A leading portion of the~lon~ted linerless .cheeting is advanced along a process path until it reaches a cut station. (c) The leading portion of the linerless cheetinp~ is laterally cut to define a first 20 cut sheet having a first lead edge and a second trailing edge. (d) A vacuum platen having an arcuate circu..~ere.lt;al surface is aligned in engagement with at least a portion of the second side of the first cut sheet adj~cent the first lead edge thereo~ A negative pressure is drawn on a portion ofthe arcuate ~ ;u--~r~ ial surface ofthe vacuum platen to affix the first cut sheet in the cut station thereto. (f) A first article having a 25 face is advanced into an applicator station ~djaG~nt the vacuum platen. (g) The vacuum platen is moved to carry the first cut sheet from the cut station to the applicator station, whereby the first cut sheet is aligned for pla ~e~..t~.~ on the face ofthe first article. (h) The negative pressure on the arcuate circu--lrele.l~;al surface is relieved to release the first cut sheet from the vacuum platen. (i) The vacuum platen is moved across the face CA 022~6~80 1998-11-30 of the article so that the pressure sensitive adhesive on the first side of the first cut sheet is pressed against the face of the article to bond the first cut sheet to the face of the ~ article. Steps (b) and (c) are repeated to define a second cut sheet from the elQng~ted linerless ~l ~ee~ g Steps (d) and (e) are repeated with the vacuum platen relative to the second cut sheet. The second article having a face is advanced into the applicator station ~djac~nt the vacuum platen. Steps (g), (h) and (i) are repeated with the second cut sheet to align, release from the vacuum platen and then press the second cut sheet against the face ofthe second article by the arcuate circ l-.~-enlial surface ofthe vacuum platen.
In one embodiment, the elong~ted linerless sheeting processed by the above-described method is light L- ~n~ e. P- e~e ~bly, the light-transmissive cheeting has, on either side, a series of lon~eitu~ ly disposed, e~ually spaced visual in~ic~tors, and the method further inclndçc the step of detectin~ each visual indicator on the cheeti~ as it is advanced along the process path to generate a signal used for process control 1 5 purposes.

BRlEF DESCRIPTION OF THE DRAWlNGS
FIG. 1 is a front view of a ml~ltip~ge advertising piece 12 having a repositionable sheet 14 adhered to cover 16 thereo~
FIG. 2 is a sectinn~l view as taken along lines 2-2 in FIG. 1.
FIG. 3 is a sCl~e~ ;c front elevational Ie,~ se~ l;on of apparatus 40 in acco. .lance with the present invention.
FIG. 4 is a s~ h~ l;c ofthe control system for the apparatus 40 ofthe present invention.
FIG. 5 is an enlarged detail view as taken along lines 5-5 in FIG. 3.
FIG. 6 is an enlarged detail view of the drive roller 90 in FIG. 3 .
FIG. 7 is an enlarged detail view as taken along line 7-7 in FIG. 3.
FIG. 8 is a front view of an advertising piece 12 having a repositinn~ble sheet (tape flag) 214 adhered to the cover 16 thereof.

.. . . ..... ~ . . ..

CA 022~6~80 1998-11-30 W O 97/48608 PCTrUS97/09333 FIG. 9 is a section~l view as taken along lines 9-9 in FIG. 8.
FIG. 10 is a PGI ~pecli~e view of a roll of elongated, linerless repositinn~ble shPeting oftape fiag material.
FIG. 11 is an enlarged detail view ofthe inventive apparatus such as FIG. 5, but5 substih~ti~ an elongated linerless tape flag ~heeting for the Plong~ted note sl.e~ p shown in FIG. 5.
While the above-idPntified drawing figures set forth preferred embo~limPrlt~ of the invention, other embodiments are also contempl~te~l, as noted in the (liccllcQir~n In all cases, this disclosure plese.lls the present invention by way of leprese..lfll;on and not 10 limit~tion. It should be understood that numerous other mo~ifi~.~tion~ and embodimP.ntc can be devised by those skilled in the art which fall within the scope and spirit of the principles ofthis invention. It should be specifically noted that the figures have not been drawn to scale as it has been nece~ y to enlarge certain portions for clarity.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In des~ilil,;ng the ,o~ ed embodiments of the invention, specific terminology will be used for the sake of clarity. The invention, however, is not int~n~ed to be lirnited to the specific terms so selP-cteA, and it is to be understood that each term so selected inclndes all the technical equivalents that operate sirnilarly.
FIGS. 1 and 2 illustrate a promotional asse.l.bly 10 that includes an advertising piece 12 and a repositionable sheet 14. The advertising piece shown has a plurality of pages: a first top page or cover 16, a second or opposite inside page 18, a third or juxtapositioned inside page 20, and a fourth or rear page 22. The pages 16, 18, 20 and 22 can be printed on a single sheet which is folded at 24. Additional pages can be provided by, for ~ PI ~ increasing the number of folded sheets. In other forms, the advertising piece 12 may co...pl;se a single sheet or multiple sheets bound in some other manner (e.g., stapled or adhered together) or may even comprise a book~ letter, product pac~g-P" etc. For purposes of this applicfltion, it is or~y Ps~nti~l that the article CA 022~6~80 1998-11-30 receiving the repositionable sheet have a face (such as cover 16) suitable for the a.ll~l~,..ce of a repositionable sheet thereon.
The terrn "repo~;tion~hle" means the sheet 14 can be adhered to and removed from a clean solid surface at least two times without subst~nti~lly losing tack.5 Preferably, the sheet can be adhered to and removed from a clean solid surface at least ten and, more p~re.~l~ly, at least twenty times without sl-bst~n1i~1ly losing tack. The repositionable sheet 14 is secured directly to the advertising piece by RPSA 26 (FIG. 2), coated at least partially on a first or back side 28 of the sheet 14. The repo~;tio--Lle sheet 14 has a second or top side 30 onto which i.lror...alion can be printed (e.g., which 10 col.e~yonds to or further e...l)hA~;~es i~ ion printed on the advertising piece 12).
As illustrated, the repo~ition~ble sheet 14 can have the name and phone number of an advertiser printed on the top side 30 ofthe sheet 14.
A repo~;~ionable sheet suitable for this application can be a repositionable note of the type sold by Minnesol~ Mining and ~l~m If ~ct~1ring Company of St. Paul, 15 Minnesota under the trade dç~igr ~tion "Post-It." Each repositiQrl~ble note innlucles a sheet of paper that has an adhesive partially coated on one side thereof. The sheet of paper is typically an unsaturated paper, which is paper that is not ,~..plegnaled with a resin. The adhesive is coated as a narrow band ~dj~cPnt one edge ofthe sheet, ~Ithml~h other embodiments are possible, such as where only corners or other portions (or even all) ofthe back side ofthe sheet are coated with RPSA. The paper may be coated with a primer to çnh~nce the anchorage of the adhesive to the substrate. The amount of adhesive on the back side ofthe repositionable sheet must be sl-ffi~iPnt to enable the sheet to adhere to a clean surface.
RPSAs are well known in the art as evidenced by U.S. Patents 5,045,569;
4,988,567; 4,994,322; 4,786,696; 4,166,152; 3,857,731; and 3,691,140. ARPSA
typically comprises polymeric microspheres having an average ~ met~r of at least about one micrometer. The microspheres are inhele-lLly tacky and typically co~,,ylise at least about 70 parts by weight of an alkyl acrylate or alkyl methacrylate ester. A majority of the l, ic,.Jsyhel es may contain interior voids, typically, at least about 10 percent of the ... . .. . . . .

CA 022~6~80 1998-11-30 d~ r of the microsphere. RPSAs are tacky to the touch and typically demonstrate a peel ~hPQion of applu,~ ly 10 to 300 gram/c~ ;...clr~ (g/cm), more typically apyro~ alely 50 to 250 g/cm, and even more typically about 70 to 100 g/cm. Peel adhesion can be determined accord;ng to the test outlined in U. S. Patent 5,045,569. A
S RPSA can be applied to a sheet using known methods incl~lding making a suspension of the microspheres and applying that suspension to the sheet by conventional coating techniques such as knife coating or Meyer bar coating or use of an extrusion dye (see U.S. Patent 5,045,569 at column 7, lines 40-50). Other methods to create repositionable adhesive co~tingc are well known in the art and may include: printing a 10 fine pattern of adhesive dots; selective det~r~ifir.~tion of an adhesive layer; and incol yol ~ing nont~c~y microspheres in an adhesive matrix. Other useful adhesives include high peel adhesives that may permanently attach a note. E~ y!~ v of suchadhesives include rubber resin and acrylic adhesives.
FIG. 3 illustrates an apparatus 40 usefi~l for forming and applying repositionable 15 sheets in registry onto a series of moving articles. The apparatus 40 inrludes an article conveyor path and a repositim~ le sheet transport path. The two paths converge at an application station (in~ic~ted generally as at 42) where a cut reposition~hle sheet is adhered to each article. The apparatus 40 includes a base unit 44 which serves to hold the supply of articles (e.g., advertising pieces 12) for processing. The base unit 44 20 inr.ludes an article conveyor 46 for sequentially transporting articles from one end ofthe base unit to the other, and in particular, across application station 42. Article conveyor 46 may include a belt conveyor 46a, chain link conveyor 46b, or other suitable conveyance devices (e.g., rollers, etc.) which may further include article spaced ~lignm-o.nt tabs 47 for ~ng~f~in~ a leading end of an article 12 and positively positioning it 25 relative to the application station 42. The article conveyor 46 is driven by a conveyor drive motor 48 to move articles in direction of arrow 49 in FIG. 3. A~er processing at the application station 42, the articles are further conveyed to a receiving area (not shown) where they are coller,ted for further processing and/or distribution. A base unit for this purpose, which inrludes a conveyor for materials like advertising pieces, flyers CA 022~6~80 1998-11-30 or m~7.inec, is the Kirk-Rudy Model 215 labeling base, available from Kirk-Rudy, Inc.
of Kennesaw, Georgia.
An optical sensor 51 is supported by the base unit 44 over the process path fol' lwe;d by the articles 12. The optical sensor 51 generates a signal when it detects the p~ elue of an artide 12 thereunder. The signal is provided to a process controller 86 (see FIG. 4) for use in controlling operation of the apparatus 40, as ~liccu~ceds~lbsequ~.ntly. Preferably, the optical sensor is a photosensor such as an Eaton sensor;
Cutler Hamrner, Comet Series, Series A2, 9501S.
The base unit 44 also serves to support a sheet applicator head 50, and a supplyof linerless repositionable 5heeting 52 which is elongated in a longih~rlin~l ori~nt~tion The ~l.c~l;"g 52 is provided in a roll 53 which is rotatably mounted on a spindle 54 which, in turn, is supported by suitable means on the base unit 44 (alternatively, the spindle 54 may be supported by the head S0). The repositionable ~he~ g 52 is referred to as "elong~ted" because it is not yet cut into a number of discrete repositionable sheets, and thus the length ofthe Plong~ted repositionable ~heeting as its name implies, is much greater than its width. The terrn "linerless" is used herein to mean an adhesive on a sheet is exposed from the time the sheet is supplied with the adhesive secured thereto (e.g., comes offa supply roll) to an apparatus for adhering the sheet to a substrate and the time the repositionable sheet is adhered to that substrate. A
repositionable sheet is not considered to be linerless when a liner covering the adhesive is removed to expose the adhesive just prior to adhering the sheet to a substrate.
The elong~te~, linerless reposition~ble .cheeting 52 is pocitioned on the roll 53 with its back or adhesive bearing side SSa facing the center ofthe roll 53 and its top or Lion bearing side 55b facing the periphery ofthe roll 53. The reposition~hle cutsheets 14 are cut from the sheeting 52. As such, the back (adhesive-bearing) side 28 of the sheet 14 corresponds to the back side 55a ofthe .~h~eting while the top side 30 of the sheet 14 corresponds to the top side SSb of the sheeting 52. The top side 55b ofthe sheeting 52 may have a low adhesion bac~ i7~ coating thereon, to f~ilitate unwinding CA 022~6S80 1998-11-30 W O 97/48608 PCTrUS97/09333 ofthe ~heetin~ 52 from the roll 53. Such a low-~-lh~sion b~C~ coating may include silicone polymers, fluorocarbon polyrners, urethanes, acrylates, and chrome complexes.
The rate of unwinding ofthe .~heetinp 52 from the roll 53 is controlled by a supply unwind apparatus 56, which is supported by the base unit 44. Unwind apparatus 5 56 in~.ludes a drive motor 57 which is operably coupled (e.g., by a belt drive) to rotate rubber drive roller 58, which in turn is ",~ .ecl in surface contact with the circu~ ence of the roll 53 of ~l.eel;..p 52. The drive motor 57 and drive roll 58 are pivotally supported above the roll 53 by a drive support arm 59, so that as the .sheetin~
52 is unwound from the roll 53 and the circu~ nce of the roll 53 becomes smaller, 10 the drive roller 58 is ...~ ed (by gravity and the weight ofthe drive motor 57, drive roller 58 and support arm 59) in surface drive contact with the roll 53, as seen in FIG. 3.
As the !I.e~ g 52 is unwound from the roll 53, it first passes over an idler roller 60 and then a dancer roller 61. Both rollers 60 and 61 are supported by the base unit 44, but the idler roller 60 is held st~tion~ry while the dancer roller 61 is mounted for 15 pivotal movement about the axis ofthe spindle 54 by a first portion 62a of a dancer support arm 62. A cowdel ~e;gl~l 63 is supported by an opposed second portion 62b of the dancer support arrn 62, as seen in FIG.3. The weight of the counterweight 63, through the dancer support arm 62, urges the dancer roller 61 upwardly. An optical sensor 64 (SUppOI led on the base unit 44) generates a signal when it detects that the 20 dancer support arm 62 has pivoted upwardly to a predetermined position. That signal is provided to the process controller 86, which in turn activates the drive motor 57 to cause rotation ofthe roll 53 and release additional sl-eel;..g 52 from the roll 53. As sheeting 52 is unwound ~om the roll 53, sheetin~-applied tension on the dancer roller 61 will ~liminich, and the dancer support arm 62 will pivot downwardly and out of its 25 signal gen~-~ling position. The lack of a signal from the optical sensor 64 will be noted by the controller 86 and the drive motor 57 deactivated. Pl ~r~- ~bly, the optical sensor 64 is a photosensor such as the BaMer Mini-Beam SM312DQG sensor, available from Banner Fn~ er-illg Corporation, Minneapolis, MiMesota, and the drive motor 57 is a .

CA 022~6~80 1998-11-30 Balder Industrial motor i(lentified as catalog No. GP7401, available from BalderElectric Co., Fort Smith, Arkansas.
The ~long~te-l, linerless reposition~kle sheeting 52 travels through a series ofrollers which define a process path before reaching a cut station 65, where the elongated S sheet 52 is cut transverse to its advance direction in the process path to provide a discrete, cut repositionable sheet 14 of desired length. As used herein, the term "cut"
means the sheet has been completçly severed from a larger sheeting The sheet applicator head 50 is a Kirk-Rudy linerless pressure sensitive stamp affixer which has been modified for use in applying linerless repositionable cheeting The specific stamp affixer used for this purpose is KR-221-223 LSA stamp head, available from Kirk-Rudy, Inc. of Kennesaw, Georgia, which was d~cigned to apply roll form linerless pressure sensitive postage stamps.
The head 50 is supported by suitable means over the base unit 44. Such means may include a transfer drive sha~ 66, which is rotatably driven by the motor 48 on the base unit 44, as well as by support bar 68. The shaft 66 and bar 68 are supported by the base unit 44, and extend through or under the head 50. The head 50 is supported over the base unit 44 in this manner to allow its transverse ~ nm~nt relative to the advancing articles thel ~elow, and thus allow selective plu~ of a sheet 14 across the face of the article 12 (as illustrated by double arrows 70 (in axis x) in FIG. 1).
The elongated, linerless repositionable cheetin~ 52 is unwound from roll 53 through the process path by passing over the idler roller 60 and dancer roller 61 as ~licc,.c.se.~ and then over a series of idler rollers 72, 74 and 76. The process path is then defined by a back-up plate 78 and idler roller 80. The rollers 72, 74, 76 and 80 and back-up plate 78 are all supported on the head 50. A sheet uncurling bar (or bars) may also be disposed in the process path to remove tendencies of the sheeting 52 to curl after cut into individual cut sheets 14.
The rollers 76 and 80 are positioned so that the sheeting 53 is urged against the back-up plate 78 disposed therebetween (see FIGS. 1 and 5). A hold-down brush 82supported by the head 50 is disposed ~dj~c~nt the back-up plate 78 and against the back CA 022~6~80 1998-11-30 side 55a of the cheeting 52 to further urge the top side 55b of the cheeting 52 against the back-up plate 78 as it passes thereover. The back-up plate 78 has a generally planar face 83 (FIG. 5) over which the ~hee~ g 52 traverses.
An optical sensor 84 is also supported by the head 50, and is disposed s ;~n,~P.d;~ely dowll~LIe~ll ofthe brush 82 along the process path, and opposite the face 83 ofthe back-up plate 78. The cheetir~ 52 thus passes between the back-up plate 78 and optical sensor 84.
In the case of paper cheetin~ used to produce cut sheets 14 resembling repositionable notes of the type comrnercially available from Minnesota Mining and 10 M~m-f~ctllring Company of St. Paul, Minnesota under the trade design~tiQn "Post-It," a series of equally spaced (and preferably identically shaped) eyemarks 85 are printed on the back side 55a ofthe ~h~.eting 52 (as seen in FIG. 5). The optical sensor 84 is positioned to illuminate and detect the p,esence ofthe eyemarks 85 as the .~l,eel;,.g 52 is advanced along the process path. Upon detectin~ an eyemark 85, the sensor 84 provides a signal to a process controller 86 (FIG. 4). The brush 82 serves to hold the sh~.eting 52 in ~ n",~"l on the back-up plate 78, and reduce possible flutter or canting ofthe .ch.oeting 52, thereby pGIllli~ling precise l~adi~ ofthe eyemarks 85 by the optical sensor 84 as the ~l~eel;~ .~ 52 is advanced along the process path. r~ erelably, the optical sensor 84 is a photoelectric sensor such as a BANNER Mini-Beam SM312CVGQD
20 sensor, available from Banner Eng;nee,ing Corporation, Minneapolis, Mi.~nesol~
A~er passing over the idler roller 80, the sheeting 52 then passes around a drive roller 90. The drive roller 90 is p~er~bly formed from .~l -minllm, and engages the back or adhesive bearing side 55a of the sheeting 52, and has its cil .;u".re. ~nlial surface formed in a manner (such as grooves 92) so that it p- e~ellls s~lffic;~nt surface to engage 25 and advance ~l.e~l;ng 52 along the process path, but does not present such a surface that allows the adhesive 26 to become adhered thereto instead of contim-it g to allow the .chPetin~ 52 to be advanced. As best shown in FIG. 6, the elongated, linerless reposition~hle ch~eting 52 is firmly pressed against drive roller 90 by one or more pinch rollers 94, so that sheeting 52 does not slip when the drive roller 90 advances the CA 022~6~80 1998-11-30 elon~te-~ linerless repositionable ~heeting 52. It is important that the ~long~te~l linerless repo~ 'E ~ g 52 not slip when the drive roller 90 advances, otherwise the ~l.e~lit~g 52 would not be cut to the proper size and some ofthe i,~"~lalion printed on the top side 55b thereof may be severed from the cut repositionable sheet 14.5 Ple~,~ly, the pinch rollers 94 do not urge portions ofthe ~heeting 52 bearing adhesive 26 against the drive roller 90. A sheet guide 96 is also provided ~dj~c~nt the drive roller 90 to aid in feeding the sheeting 52 along the process path and into the cut station 65.
The sheet guide 96 has a curved face 98 which is radially spaced from the circun~elence ofthe drive roller 90 a rlict~nce s ~fficient to permit ~heeting 52 to pass therebetween, as seen in FIG. 3. The pinch rollers 94 and sheet guide 96 are also supported by the head 50.
The drive roller 90 is driven by a stepper motor 100 mounted on the head 50, preferably a synchronous stepping motor ofthe type available from Superior Electric, Bristol, Connectic~lt under the trade de~ign~tion "SLO-SYN," model M093-FD-8014.Activation of the stepper motor 100 is in turn controlled by signals provided by the process controller 86. More specifically, the stepper motor 100 is activated by a signal from a plo~llli~y switch 101 (FIG. 4) which serves to coordinate the advance of articles 12 and ~l.e~ g 52. The prc,~nllly switch 101 detects rotation of a sha~ (not shown) on the head 50 which is rotatably driven via the transfer drive sha~ 66 (which is, in turn, driven by the base unit conveyor motor 57). The proximity switch 101 is preset to detect a rotation position of the shaft that then coordinales activation of the stepper motor 100 with the advance of articles 52 into the application station 42. When the stepper motor 100 is activated, the process controller 86 also signals the supply unwind motor 57 to permit a like amount of slle~ling 52 to be dispensed from the roll 53 as it is advanced by the drive roller 90. The stepper motor 100 is deactivated by the process controller 86 when an eyemark 85 is detected by the photosensor 84.
From the drive roller 90, the process path enters the cut station 65, where the ~Jon~te-l, linerless repositionable ~l~e~ g 52 is cut along a line transverse to the direction of its ad~ c~ .?nl into a plurality of sequentially formed, discrete CA 022S6~80 1998-11-30 reposition~hle sheets 14. With the exception ofthe very first sheet cut from theelc!ng~te~l, linerless repo~ition~le .~hec~ 52, each cut may define the trailing edge of the i.. e.li~P.ly cut sheet and the leading edge ofthe next cut sheet. Thus, virtually all of the linerless repositinn~hle sheeting is used to form cut repositionable sheets, and the 5 generation of excess waste is avoided. In ~ ition, no elongated sheetin~ remains which exits the appa~ IS after the ~heeti~ has been cut, and thus no take-up reel is necce~ry to gather residual or unused elongated ~hee1ing or liner.
At the cut station 65, a rotary knife 102 is mounted on the head 50. The rotary knife 102 has a cutting edge 104 which acts against opposed anvil 106 to sever the ~heeting 52 disposed therebetween. The anvil 106 is supported by the head S0 andserves to support the ~heeting 52 as it exits the drive roller 90 and sheet guide 96. Each cut by the knife 102 is made after adv~nrement of the .~I.ec~ g 52 a desired length to define a repositionable sheet 14. During each rotation ofthe knife 102, the blade 104 also passes across a blade rle~ning roll 108, which serves to wipe the blade 104 clean of any adhesive or ~ e~ g material carried thereby. The blade .,l ~nil~g roll 108 is p~crcl~bly forrned from felt or some other suitable material for wiping the blade 104 as it passes.
Drive roller 90 is selectively rotated to advance the elongated, linerless repositionable ;,l.ee~ g 52 through the cut station 65 on the process path defined on the head 50. A~er the !I.eel;ng 52 has advanced, the blade 104 ofthe rotary knife 102 is rotated past the anvil 106 to sever a cut sheet 14 from the leading portion ofthe elon~te-l, linerless reposition~hle sheel;~.g 52. As the rotary knife 102 is cutting the ~heel;.~g 52, a rotary transfer assembly 110 moves into place under the cut sheet 14.
Rotary transfer assc"lbly has a transfer head 112 which is aligned to rotate about a central drive shaft 114. The transfer head 112 has an arc-shaped platen face 116 which is rotated through the cut station 65 and transfer station 42 in direction of arrow 117.
As the transfer head 112 passes through the cut station 65, its platen face 116 engages the nc-n~-lhe.~ive side 30 of the cut sheet 14. The transfer head 112 has a vacuum cl,a".bel (not shown) therein, which is coupled to one or more vacuum pickup ports CA 022~6~80 1998-11-30 118 on the platen face 116. A vacuum manifold 122 is also coupled to a chamber in the transfer head 112 ~ cçnt the shaft 114, and the m~nifold 122 is fiurther coupled to a vacuum source by suitable means, such as tubing 124. As is convention~l, a vacuum is drawn through the tubing and m~nifold on a con.~t~nt basis, but the r.h~mbçr and thus vacuum pickup ports 118 are shi~lded during rotation of the transfer head 112 so that a negative pressure is drawn through vacuum pickup ports 118 only when desired (from the time cut sheet 14 is picked up at the cut station 65 until it is laid down at the application station 42). As the leading edge 120 ofthe transfer head 112 rotatesthrough the cut station 65, it becomes aligned with a leading edge 130 of cut sheet 14.
10 When that ~lig""~ç"l is ~ ined, a vacuum is drawn through vacuum pickup ports 118 to pull sheet 14 down against the platen face 116 and secure it thereto (see FIG. 7).
Contim~e~ rotation ofthe transfer head 112 (in the direction of arrow 117) thus carries the cut sheet 14 from the cut station 65 to the application station 42. A spring steel sheet guide 126is aligned on the head 50 and adj~cent the path traversed by the platen 15 face 116 ofthe transfer head 112 to further prevent the dislodg~ l ofthe cut sheet 14 from the platen head 116.
As the leading edge 120 ofthe platen face 116 approaches the anicle 12 (which is also e~lel ;ng the applic~tion station 42), the suction through vacuum pickup ports 118 is cut offto release the cut sheet 14 from the transfer head 112. The adhesive 26 on the 20 back side 28 ofthe cut sheet 14 adheres to the cover 16 ofthe article 12 to engage it thereto. The article 12 continues to advance (by operation of conveyor 46) through the applir.~tion station 42, and the transfer head 112 continues to rotate, thereby pressing or wiping the cut sheet 14 against the cover ofthe article 12 and further e..l~ g the adhesion of adhesive 26 therebetween.
A driven back-up roll 132 is supported by the base unit 44 to further define a nip through which the cut sheet 14 and article 12 must pass in the application station 42 to facilitate this bonding process. The transfer head 112 and back-up roll 132 are driven by the base unit conveyor motor 48. The operative coupling ofthe drive sha~ 114 for the transfer head 112 (on the head 50) and the conveyor motor 48 (on the base unit 44) is CA 022~6~80 1998-11-30 accompli~hP.d via the transfer drive sha~ 66 mounted between the base unit 44 and head 50. A~er depo~iting a cut sheet 14 in the application station, the transfer head 112 contin-~es to rotate (in direction of arrow 117) back to the cut station 65 and into position to accept another cut sheet 14 for pickup, transfer and application to another S article 12. This process is continl-ed as desired until the approp,iale number of promotional assemblies 10 are formed. In each assembly 10, the cut sheet 14 will be applied in the same position ("legisl-~lion") relative to the cover 16 ofthe article 12, thus e~abl ch;~ a very uniforrn and reliable set of promotional asse",l)lies 10. The transfer head 112 pl~r~l~bly has two platen faces 116, opposed by 180~, so that for each rotation of the transfer head 112, two cut sheets 14 are moved from the cut station 65 to the application station 42.
In the case illustrated by FIG. 7, the sheet 14 is longer than the platen face 116 (trailing edge 121 of platen face 116 is o~ lapped by trailing edge 131 of sheet 14).
The sheet 14 is released by the transfer head 112 just prior to entering the application station 42 so that as the transfer head 112 rotates, it wipes the entire sheet 14, out to its trailing edge 131. This may also be accol-lpli~l,ed by setting the conveyor 46 for overtravel relative to the moving transfer head 112.
The rotary knife 102 is also driven by the base unit conveyor motor 48. Again, the operative coupling ofthe rotary knife (on the head 50) and the conveyor motor 48 20 (on the base unit 44) is ~cco...~ l.ed via the transfer drive shaft 66 mm-nted between the base unit 44 and head 50. A ~..e~ nic~l clutch (not shown) is dispoc.- i between the transfer drive sha~ 44 and the rotary knife. That clutch is eng~ged by the process controller 86 when the pholQsel~cor 51 detects an advancing artic}e 12 to rotate the knife 102. A knife rotation sensor 134 (FIG. 4) monitors the rotation ofthe knife 102, and "~o-~e,-t~r;ly f~is~ng~es the clutch when the blade 104 is closely spaced to the anvil 106 to allow sllfficiont sh~etin~ 52 to be advanced therebetween (to define the desired cut length for the cut sheet 14) before the blade 104 reaches the anvil 106 to make a cut.
As mentioned above, the apparatus is controlled by a process controller 86, based upon preset inputs (e.g., desired length of cut sheet 14, desired registration CA 022~6~80 1998-11-30 WO 97/48608 PCT~US97/09333 position of sheet applied on article 12 (both in the x-axis and the y-axis, as seen in FIG.
1), as well as in-process signals from optical sensors 51 and 84, and the knife rotation sensor 134 and the pru~nlily switch 101. The process controller 86 thus activates the motors 48, 57 and 100, dçp.o.n-l~nt upon the preset conditions and in-process signals to continustlly, Ltluru~ y and seq-lentisllly apply each cut sheet 14 in the same relative position on an article 12. With this apparatus, it is possible to create, for C~ , up to 15,000 id~ntirstl promotional ?cc~mblies 10 per hour (with each cut sheet 14 having a length of 3 inches). pceducir-g the length of the cut sheet to one inch allows processing of up to 30,000 ;1~c~mhlies 10 per hour, and even faster processing times are 10 conlç~ lated. Conventional m~g;t7ine binding eq-~irm~nt typically runs in the range of 9-10,000 articles per hour, and thus the disposition of the apparatus of the present invention and its method along a mstgst7ine binding line will not inhibit normalprocessing, and the result will be a bound m~;t7ine bearing a partially coated RPSA
sheet on at least one page thereo~
In short, and with . t;rert;l.ce to FIGS. 3-7, the apparatus of the present invention perfomls the following steps to adhere a cut repos~itions hle sheet 14 to an advertising piece 12. First, the base unit conveyor motor 48 is activated to initiate conveyance of articles 12 sequentially through the application station 42. As sensor 51 detects an approaching advertising piece 12, it relays a signal to process controller 86, which in 20 tum activates the rotary knife 102 clutch so that the knife 102 rotates for cutting. The prù~ lu~y switch 101 detects rotation driven by the base unit conveyor motor 44 and activates the motor 100 to rotate drive roller 90 to advance the elongsterl, reposi~ic -ble ~l.eel;n~ 52. As .~l.e~l;ng 52 is pulled from the supply roll 53, the dancer support arm 62 will move upwardly to be detected by optical sensor 64. The sensor 64 will relay a 25 signal to the process controller 86, which in turn activate the drive motor 57 (as necPc.~. y) to facilitate the unwinding ûf ~heeting 52. The supply unwind apparatus 56 thus serves to S~tt~n~-s~te the otherwise incremental advance of.~heeting 52 from the roll 53.

CA 022~6~80 1998-11-30 WO 97/48608 rCT/US97/09333 As the ~heetin~ 52 traverses the process path, the sensor 84 detects an eyemark 85 on the back side 55a ofthe elongated repos;~ion~hle ~l.e~ g 52. Sensor 84 relays a signal to the process co~lt~ 86, which in turn deactivates the motor 100 to stop the rotation of drive roller 90 and advance ofthe 51,Pe~ 52 along the process path.
Rotation ofthe rotary knife 102 was Ill~ h- jly stopped by knife rotation sensor 134 to permit the desired length of ~heeting 52 to pass by the knife 102 prior to its severing the leading portion ofthe ~lone~ted repositionable sheeting 52 into a cut sheet 14. The transfer head 112 ofthe rotary transfer assembly 110 is rotated to a position below the just cut sheet 14, and a negative pressure drawn through vacuum ports 118 to adhere thecutsheet 14totheplatenface 116Ofthetransferhead 112. Thetransferhead 112 continues to rotate, approaching the applicalion station 42. As the leading edge of the cut sheet 14 comes into ~eg.~ Lion and contact with the face ofthe article 12, the negative pressure is released, thereby releasing the cut sheet 14 from the platen face 116.
The adhesive 26 on the cut sheet 14 engages the article 12 as it moves through the al~plic.~l;on station 42. The transfer head 112 continues to rotate and the platen face 116 presses or wipes the cut sheet 14 onto the article 12, backed up in this position by the driven back-up roller 132. The advertising piece 12 and sheet 14 adhered thereon (now a promotional asscl"bly 10) continl~e to advance in the direction of arrow 49 (via conveyor 46) to exit the apparatus. This process is repeated over again to register and adhere each cut repositionable sheet 14 to an advertising piece 12. Once applied, the cut sheet 14 adheres via adhesive 26 to the article 12, but as mP.ntionP~d above, the adhesive is RPSA and thus the cut sheet 14 may be removed and re-adhered to the article 12, or removed for pt~.emPnt on an alternative clean surface (e.g., deskIc:r~igel~lor or for use, for ~,.~nl)le, as a coupon).
The elone~te(l~ linerless repositionable sheeting can be formed from a bond paper, preferably having a basic weight of 15 to 25 pounds. Such paper is provided in elong~te~, roll form~ and then cut into separate note sheets by the inventive apparatus.
Typical properties of such sheets include a caliper of 0.002 to 0.00g inches (51 to 229 microns), and an adhesive area covering a portion of one surface of the sheet. The CA 022~6~80 1998-11-30 adhesive may cover from 10 percent to 90 percent of the surface, preferably between 20 percent to 75 percent, and more plGr~l~bly between 15 to 50 percent. The adhesive may be coated as a continllouc stripe along an edge or be coated in a d;sco..l;...lollc pattem, such as lines of adhesive dots. Each sheet prere-~bly bears a strip of RPSA
along one edge thereof on its back side, while on its top side, each sheet bearspreprinted indicia or images. P~Gr~-~bly, only a minor portion ofthe back side ofthe cut sheet may bear RPSA. The top (nc n~hecive bearing) side of the cheetin~ may be coated with a release layer to f~ t~te the unwinding of the roll.
The indicia or image borne by the sheets is pl ~r~-~bly the same for each cut sheet. Thus, the elongated .cheeting material (prior to cutting) bears a repeating pattern of the same indicia or image along its length. The pattern repeats in equal length segments, with each segrn~nS dPci~ned to be cut into a separate cut sheet.
The .chPeting may also contain a line or path of weakness (such as pe-rol~lions)generally parallel to the adhesive so that a portion of the sheet (without adhesive) could be separated from that portion of the sheet bearing adhesive. Thus, the non~-~h~cive portion can be tom away from the adhesive portion (which may remain on the article).
This embodiment may be particularly useful for coupons or return mail postcards.The eyemarks printed on the back of the cheeting are used to define the cut length and control p~ a.llelel ~ for the apparatus. Pl ~r~, ~Iy, the eyemarks are positioned along what would be the cut line between ~ c~nt cut sheets on the ~lon~ted ,~1.et;~ g so that a~er cutting, half of each eyemark is borne by subsequ~ntly cut a~ljac~nt sheets.
Typically, a cut note sheet will be cut by the inventive apparatus to a size of less than 100 square inches (645 cm2). More typically, cut sheets have a size in the range of 1 to 30 square inches (6 to 194 cm2), and even more typically in the range of 2.5 to 25 square inches ( 16 to 161 cm2). Cut repositionable sheets frequently measure about 3 inches by about 5 inches (7 by 13 cm) or about 4 inches by about 6 inches (10 by 15 cm). Another common size is about 1.5 inches by about 2 inches (3 cm by 5 cm).

CA 022~6~80 1998-11-30 Using the present apparatus, typical cut lengths for each cut sheet range from 1 to 6 inches.
In the present apparatus, it is coll1r....~ ed that rolls of.chPeting m~tPri~l up to 20 inches in ~i~meter can be accommod~ted (depel.dillg upon the th;c~nçs~ ofthe 5 sh~eting material) and may provide a supply of ~heetin~ material having a generated length of about 2300 lineal yards (about 2100 meters). For such a roll having a width of about three inches, the rollers 60, 6 l, 72, 74, 76, 80 and 90, plate 78 and applicator head 1 12 have widths (transverse to the process path) of about 3 .25 inches.
In the inventive apparatus, the optical sensor 84 which is e~ loyed to detect the l0 eyemarks 85 is a sensor suitable for detecting changes in opacity. Thus, dependent upon the color of the sheetin~ the eyemark may be darker or lighter than the ~h~e~ color, so long as the change in contrast between the eyemark and sheeting substrate color is s~fficient to gen~ e a rlPtection signal by the optical sensor 84. Typically, the eyemark will be a mark made with black ink, such as illustrated in FIG. 5.
For a ~1-P.~;I;.~P material which results in a cut repositionable paper sheet, the sheet substrate is an opaque paper. Printing is required on both sides ofthe ~he~ g to deposit the eyemarks on the back side thereof and the p,~;~"inled indicia or image on the top side thereof. In addition to opaque or paper cut sheets, the present invention is also applicable to other sheet structures. The ~I.e~ p material may be conventional bond or clay-coated paper, carbonless paper, a polymeric sheet material or even a metallic foil.
Further, ll~l~Ja~ l or tr~n~ cçnt substrate materials (i.e., light-ll-~n~ e) such as those used for repos;li~ e tape flags sold by ~ esol~ Mining and ~n-lf~ç~lring Company of St. Paul, Min~-esota under the trade dç~i~n~tion "Post-It," are also possible sheetin~ materials.
A tape flag is a discrete, flexible sheet which has a first major side and a second major side. On its first major side (back side), RPSA is provided ~ c~nt a first end of the elongated sheet (typically on at least half or a major portion ofthe back side ofthe sheet). ~djac~nt its second end, the tape flag is provided with a visible indic~tQr of contrasting color. This may be an inked color covering a tab portion of the second end CA 022~6~80 1998-11-30 of the sheet (on either side thereof) or a preprinted image or mP~e (such as "Sign Here"). Tape flags are typically used as temporary in~ic~tors of pages in books or docl-ment.c, or portions of doc~m~nt~ to be noted by a reader. That portion of the tape flag which bears RPSA is sllffiriently ~ enl when adhered to a page so that underlying text on the page may be perceived and read. Often, an indicator image (such as an arrow) is printed on this first l- ~tns~ el-l portion of the tape flag to ~nh~n~e its use as an indicator of sections of a page to which it is adhered.
Because of the ~l ~.-spale--l nature of a portion of the tape flag, the preprinted indicia or image thereon itself can serve as an eyemark for tape flags dispensed and applied using the apparatus of the present invention. This is more fully described in co.~ l;on ~,vith FIGS. 8-11 and FIG. 3.
FIGS. 8 and 9 illustrate a promotional assembly 10a that in~l~ldes an advertising piece 12 and a repositionable sheet 214. The advertising piece is, for illustrative purposes, the same as that shown and described previously, and again can be any article suitable for mounting a repo.sition~hle sheet thereon. As seen in FIG. 9, repo~ition~l'e sheet 214 is again secured directly to the advertising piece 12 by RPSA 226 coated partially on the first or back side 228 ofthe sheet 214 (with the RPSA 226 p~er~.~bly coated over 25 to 75 percent ofthe back side 228). Repositionable sheet 214 has a second or top side 232. Ink of a conl~sL;~g color or a preprinted m~c~ge may be printed on either side of the sheet 214 (if printed on the first side 228, the RPSA is applied over the printing).
Each sheet 214 (as a tape flag) is typically elong~ted (with a length ranging from 1 to 3 inches), with a first end 231 and a second end 233. The substrate polymermaterial for the sheet 214 is flexible and generally ~ e..l, as is the RPSA (disposed adjacçnt the first end 231). Thus, when the sheet 214 is adhered to an article 12, underlying indicia or images on the article face can be seen through a first ll~spare..l or read-through section 235 ofthe sheet 214. Adjacent its second end 233, the sheet 214 will bear a visually distinctive color ink in a second subslh~ lly opaque section 237, which is useful in calling attention to portions ofthe article 12 (and/or the second , ~ , . . . .

CA 022~6~80 1998-11-30 section 237 may include a printed mecc~e 238). The sheet 214 may also include anarrow or other intlir.~tor 239 printed on the first section 235 thereo~ In one emboflinlent, the tape flag sheet is formed from cellulose acetate, such as disclosed in Miles et al. U.S. Patent 4,907,825. In another embodiment, the tape flag sheet is formed S from biaxially oriented polyethylene terephthalate (PET). In either case, the tape flag sheet may have a thic~nçsc ranging from .001 inch to .005 inch, and more ple~,~bly .002 inch.
The physical h~nrlling of the tape flag sheeting in the apparatus 40 of the present invention to effect sequential l~ tion and application of cut tape flag sheets 214 10 onto the articles 12 is the same as described previously for paper cut sheets 14, except that the preset p~ eters (e.g., cut length of sheet 214) may be di~erelll. ~heetin~ 252 is provided in the form of a roll 253, as illustrated in FIG. 10. The sheeting 252 has a back adhesive-bearing side 255a facing the center ofthe roll 253 (which co,lesponds to back side 228 of sheet 214), and a top or ;l~l "~alion readable side 255b towards the pe~;phely ofthe roll 253 (which corresponds to top side 230 of sheet 214). The ee~ g 252 traverses the process path through apparatus 40 in the sarne manner aspreviously desc,il,ed, with its adhesive side 255a facing drive roll 90, and itsnonarlhesive side 255b l~him~t~ly engaged by transfer head 112. The arrows 239 are repeatedly printed along the length of the sheetin~ 252, one for each cut sheet 214 to be 20 severed ~l~e~t;fluln. Because a portion ofthe sheeting 252 is generally l,~,~y~e"l (portion 261 (FIG. 10), col,~onding to first section 235 of cut tape flag sheet 214), the arrows 239 are visible on either side ofthe sheet (r~g~.lless of which side the arrows 239 are printed on), and thus can serve as the eyemarks 285 for the tape flag .ch~eting 252. Other collLl~s~in~, patterns or in~ic~tor marks printed on the ,cheeting 252 25 can also serve as the legi~ ion means (eyemarks) so long as they are s lffiri~ntly detect~ble.
A portion ofthe ch~eting 252 is shown in FIG. 11 as disposed for detection of eyemarks 285 by optical sensor 84. The tape flag sheeting 252 extends between rollers 76 and 80, and across the face 83 of back-up plate 78. The brush 82 aids in holding the CA 022~6~80 1998-11-30 .~l.c~,l;"g 252 flat against the back-up plate 78 for eyemark 285 detection by optical sensor 84 disposed thereabove (see FIG. 3). The arrows 239 present a sllffiri~ntcontrast to the l~ p~elll portion 261 ofthe ~l~e~ g 252 to permit detection and signal generation by optical sensor 84. The signal generated by optical sensor 84 is 5 provided to the process controller 86, and again serves to register the tape flag sheetin~
for advancem~nt and cutting into discrete cut sheets 214, and ultim~trly for application onto the articles 12.
Conventional tape flags are relatively narrow, and may range in width from 0.4 inch to 2 inches, and more p. erer~bly, about 1 inch. Using the apparatus 40, one inch 10 wide (or long as viewed in direction of adv~nc~ment through the process path) cut sheets are possible. For narrow width cut sheets of this type, some of the vacuum pickup ports 118 may be covered (i.e., masked by the application of adhesive tape) so that a vacuum is dra~vn only through those ports that are presented to the cut sheet at the cutting station (e.g., in FIG. 7, port 118a for cut sheet 214). Relatively long lengths 15 of .eheeting may be processed into tape flags individually disposed on articles. For example, a roll oftape flag ~heeting up to 14 inches in di~met~r can be processed, which would rtp~ esenl a generated length of about 1800 yards (1645 meters).
One fi.~ 1 objective ofthe inventive method and apparatus is the formation of a multitllde of id~ntir~lly registered promotional articles, where the cut 20 sheet is adhered to the article in precisely the same location every time. The system sensing and control means described are thus provided to apply the cut sheet in register to the article (e.g., a m~7irle signature). In part, the degree of registration is controlled using register marks or eyemarks. The present inventive method and apparatus can provide a predetermined degree of ~ Lion bet~,veen the cut sheet and 25 article of +/- one inch in any direction (x and y, as noted in FIG. 1); preferably, the degree of registration attained is +/- 0.33 inch in any direction (a tolerance known as "loose register"); more preferably, the degree of registration attained is +/- 0.125 inch in any direction; and most preferably, the degree of registration is +/- 0.03125 inch in any direction (a tolerance known as "lap register"). These registration criteria are possible at CA 022~6~80 1998-11-30 all run rates of the inventive apparatus and method, incl~lding specifically run rates faster (over 3,000 assemblies per hour) than any known process or apparatus, run rates as fast (about 9,000 to 10,000 ~c~emh!ies per hour) as conventional m~g~7ine binding equipment operates, and even faster run rates.
"Registration" is a term used in the printing industry relating to the placçmçnt of ink or other converting between di~-e--l stations on the printer or di~ere.,l pieces of equirmPnt Register marks or eyemarks are indicia (usually separate from the ~el~ lg printed graphics of a printed piece) that are typically located along an edge of the printed piece. Such marks may be "crosshairs" (indicia printed as two perpP.n~lic~ r~ straight 10 lines intersecting at their midpoints) or may be printed as a simple rect~ngle. Typically, these marks are cut offwhen the printed product is finichPd.
As described, the marks for the present invention may be separately printed on the sheetin~ (e.g., as in FIG. 5) or may be defined as a portion of the indicia or image printed on the sheeting (e.g., as in FIGS. 10 and 11). This latter approach çlimirl~tes 15 printing on both sides of the ~heetin~ (such as when the she~ g is ~ ) and .; n;~.~s waste ofthe ~het;~ material (since no lli..l-- i--g is required), thus improving the overall Pffiri~ncy ofthe process and its material usage. While the invention is illustrated by ,eg;sl.~lion means such as visually d~le~ ble eyemarks and detecting means therefor such as photosensors, alternative .egisl~lion and detectin~ systems are 20 possible. For c~ Jle, the ~egi~ lion means can be visible, tactile, olfactory, auditory or tasteable, as disclosed in U.S. Patent 5,382,055 Although the present invention has been described with reference to p~e~llt;d embo~i~nP~nt~ workers skilled in the art will recognize that changes may be made in form and detail without dep~ l;ng from the spirit and scope of the invention.

Claims (30)

Claims,

1. In a roll of sheet material which is elongated longitudinally, has first and second opposed sheet surfaces. and first and second opposed side edges, the improvement which comprises:
a pressure sensitive adhesive extending in a predetermined pattern on only a first adhesive portion of the first surface of the sheet material, adjacent the first side edge thereof;
the sheet material, adjacent its first side edge and including the first adhesive portion, being formed from a material that is sufficiently transparent when adhered to a substrate that underlying images on the substrate are substantially visiblethrough the sheeting material, and a plurality of longitudinally spaced and detectable images disposed in predetermined locations on the first adhesive portion of the sheet material.

2. The roll of sheet material of claim 1 wherein the first adhesive portion is defined as approximately half of the first surface of the sheet material.

i. The roll of sheet material of claim 1 wherein the sheet material has a secondtab portion adjacent the second side edge thereof, and further comprising a plurality of longitudinally spaced and visible tab images disposed in predetermined locations on the second portion of the sheet material.

4. The roll of sheet material of claim 3 wherein the images on the first adhesive portion of the sheet material are equally spaced longitudinally, and wherein the tab images on the second portion of the sheet material are equally spaced longitudinally.

5. The roll of sheet material of claim 1 wherein the sheet material has a secondtab portion adjacent the second side edge thereof, and further comprising:
a coating of opaque material on the second tab portion of the sheet material.

6. The roll of sheet material of claim 1 wherein the images have sufficient visual contrast from the sheet material to be readily visually detectable.

7. The roll of sheet material of claim 1 wherein the adhesive is a repositionable pressure sensitive adhesive.

8. The roll of sheet material of claim 1, wherein the plurality of images form arepeating indicia pattern which is visible on either side of the sheet material for use during processing as an indicator to facilitate cutting apart discrete sheeting segments, of equal cut length with each segment bearing a repeated pattern of the indicia printed thereon.

9. The sheet material of claim 8 wherein the pressure sensitive adhesive is repositionable pressure sensitive adhesive disposed to cover a majority of the first surface of each discrete cut sheeting segment.

10. The sheet material of claim 8 wherein the indicia is an opaque arrow disposed laterally across the sheeting material.

11. The sheet material of claim 8 wherein each segment has a longitudinal extentof from 1.01 cm to 5.08 cm.

12. The sheet material of claim 8 wherein the pressure sensitive adhesive and indicia pattern are adjacent the first side edge, and further comprising:
a coating of opaque material on one side of the sheeting adjacent the second side edge thereof.

13. A method of sequentially adhering linerless repositionable sheets to a corresponding sequence of articles, the method comprising:
(a) supplying an elongated linerless sheeting in wound roll form, the sheeting having a first major side and an opposite second major site, with pressure sensitive adhesive coating partially disposed on the first side of the sheeting and with the second side thereof being free of adhesive:
(b) advancing a leading portion of the elongated linerless sheeting along a process path until it reaches a cut station;
(c) laterally cutting the leading portion of the linerless sheeting to define a first cut sheet having a first lead edge and a second trailing edge;
(d) aligning a vacuum platen having an arcuate circumferential surface into engagement with at least a portion of the second side of the first cut sheet adjacent the first lead edge thereof;
(e) forming a negative pressure on a portion of the arcuate circumferential surface of the vacuum platen to affix the first cut shed in the cut station thereto;
(f) advancing a first article having a face into an applicator station adjacent the vacuum platen;
(g) moving the vacuum platen to carry the first cut sheet from the cut station to the applicator station whereby the first cut sheet is aligned for placement on the face of the first article;
(h) relieving the negative pressure on the arcuate circumferential surface to release the first cut sheet from the vacuum platen;
(i) moving the vacuum platen across the face of the article so that the pressure sensitive adhesive on the first side of the first cut sheet is pressed against the face of the article to bond the first cut sheet to the face of the article;
(j) repeating steps (b) and (c) to define a second cut sheet from the elongated linerless sheeting;
(k) repeating steps (d) and (e) with the vacuum platen relative to the second cut sheet;
(l) advancing a second article having a face into the applicator station adjacent the vacuum platen, and (m) repeating steps (g), (h) and (i) with the second cut sheet to align, release from the vacuum platen and then press the second cut sheet against the face of the second article by the arcuate circumferential surface of the vacuum platen.

14. The method of claim 13 wherein the cutting step includes rotating a laterally disposed rotary knife across the process path at the cut station.

15 The method of claim 14, and further comprising the step of:
cleaning the rotary knife during each rotation thereof to inhibit the build-up of adhesive or sheeting material on the knife.

16. The method of claim 13 wherein the advancing step includes driving the rotation of the wound roll of elongated linerless sheeting as it is unwound onto the process path.

17. The method of claim 13 wherein the elongated linerless sheeting has, on its first side, a series of longitudinally disposed, equally spaced visual indicators, and wherein the method further comprises the step of:
detecting each visual indicator on the sheeting as it is advanced along the process path to a generate a signal used for process control purposes.

18. The method of claim 13 wherein the elongated linerless sheeting is opaque.

19. The method of claim 13 wherein the elongated linerless sheeting is light-transmissive.

20. The method of claim 19 wherein the light-transmissive sheeting has, on either side, a series of longitudinally disposed, equally spaced visual indicators, ant further comprising the step of:
detecting each visual indicator on the sheeting as it is advanced along the process path to generate a signal used for process control purposes.

21. The method of claim 13 wherein at least that portion of the elongated linerless sheeting coated with pressure sensitive adhesive is light transmissive.

22. The method of claim 13 wherein each article is continually advanced through the applicator station during the moving steps.

23. The method of claim 13 wherein the vacuum platen is rotatable about an axis, and wherein the moving steps include rotating the vacuum platen about its axis to pass the arcuate circumferential surface thereon through the cut station and applicator station.

24. The method of claim 13 wherein the cut sheets are adhered to the articles toform an adhered sheet assembly at a rate of up to 30,000 adhered sheet assemblies per hour.

25. The method of claim 13 wherein the advancing step includes;
rotating a drive roll in engagement with the elongated linerless sheeting along the process path; and driving the unwinding of the supply roil of elongated linerless sheeting to advance the sheeting onto the process path in controlled coordination with the rotation of the drive roll.

26. The method of claim 13 wherein the adhesive is a repositionable pressure sensitive adhesive.

27. A method for affixing a plurality of sheets to a plurality of moving articles comprises:
providing a roll of sheet material;
sequentially cutting the sheet material from the roll into identically sized sections, with each section defining one sheet ant wherein each sheet has repositionable pressure sensitive adhesive on at least a back portion thereof, providing a supply of articles, each article having a face presented for adhesion of a corresponding sheet thereto;
sequentially applying the sheets to the articles at a rate of over 3,000 per hour, and aligning each sheet on the face of its respective article to within 0.125 inch of a desired location in any planar coordinate.

28. The method of claim 27 wherein each cut sheet is aligned on each article to within 0.03125 inch of a desired location in any planar coordinate on the face of the article.

29. The method of claim 28 wherein the sheet material of the roll has a plurality of identically spaced registration indicators thereon, and wherein the aligning step includes detecting the registration indicators; and aligning the sheets relative to the articles as a function of the detection of the registration indicators.

30. An article and sheet assembly formed by the method of claim 27.