EP2148311A1

EP2148311A1 - A Label With An Easy Opening Tab And A Method For Making The Same

Info

Publication number: EP2148311A1
Application number: EP09165722A
Authority: EP
Inventors: Paul Geofrey Atkins
Original assignee: Chesapeake Ltd
Current assignee: Chesapeake Ltd
Priority date: 2008-07-21
Filing date: 2009-07-16
Publication date: 2010-01-27
Also published as: GB2462077A; GB0813311D0

Abstract

A label assembly (10), and method of making such a label assembly (10). The label (10) comprising a base label (4); a laminar label component (12) overlying at least part of the base label (4); an overlaminate (14) overlying and adhered to the base label (4); a label component (12); and a tab (6) separate to the base label (4) and label component (12). The tab (6) does not extend across a full width of the overlaminate (14) and label (10), and is preferably disposed in a corner region of the label (10). An extended portion (15) of the overlaminate (14) overlies and adheres to an upper surface of the tab (6). The tab (6) is formed from a portion of the base label (4) of an adjacent label (10) produced on a web carrying a line of such labels. The tab (6) furthermore, and a region of the adjacent base label (4) forming the tab (6) has an underside that is adhesive free (or has neutralized adhesive) to allow the tab (6) and so overlaminate (14) to be more easily peeled from the container and the label opened, when the label (10) is applied to a container.

Description

The invention relates to labels, and in particular self adhesive leaflet type labels that include a non-adhesive tab that provides easy access to the leaflet label, and a method for producing the same. In particular, the invention relates to a self-adhesive multi-laminar label arrangement comprising a carrier substrate, generally in the form of a self-adhesive base label, for one or more additional layers mounted on the base label. The additional layers may include leaflets or booklets including information relevant to the product to which the label is to be applied. An overlaminate is then applied over the booklet and carrier base label.
In the current market conditions, there is a growing requirement to provide consumers with increased product information. This need can stem from legal requirements (for example for pharmaceutical products), and for exported goods, the requirement is to provide repeats of the same information in various languages. This need to provide such additional information has been addressed by providing "leaflet" labels, in which information provided on a self adhesive product label is supplemented with a folded leaflet carried on the base label.
One problem associated with labels of this kind is that it is difficult to apply the leaflet, particularly when the label is applied to a cylindrical container which has a relatively small diameter, and/or when the leaflet comprises numerous pages. It has been found that when the label is applied around a cylindrical container, the assembly tightens at the trailing end and is difficult to smooth down the remaining length of the label, causing it to bunch up and crease the support label.
To address this problem an arrangement with a self-adhesive cover, or "overlaminate" layer is provided over the leaflet to both protect the leaflet, and provide access to the leaflets's contents. The self-adhesive over laminate adheres directly to the release sheet ofthe base label, and so when removed from the release sheet and applied to a container it will adhere to the container. In this way, the arrangement does not crease when applied to the container, because the leaflet can move before the overlaminate seals to the container.
To assist a user in finding the "end" of the overlaminate in order to open the label and leaflet, a non-adhesive tab or a non-adhesive region of the overlaminate acting as a tab, can be provided. However known methods to provide such a non-adhesive tab generally involve specialist equipment, additional steps in the process, are costly, or not effective.
In particular a tab can be formed by extending the front page of the leaflet or booklet, which is either die-cut before folding or cut-out on a folding machine using specialist equipment. This additional operation increases the cost of the leaflet or booklet and makes feeding for subsequent operations difficult due to the uneven edge.
Another method used to provide a tab is to produce a separate label and overlabel the die-cut base material. The separate label is positioned in the label gap of the die-cut base material, before overlaminating the web overall with self adhesive material and die cutting again. This method involves the additional cost of a separate overlabel.
Yet another method is to 'kill' or deactivate or remove the adhesive on one corner of the self adhesive overlaminate material. This can be achieved by printing a deadening varnish or ink on an area of the silicone coated release backing material on which the label is carried so that the ink/varnish will transfer to the adhesive of the overlaminate material, when applied. This is however not as effective as printing directly onto the adhesive of the overlaminate material because of the difficulty of printing onto a silicone coating. However to print directly onto the adhesive of the overlaminate material would require a separate operation and a system to register the printed overlaminate to the base material in the correct position, and can give rise to other complications.
An example of such prior basic leaflet label comprising a base label and over laminate is described in EP 0506202 . Such a label is however difficult to open since it does not include an opening tab. An arrangement incorporating an opening tab is described in GB 2303351 . In some of the arrangements (Figs 7 and 8) described in GB 2303351 , and according to the preamble of claim 1, the tab is formed from part of the base label material used to form an adjacent label. The tab portion is spaced from the remainder of the label, and at an edge of the overlaminate and extending across the full width of the label and overlaminate. The tab is coated with adhesive on the release sheet and container to locate the tab especially during production. In such a case the tab and leaflet is not as easy to open. In other alternate described arrangements the tab is formed from a portion of the leaflet and is free from adhesive making it easier to open. However this requires a more complex leaflet and cutting of the leaflet.
Another leaflet arrangement including a tab is described in EP 0833295 , in which a tab or lug is again formed from a portion of the booklet label, but in this case is integral with and connected to the front panel of the leaflet which extends beyond the reminder of the leaflet and base label and over an additional separate adhesive sheet portion which is printed with varnish mixed with silicone to allow the overlaminate attached to it to be resealable. The additional adhesive sheet spaced from the base label in this arrangement is and covered with varnish allows the edge of the overlaminate to be more easily peeled to open the label in conjunction with the tab and accommodates the wrapping of the label around the container. However this requires separate additional adhesive sheet portion which must be carefully placed and spaced from the remainder ofthe label, and in addition must be carefully and separately printed with varnish. In addition a relatively complex leaflet is required including the integral tab/lug.
Further similar examples of leaflet label arrangements including opening tabs, all with similar or other drawbacks, are described in WO00/23970 ; GB2341166 ; WO97/48085 ; US 5234735 .
Other laminate labels with tab arrangement are described in EP0303400 and US5672224 , although these do not relate to leaflet type labels and the specific different considerations and problems associated with such more complex leaflet arrangement. In US5672224 a tab is defined in a portion of the overlaminate by a cut out from the base label layer. In EP0303400 relates to a tamper evident label with a tab is formed from an end portion of the overlaminate that has an anti-adhesion strip applied to it overlying the base label portion.
It is therefore desirable to provide an improved label which offers improvements to the opening methods discussed above, which is easier to manufacture, and an improved method of making such a label, which address the above described problems and/or which more generally offers improvements or an alternative to existing arrangements and methods.
According to the present invention there is therefore provided a label assembly, and a method of making a label, as described in the accompanying claims.
In an embodiment of one aspect of the invention there is provided a label assembly comprising a base label; a laminar label component overlying at least part of the base label; an overlaminate overlying and adhered to the base label and label component; and a laminar tab separate to the base label and label component. The overlaminate has at least a part of an underside of the overlaminate coated in adhesive to adhere the overlaminate to the base label and label component. The overlaminate also has an longitudinal extended portion extending beyond the base label and label component. The extended portion of the overlaminate overlies and adheres to an upper surface of the tab. The laminar tab does not extend across a full width of the overlaminate and label, and preferably is disposed in a corner region of the overlaminate and label assembly.
The tab of such an arrangement allows the overlaminate to be more easily peeled back to open the label and label component, whilst ensuring when the label is attached to a product or release sheet, that the label remains securely closed and attached by virtue of the overlaminate extending over an enlarged area and the tab only comprising a small, preferably corner region of the label, and the extended portion of the overlaminate attaching to the product.
The laminar tab is preferably spaced from base label, and preferably label component, with more preferably the spacing of the laminar tab from the base label and label component defining a gap therebetween and the extended portion of the overlaminate extending and bridging this gap.
The tab is preferably formed from the same material and layer of laminar material as the base label.
At least a part of an underside of the base label is preferably coated in adhesive. Moreover preferably an underside of the tab has substantially no adhesive coating, or has an adhesive coating which has been substantially neutralized.
The portion of overlaminate overlying and adhered to the base label preferably advantageously assists in securing the label component to base label.
The label component may typically comprise a multilaminar label component, and preferably a multilaminar booklet.
The label is typically carried on a release backing sheet prior to being removed from the release backing sheet and applied to a product or container upon which the label assembly is mounted.
In another aspect of an embodiment of the invention there is provided a method of producing a succession of labels carried on an elongate web of release backing material. The method comprises providing a plurality of base label blanks spaced apart in succession along an elongate web of release backing material. Each base label blank has a tab forming portion and an underside at least partially coated in adhesive to adhere and mount the base label blank on the web of release material. The method further comprises providing adhesive free regions of underside of the base label blanks which have no adhesive or deactivated adhesive. The adhesive free regions extend over at least part of said tab forming portions of the base label blanks. The method then includes applying an overlaminate over the base label blanks and release backing. The overlaminate extends between adjacent blanks from a first base label blank to at least the tab forming portion of a second adjacent base label blank and has an adhesive coating on at least part of an underside of the overlaminate to attach the overlaminate to at least the blanks. Next the method comprises cutting the labels from the overlaminate and base label blanks. The cutting is offset from the base label blanks to cut across the first and second blanks and thereby cut a base label portion of a first label from said first base label blank and the tab of the first label separate to the base label portion from the tab forming portion of the second adjacent blank with the tab portion preferably unadhered to the elongate web of release backing material. The tab preferably also does not extend across a full width of the label, and more preferably only comprises a corner region of the label.
This method advantageously produces a separate discrete opening tab for each label in a simple and easy manner.
The base label blanks are preferably formed from an elongate layer of base label material laminated onto the elongate web of release backing material.
The elongate layer of base label material is preferably separated from the elongate web of release backing material, prior to providing said adhesive free regions. Preferably the elongate layer of base label material is laminated onto the elongate web of release backing material, after providing said adhesive free regions.
More preferably the elongate layer of base label material is delaminated from the elongate web of release backing material. The adhesive free regions are then produced and then the elongate layer of base label material relaminated onto the elongate web of release backing material.
The plurality of base label blanks are preferably cut from the elongate layer of base label material laminated onto the elongate web of release backing material. The base label material surrounding the base label blanks is then removed, to leave and provide the plurality of base label blanks spaced apart in succession along an elongate web of release backing material.
The adhesive free regions may be provided by neutralizing the adhesive coating in said regions. In particular neutralizing the adhesive coating in said regions may comprise printing varnish or ink onto the respective regions of the adhesive coating.
A label component is preferably applied to the base label blanks prior to applying the overlaminate, and applying the overlaminate over the label components attaches the label component to the base label blanks and label. Furthermore preferably the label component does not cover all of the base label blank an base label, and the overlaminate is adhered to a portion of the base label blank and base label to thereby secure the label component to the base label.
In particular according to an aspect of an embodiment of the present invention the tab is formed from a base portion of the next label on the web. The leading edge of this label has an area of adhesive killed by printing a deadening varnish or ink and is die-cut to shape, with the waste material removed. When the leaflet or booklet has been applied in the correct position onto this web, it is then overlaminated to produce the label assembly.
By offsetting the position of the second die-cutting operation, to cut the leading edge of the following label and removing the waste material, the finished label assembly produced has self adhesive overlaminate material sealed to the release sheet with an opening tab and a gap between each label assembly.
While the tab could be any size or shape if the tab extends the full width of the label assembly and clear overlaminate material is used, it might confuse the label applicator by receiving two sensing signals. This is because the sensor used to detect label gap will receive one signal after the leaflet/booklet and another signal after the tab. Therefore although it is possible to produce a tab that will extend the full width of the label assembly, the present invention will cut the tab, so as to leave an area clear for uninterrupted sensing on the labeler.
In addition it has been found that a small tab area is sufficient for easy opening. If a larger area is provided then it will stand away from the container and may catch on the conveyor line after application.
The tab area may be printed with opening instructions or a symbol to guide the user.
An 'in line' system in which the label with easy opening tab is produced in a continuous operation is the preferred method of production, to give cost benefits. An 'offline' system, involving separate operations and in which some of the various stages are carried out on separate machines and/or production lines, at different times could however also be used.
According to a yet further aspect of an embodiment of the invention there is provided a method for producing labels comprising the steps of:

providing an elongate support web on a release backing web;
delaminate the face material with adhesive on reverse side from the release backing;
print a deadening varnish or ink onto the adhesive to neutralize the adhesive in the area required;
relaminate the face material and release backing together again;
turn the web over to print onto the face material;
die cut the support web to provide a succession of base portions along the length of the web;
disposing a succession of discrete label components in registration with a respective base portion;
covering the support web with a web of a self-adhesive laminar material which is adhered by its self-adhesive surface over the label components and base portion;
cutting through the self-adhesive laminar material, and the support web so as to form a succession of labels each one of which has a label component adhered to the base portion by the laminar material, and having the laminar material adhered to the release backing web except in the region of the base portion with adhesive kill used to create the opening tab.

Preferably, a plurality of like self-adhesive label assemblies are carried in succession on a length of release backing material, which can be wound on a reel. Multiple label assemblies may also be provided across the width of the web. The labels on the reel are applied to containers, when required, using conventional label applicator machinery.
The present invention will now be described by way of example only with reference to the following figures in which:

Figure 1 is a schematic perspective illustration of a label in accordance with an embodiment of the invention, showing the label and a leaflet of the label partly open;
Figure 2 is a cross sectional view on section X-X of figure 7 through the label in accordance with an embodiment of the invention;
Figure 3 is a schematic illustration of a production line system for producing the labels in accordance with an embodiment of the invention;
Figures 4 to 7 show the labels being carried on a web of release material in various stages in their production on the system shown in figure 3, and in accordance with an embodiment of the invention;
Figure 4 is a plan view of a series of base label blanks cut from a web of self adhesive base label material used to produce the labels, and showing zones of deactivated base label adhesive;
Figure 5 shows the placement of leaflets on the series of base label blanks shown in figure 4;
Figure 6 shows the offset die cutting of the labels in accordance with an embodiment of the invention; and
Figure 7 shows a series of the finished labels being carried on the web of release material.

In the following description of the invention, certain terminology will be used for the purpose of reference only, and are not intended to be limiting. Terms such as "upper", "lower", "above", "below", "rightward", "leftward", "clockwise", and "counterclockwise" refer to directions in the drawings to which reference is made. Terms such as "inward" and "outward" refer to directions toward and away from, respectively, the geometric center of the component described. Terms such as "front", "rear", "side", "leftside", "rightside", "top", "bottom", "horizontal", and "vertical" describe the orientation of portions of the component within a consistent but arbitrary frame of reference which is made clear by reference to the text and the associated drawings describing the component under discussion. Such terminology will include the words specifically mentioned above, derivatives thereof, and words of similar import.
Referring to figures 1 and 7 a self-adhesive label assembly 10 is provided on a backing of release material 2. The assembly 10 comprises a carrier or base label 4, and a tab 6. The base label 4 (and tab 6) may be blank, or more preferably is printed, in particular prior to assembly, or during assembly, with either product information or a suitable design. The tab 6 may be printed, for example in a bright and/or contrasting colour, so as to distinguish it more clearly visually from the remainder of the label assembly 10 so that it can be more readily identified. The tab 6 in the final assembly 10 is separated and spaced from the base label portion 4 such that there is a gap 7 between the tab 6 and the base label 4. As will be described further below the base label 4 and tab 6 are formed from and cut from the same base label material layer and stock adhered to the release sheet, and which has an area 5 of 'killed' adhesive to form the tab 6. The base portion 4 is releasably adhered to the release material 2 by adhesive layer 8, and when applied to a container or other product (not shown), is adhered to the container or other product to attach the label assembly to the container or product.
A label component 12 is provided in the form of a multi-laminar leaflet portion, which could be a folded leaflet or booklet. The leaflet 12 is applied to the base portion 4, and is offset from the base label 4, or is smaller than the base label such that it does not cover all of the base label 4. The leaflet allows to printing of additional text and information.
The self adhesive over-laminar layer 14 adheres by an adhesive layer 16 to any part of the base label 4 not covered by the leaflet portion 12 and thereby holds the leaflet 12 in place on the base label 4. Preferably and as shown the overlaminate is adhered to the base label 4 along a closed or folded side of the leaflet 12, opposite to the opening side of the leaflet 12 or booklet. The self adhesive overlaminate layer 14 also has an extended portion 15 which extends beyond the base label 4 and open side of the leaflet 12 and adheres to the release sheet 2 in the gap 7 between base portion 4 and tab 6, and so the container or product when the label assembly 10 is applied. This seals the open side of the leaflet 12, keeping it closed and attached to release sheet 2, and when the label 10 is applied to the container or product. In addition the attachment of the overlaminate directly to the release sheet, and so directly to the product, as opposed to attaching to the base label 4 better accommodates the attachment to the of the label to the a curved product or container. In particular the overlaminate covering the leaflet, and attachment of the trailing end can find its own direct position on the product relative to the base label attachment to take account of the tightening of the label as it is applied to the curved product.
The self adhesive over-laminar material is usually a clear film, but may be clear or white, gloss or matt finish, paper or film, with adhesive 16. The adhesive is preferably a peelable adhesive, and preferably allows the overlaminate to be resealed and reattached to the container or product to close the label 10. Such suitable overlaminate materials and adhesives are however well know to those skilled in the art.
The tab 6 is not adhered to the release sheet 2 since the adhesive under the tab 6 has been 'killed'. The self adhesive over-laminar layer 14 also adheres to the top surface of the tab 6 to thereby locate and hold the tab 6 in position and to remainder of the label assembly 10. The tab 6 since it is not adhered to the release sheet 2, nor container/product, and since it prevents the overlaminate 14 from adhering to the release sheet 2 and product in the region of the tab 6, defines a free area of the label assembly 10 and of the overlaminate 14. This allows a user to more easily peel and lift the tab 6 and so overlaminate 14 to then open up the label 10 and in particular gain access to an open the leaflet 12.
In the preferred arrangement, as shown, the tab 6 only comprises and covers a small corner portion of the label assembly 10 and overlaminate 14. In particular and in contrast to other prior arrangements the tab 6 does not extend over the full width of the label 10, and only extends over a part of the width. As a result only a small portion (the tab 6 portion with no adhesive) of the label 10 is not adhered to the release sheet 2 and so product when the label is applied, and there is an enlarged are overlaminate 14 that adheres to the product to thereby more securely attach the label 10. The small unattached area of the tab 6, while sufficient for starting opening is also less susceptible to being inadvertently caught, and so opening the label and/or jamming as the labels are used on production lines as well as once applied to a product. In particular the remaining width of the overlaminate 14 secures and holds the tab 6 flush and adjacent to the release sheet 2 and/or product. The tab 6, by defining a free corner region of the label 10 also means that when opening the label 10 it is peeled diagonally, from the corner. This in itself makes opening the label 10 easier, with such diagonal peeling of the overlaminate 14 and label requiring less force, at least initially, to start the opening process. A corner tab 6 is also more easily identifiable and distinguishable from the remainder of the label assembly 10, making identification of where to open the label 10 easier. In addition a corner tab 6, and having a tab 6 only in a small part of the label 10, means that automated sensors monitoring the labels in production lines, can be located to sense the main base label 4 portion, and not be confused by or sense the tab 6. This provides a clearer signal when the labels 10 are used on production lines. Alternatively or additionally since the tab 6 in a corner region is very different, and of a different shape and size to the remainder of the label 10 the tab 6 can be used as an identifier to index and sense the position of the labels 10 in a production line process.
This tab 6 arrangement accordingly provides such a desirable free area of the label 10 and overlaminate 14 to assist in opening, and with the other described advantages, in a simple and much easier way than other prior arrangements. In particular the, and as will be described further below the formation of the tab from the same base label material and layer at in the same process simplifies manufacture. In addition the overlaminate also positions and holds the tab in the correct alignment and position, and the tab 6 does not have to be separately produced and located.
Figure 3 shows a production line apparatus 100 for producing the label assemblies 10, and figures 4 to 7 show various stages in the production of the label assemblies 10 on the production line 100 and in a method of producing the label assemblies 10.
In the method and production line 100, a succession of labels 100 are produced from an elongate web of self-adhesive laminar base label material and stock 102, comprising a laminar sheet of base label material 103 with an adhesive coating on its underside which is adhered to and carried on the backing release material 2, for example silicone coated release material. The base label material 103 is typically already printed with the base label 4 detail, although in other embodiments may be unprinted. A reel 104 of the elongate web of self-adhesive laminar base label material 102 is unwound with the release backing material 2 uppermost.
The self-adhesive laminar base label material 103 is separated (delaminated) from the release backing material 2 in a delaminating station. In a printing station 108 a deadening varnish or ink is then printed onto the adhesive coating on the underside of the base label material 103 to neutralize ('kill') the adhesive in specific areas and bands 105 as shown in figure 4. These areas or bands correspond to, but as shown extend beyond the areas 5 of 'killed' adhesive that will form the tabs 6. It will of course be appreciated that these areas and bands may be of any required shape and size according to the particular label design and requirements, and in particular in order to make printing and the manufacturing steps as easy and simple as possible. Indeed a particular advantage of the method is that the printing of this varnish, and neutralizing of the adhesive does not need to be exactly correlated with the small area of the tab 6 but can be applied in a broader region so long as it covers the particular region that will form the tab 6. This greatly simplifies the manufacture.
It will be appreciated that in other embodiments the laminar sheet of base label material 103 and release backing 2 could be supplied from separate rolls and the adhesive then only applied to the required regions, omitting applying adhesive in areas corresponding to the neutralized zones 105. This would omit the requirement to delaminate the self-adhesive laminar base label material and stock 102. However such stock is readily available and separately applying the adhesive and providing separate rolls of material is less preferred.
The base label material 103 with an adhesive coating and neutralized adhesive zones 105 is then joined back together (relaminated) with the release backing 2 in a relaminating station 110, reforming (or in the alternate embodiment forming) the elongate web of self-adhesive laminar base label material 102 before being turned over through a web turner 112 so that an upper surface of the web and base label material 103 can be printed in a printing station (if required).
The web 102 is then passed through a first roller die cutting station 116, where the base label material 103 web is die cut through to the release backing material 2 to provide a series of base label blanks 118, as shown in figure 4, spaced apart along the length of the web 102. While described as 'blanks' it will be apprecaited that they are typicaly printed with the base label 4 detail (although could be unprinted), and the term 'blank' is used in this context to refer to them being the no final format from which the base labels 4 themselves are formed. The leading edge of the base label blanks 118 are cut to the required tab shape define tab forming portions 120 of the base label blank 118 and base label material 103 which will subsequently form the tabs 6. As shown these tab forming portion and leading edges of the base label blanks 118 are arranged to coincide and are aligned with the neutralized adhesive zones 105, and regions where there is no active adhesive under the base label material 103. However since the neutralized zone 105 extends significantly beyond the tab forming portions 120, and as will be explained later the tabs 6 are subsequently cut from these tab forming portions 120, exact alignment is not required making such alignment much easier and less critical. As shown in this embodiment three label assemblies 10 are formed and produced across the width of the web 102. A single blank extending across the web 103, and having three tab forming portions 120 is however used to simplify manufacture. It will though be appreciated that separate base blanks for each individual base label 4 could be used, or each blank could be used to form any number of base labels 4, and labels 10 across the web 102. The waste base label material surrounding the base blanks 118 is then stripped from the web 102 and release backing 2 onto waste reel 122 in a first striping station 124.
Label components 12, typically in the form of folded booklets or multi-laminar sheets, are loaded into a hopper feed unit (not shown). The base label blanks 118 are passed under the hopper feed unit 126 which applies the sets of label components 12 in registration with the base blanks 118. As shown in figure 5, the label components 12 do not cover the entire base label blanks 118, and may preferably be offset from the blanks 118. As also shown the label components 12, similarly to the base label blanks 118, in this embodiment comprise three separate label component portions corresponding to three separate label components 12 of the three separate label assemblies 10 disposed across the web 102. Again separate individual label components 12 could be applied in other embodiments, and hopper feed unit 126 may be adapted to apply multiple individual separate label components 12 across the width of the web 102.
The elongate web then passes to an overlaminate application station at which a layer of self-adhesive, preferably clear, overlaminate 130 from a supply roll 132 and having adhesive, preferably peelable adhesive, on an underside surface is applied on top of and pressed by application rollers 134 onto the top ofthe label components, base label blanks 118 and web 102. The self-adhesive overlaminate 130 adheres to the label components 12, base label blanks 118 and in the regions between the blanks 118 where the base label material has been removed, directly adheres to the release backing 2.
The composite combined web 102, label components 12 and overlaminate 130 is then fed to a second cutting station 136, comprising a second rotary die-cutter 13 8. The die-cutter 138 is adapted to cut as shown by line 140 through the overlaminate, label component 12 and base label blank 118 layers up to the release sheet web 2, so as to form a succession of completed labels 10, each of which includes a label component 12 which is adhered to the base portion 4 by the overlaminate 14. This second cut 140, as shown is offset from the base label blanks 118 and label components 12, to cut across two adjacent consecutive base label blanks 118 so as to cut the tab 6 of each respective label 10 from the leading edge and tab portion 120 of the blank 118 of the next consecutive adjacent base label blank 118 to form the tab 6, and cut the extended portion of the overlaminate extending beyond the base label 4 and gap 7 to the tab 6. In this way, the separate discrete tab 6 is formed in a simple manner from the same base label material 103 and blank 118. In particular the separate tab 6 is formed at the same time as the formation of the remainder of the elements of label 10 and without significant additional steps and in particular separate formation and application of a separate tab components and requisite alignment as in prior arrangements. It should also be noted that in this method the tab 6 , and tab portion 120 which is not adhered to the release material 2, and which is spaced from its respective base label part 4, is held in place during manufacture by its attachment and being part of the base label blank 118 of an adjacent blank 118, until it is then covered by the overlaminate 14 which then adheres and secures the tab 6 in place so that it can then be cut from the base label blank 118, and base label material 103. This ensures that the tab 6, while separate to the base label 4 and free from the release sheet 2 is securely and accurately positioned. This also allows the adhesive to be neutralized, removed, or not applied to the tab portion 120 at an early stage in the production of the label 10 which in itself is simpler and has advantages.
After the second die cut 140 and cutting station 136, the waste material 142 surrounding each label 10 is removed with the waste overlaminate surrounding each label onto a take-up roll 144. The finished label assemblies 10 on the web of release sheet 2, are shown in figure 7. The finished label assemblies 10 produced by this method has self adhesive overlaminate material sealed to the release sheet 2, a separate spaced opening tab 6 and a gap between each label assembly 10. The finished label assemblies 10 are then wound onto a supply roll 146. The web may then be cut and split, lengthwise, to separate the label assemblies 10 across the web, and produce ribbons of label assemblies 10 which can be used on a label machine. This cutting and splitting , may be carried out at the end of the production line 100 in a subsequent station (not shown) prior to being wound on separate supply rolls 146, or after being wound on the supply roll 146 by cutting the entire roll 146, and/or on a separate machine once removed frm the production line 100. Of course if only one label assembly 10 is disposed across the width of the web then no such splitting is required. The labels 10 on the supply roll 146 may then be subsequently removed from the backing material as the supply reel 146 is unwound and then applied to containers using conventional labeling machinery, with the base label 4 and overlaminate 14 adhering to the outer surface of the container or product.
While in this embodiment the apparatus and method comprises an 'in-line' production line arrangement, and this is the preferred arrangement, it will br appreciated that the various steps could be carried out separately in separate discrete operations and steps. There are also a number of other detailed modifications that could be made to the method and apparatus, in particular for example the number of labels produced across the web 102 could be varied, the application and neutralization/removal of the adhesive could be varied, and different specific materials could be used, amongst other variations. The self adhesive overlaminate could for example also be replaced by applying a non-adhesive overlaminate sheet of film with tan adhesive then applied in a separate operation either to the underside of the overlaminate or to the upper surface of the composite combined web 102, and label components 12 to thereby attach the overlaminate sheet therto.
The principle and mode of operation of this invention have been explained and illustrated in its preferred embodiment. However, it must be understood that this invention may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope.

Claims

A label assembly (10) comprising:
a base label (4);

a laminar label component (12) overlying at least part of the base label (4);

an overlaminate (14) having at least a part of an underside of the overlaminate coated in adhesive (16) and overlying and adhered to the base label (4) and label component (12), the overlaminate(14) having a longitudinal extended portion (15) extending beyond the base label (4) and label component (12); and

a laminar tab (6) separate to the base label (4) and label component (12) with a portion of the extended portion (15) of the overlaminate (14) overlying and adhered to an upper surface of the tab (6),
characterized in that the laminar tab (6) does not extend across a full width of the overlaminate (14) and label assembly (10).
A label assembly (10) according to claim 1 in which the laminar tab (6) is disposed in a corner region of the overlaminate (14) and label assembly (10).
A label assembly (10) according to claim 1 or 2 in which the laminar tab (6) is spaced from base label (4), and preferably label component (12).
A label assembly (10) according to any preceding claim in which the laminar tab (6) is spaced from the base label (4) and label component (12) to define a gap (7) therebetween, and the extended portion (15) of the overlaminate (14) extends and bridges said gap (7).
A label assembly (10) according to any preceding claim in which the tab (6) is formed from the same material and layer of laminar material (103) as the base label (4).
A label assembly (10) according to any preceding claim in which at least a part of an underside of the base label (4) is coated in adhesive (8).
A label assembly (10) according to any preceding claim in which an underside (5) of the tab (6) has substantially no adhesive coating, or has an adhesive coating which has been substantially neutralized.
A label assembly (10) according to any preceding claim in which the label component (12) comprises a multilaminar label component, and preferably a multilaminar booklet.
A label assembly (10) according to any preceding claim further comprising a release backing sheet (2) upon which the label assembly (10) is mounted.
A method of producing a succession of labels (10,100) carried on an elongate web of release backing material (2), the method comprising:
providing a plurality of base label blanks (118) spaced apart in succession along the elongate web of release backing materia (2)1, each base label blank (118) having a tab forming portion (120) and an underside at least partially coated in adhesive (8) to adhere and mount the base label blank (118) on the web of release material (2);

providing adhesive free regions (105) of underside of the base label blanks (118) which have no adhesive or deactivated adhesive, the adhesive free regions (105) extending over at least part of said tab forming portions (120) of the base label blanks (118);

applying an overlaminate (14,130) over the base label blanks (118) and release backing (2), the overlaminate (14,130) extending between adjacent blanks from a first base label blank (118) to at least the tab forming portion (120) of a second adjacent base label blank (118) and having an adhesive coating (16) on at least part of an underside of the overlaminate (14,130) to attach the overlaminate (14,130) to at least the blanks (118);

cutting (140) the labels (10,100) from the overlaminate (14,130) and base label blanks (118), wherein the cutting (140) is offset from the base label blanks (118) to cut across the first and second blanks (118) and thereby cut a base label portion (4) of a first label (10,100) from said first base label blank (118) and the tab (6) of the first label (10) separate to the base label portion (4) from the tab forming portion (120) of the second adjacent blank (118).
A method according to claim 10 in which the base label blanks (118) are formed from an elongate layer of base label material (103) laminated onto the elongate web of release backing material (2).
A method according to claim 11 comprising delaminating the elongate layer of base label material (103) from the elongate web of release backing material (2), providing said adhesive free regions (105), and relaminating the elongate layer of base label material (103) onto the elongate web of release backing material (2).
A method according to any of claims 11 or 12 in which the plurality of base label blanks(118) are cut from the elongate layer of base label material (103) laminated onto the elongate web of release backing material (2), and the base label material (103) surrounding the base label blanks (118) is removed, to leave and provide the plurality of base label blanks (118) spaced apart in succession along an elongate web of release backing material (2).
A method according to any of claims 10 to 13 in which the adhesive free regions (105) are provided by neutralizing the adhesive coating (8) in said regions (105), for example by printing varnish or ink onto said regions (105) of the adhesive coating (8) or by any other suitable method.
A method according to any of claims 10 to 14 further comprising applying a label component (12,112) to said base label blanks (118) prior to applying the overlaminate(14,130), and applying the overlaminate (14,130) over the label components (12,112) to attach the label component (12,112) to the base label blanks (118) and label (10,100).
A method according to any of claims 10 to 15 in which the tab (6) does not extend across a full width of the label (10,100), and preferably comprises a corner region of the label(10,100).
A method according to any of claims 10 to 16 in which the label (10,100) comprises the label assembly (10) of any of claims 1 to 9.