Methods of making pop-up promotional items

BACKGROUND OF THE INVENTION
This invention relates generally to printed novelty items made of paper or other sheet material, more particularly to promotional pop-ups multiple copies of which can be fabricated from separate sheets or from a continuous web and most particularly to mass production methods of making such items from a continuous web, as on a web-press or the like, which items assume three-dimensional configuration and are designed to permit mounting in such orientation.
Pop-ups have fairly recently become frequently used in advertising and in other promotional endeavors, whereas they had been used in the greeting card field and in children's books for a number of years. Such pop-up pieces have become generally available to the advertising field as a result of the developments shown in several earlier patents, particularly U.S. Pat. No. 3,995,388, issued Dec. 7, 1976, which discloses methods for making pop-up paper products having significant advantages over hand-assembly methods that had been generally theretofore employed. U.S. Pat. No. 4,146,983, issued Apr. 3, 1979, discloses other methods for making novel promotional items, particularly those which are designed to present a plurality of coupons or the like to a recipient upon the opening of a folder. U.S. Pat. No. 4,337,589 discloses manufacturing techniques, specifically suited for mass production on a web-press or the like, for making pop-up advertising pieces and the like, the details of the disclosure of which are incorporated herein by reference.
The foregoing patents describe different manufacturing techniques useful for making advertising and promotional pop-ups as a part of a continuous web arrangement, and pop-ups such as these have been frequently used to create impact and enjoyment in books, in greeting cards and in advertising inserts. The foregoing advances in designs and in manufacturing methods have enabled volume production of such products at significant cost savings and thus have increased their use.
A general characteristic of such pop-ups is the movement of the pop-up element from a flat, substantially single plane into a three-dimensional orientation upon the opening of a pair of cover pieces or basepieces, generally in the form of a folder inside which the pop-up is located. By attaching the pop-up elements to opposite panels of the basepieces, for example, along angles created by lines of weakness, such as score lines and/or perforations, in combination with adhesive bonds, pressure or stress points are created which, upon opening of one cover, cause the pop-up to be erected. However, the pressure or stress which is created upon opening is sufficient so that, when the cover is manually released, it will draw the cover either partially or entirely closed.
Although a pair of basepieces have heretofore been utilized in such pop-up units, it has now been found that improved pop-up designs are feasible that eliminate one or more of the basepieces, as are methods for mass production of such improved designs.
SUMMARY OF THE INVENTION
Improved pop-up items and methods for making such items are provided in the form of either a basepiece that is pivotally interconnected to a pop-up element or individual pop-up elements. The exterior surfaces of such basepieces and pop-up elements carry pressure-sensitive adhesive, and the adhesive-carrying surfaces may optionally be covered by release liners. Once such optional release liners are removed from exterior surfaces, the pop-up item can be affixed to a supporting surface in attention-attracting three-dimensional orientation, or between facing panels or pages where it will assume such orientation upon opening.
Such pop-up items can be adhesively attached to a carrier strip or web for distribution as a part of an arrangement which facilitates handling, storage and distribution of the pop-up items. These pop-up items are susceptible to distribution in the form of a stack or pad from which the recipients can one-by-one remove and utilize individual items. Mass production methods of manufacturing such pop-up items are likewise provided in order to facilitate volume production at affordable cost.

BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a continuous web which has been printed so as to define a series of blanks each containing a pair of basepieces and a pair of pop-up panels, illustrating the web after a glue pattern has been applied thereto;
FIG. 2 is a similar perspective view showing the web of FIG. 1 after it has been folded onto itself, illustrating the application of pressure-sensitive adhesive to the upper surface of the folded web followed by the association of a continuous sheet of liner material thereupon;
FIG. 3 shows the composite web of FIG. 2 after it has been rotated 180.degree. to facilitate the application of a further adhesive pattern in the region of the pop-up panels followed by the trimming of both lateral edges of the composite web;
FIG. 4 shows the web of FIG. 3 after it has been again folded upon itself;
FIG. 5 shows the folded web of FIG. 4 as it might be thereafter handled so as to produce individual pop-up carrying pieces;
FIG. 6 illustrates an alternative to FIG. 5 wherein the folded web of FIG. 4 is associated with a continuous carrier sheet;
FIG. 7 shows treating the associated web arrangement of FIG. 6 to create a plurality of structurally identical, spaced apart, individual pop-up-carrying pieces on the continuous carrier sheet;
FIG. 8 is a perspective view showing one of the pop-up items illustrated in FIG. 5 mounted on a horizontal surface, such as a shelf, in its open or display position;
FIGS. 9 and 10 show alternative versions of the pop-up piece illustrated in FIG. 5;
FIG. 11 illustrates an alternative method for making pop-up pieces attached in piggyback form to an intermediate substrate which is in turn cut into discrete units that are attached for handling and storage purposes to a continuous web;
FIG. 12 is a schematic perspective view showing the initial steps of manufacture of a pop-up element of an alternative design;
FIG. 13 shows the composite web of FIG. 12 rotated 180.degree. with an adhesive pattern being applied;
FIG. 14 shows the web of FIG. 13 after it has been folded onto itself and as the severing into individual units is being carried out;
FIG. 15 illustrates how the individual units might be placed onto a carrier web for handling storage and/or distribution purposes;
FIG. 16 is a schematic view showing the manipulation of the pop-up element produced in FIG. 15;
FIG. 17 is a perspective showing how the pop-up of FIG. 16 might be mounted directly upon a surface in three-dimensional form;
FIGS. 18 and 19 are schematic views showing an alternative way in which the pop-up elements of FIG. 16 can be attached to supporting surfaces;
FIG. 20 is a perspective view of a continuous web which has been printed so as to define a series of blanks containing a pair of basepieces, a single pop-up panel and one liner panel illustrating the web following die-cutting and the application of adhesive, which web is useful in the creation of individual pop-up carrying pieces of a further alternative embodiment to those formed from the continuous web shown in FIG. 1;
FIG. 21 is a similar perspective view showing the web of FIG. 20 after it has been folded onto itself and illustrating the severing of a separate ribbon from the main body of the web;
FIG. 22 shows the main web of FIG. 21 after it has been folded a second time and following the application of an adhesive pattern to the upper surface of the twice-folded web;
FIG. 23 shows the superimposition of the severed ribbon onto the upper surface of the twice-folded web;
FIG. 24 is a perspective view showing the composite web as its lateral edges are being trimmed and as a pressure-sensitive adhesive pattern is being applied to the upper surface, followed by the severing of the web into a plurality of individual units;
FIG. 25 shows the rotation of the individual units 180.degree. and their application to a roll of liner material;
FIG. 26 is a perspective view showing one of the pop-up pieces illustrated in FIG. 24 mounted on a horizontal surface in its open or display position.
FIG. 27 is a perspective view of a continuous web which has been printed so as to define a series of blanks each containing a single pop-up unit which web is shown as being manipulated and then severed to create such individual pop-up units;
FIG. 28 is a perspective view showing a stack of pop-up units of the type created in FIG. 27;
FIG. 29 is a perspective view showing one of the pop-up units fabricated in FIG. 27 mounted to a pair of hinged panels which are opened so the pop-up unit is in its display condition;
FIG. 30 is a perspective view of a continuous web which has been printed so as to define a series of blanks each containing a pair of panels which together form pop-up units of still another design;
FIG. 31 shows a segment of the web fabricated in FIG. 30 being fan-folded into a stack of pop-up units;
FIG. 32 shows the trimming of such a stack so as to create a plurality of individual units;
FIG. 33 is a perspective view of one such individual unit from the stack of FIG. 32;
FIG. 34 illustrates the pop-up unit of FIG. 33 attached to a pair of panels that are hinged together;
FIG. 35 is a plan view of a continuous web, shown somewhat schematically, which web has been printed so as to define a series of double blanks, each blank being designed to form a pop-up unit including a pair of panels similar to those units depicted in FIG. 33;
FIG. 36 is a perspective view, similar to FIG. 31, showing the continuous web of FIG. 35 being fan-folded;
FIG. 37 is a perspective view, similar to FIG. 32, showing a stack (formed from a predetermined length of the web of FIG. 36) being severed to create a stack of individual pop-up units;
FIG. 38 is a perspective view of a continuous web which has been printed to define a series of blanks each containing a single pop-up unit generally similar to that shown in FIG. 27 being superimposed upon another continuous web;
FIG. 39 is a view enlarged in size of a portion of the composite web produced by the method illustrated in FIG. 38 with the scrap portion being stripped therefrom;
FIG. 40 is a fragmentary perspective view through a web of material that comprises a pair of separate sheets interconnected by a layer of pressure-sensitive adhesive material;
FIG. 41 is a perspective view, enlarged in size, of a continuous web of the material illustrated in FIG. 40 which has been printed so as to define a series of blanks each containing a pair of pop-up elements, which web is being kiss-cut, die-cut and manipulated so as to fabricate individual pop-up elements therefrom;
FIG. 42 is a perspective view of one such pop-up element as various subpanels are being peeled therefrom to expose the underlying pressure-sensitive adhesive which will then allow the pop-up element to be secured in place between a pair of hinged panels;
FIG. 43 is a schematic view of still another continuous web which has been printed to define a series of blanks each containing a pair of pop-up elements which is being subjected to several die-cutting operations and an adhesive application step as a part of its fabrication into pop-up elements;
FIG. 44 is a rear view of one of the pop-up elements fabricated by severing from the web illustrated in FIG. 43;
FIG. 45 is a perspective view showing the pop-up element of FIG. 44 in display position between a pair of hinged panels;
FIG. 46 is a perspective view of yet another continuous web which has been printed to define a series of blanks each containing a pair of panels which are subjected to a series of steps to apply adhesive and create lines of weakness before being severed into individual pop-up elements;
FIG. 47 is a perspective view showing the pop-up element of FIG. 46 in display position between a pair of hinged panels;
FIGS. 48 and 49 are similar to FIGS. 46 and 47, respectively, showing the fabrication of an alternative embodiment of the pop-up element to that illustrated in FIG. 47;
FIG. 50 is a plan view of a continuous web which has been printed to define a series of structurally identical blanks each containing one basepiece and one pop-up element which is shown being subjected to a series of steps of die-cutting, adhesive application, scrap removal, folding and severing as a part of its fabrication into pop-up units;
FIG. 51 is a perspective view, reduced in size, showing one of the pop-up units from FIG. 50 having been applied to the front face of a mailing envelope;
FIG. 52 is a fragmentary perspective view of the envelope depicted in FIG. 51 with the pop-up unit fully opened in its display position;
FIG. 53 is a view similar to FIG. 50 of a continuous web which has been printed to define a series of structurally identical blanks for forming an alternative embodiment of units of the type shown in FIG. 52;
FIG. 54 is a view similar to FIG. 52 of a pop-up unit made from the web shown in FIG. 53;
FIG. 55 is a perspective view showing still another mass production method for making pop-up elements from a printed web wherein a separate strip of pressure-sensitive adhesive-bearing transfer tape is employed, the mass production method being shown as it would be viewed from below in the preferred method of running in order to better illustrate certain details;
FIG. 56 is an inverted view of FIG. 55, showing the method as it might more normally be run, wherein the folding is carried out so the portion being folded is moved atop the remainder of the web;
FIG. 57 is a fragmentary perspective view showing the pop-up element manufactured by the method of FIGS. 55 and 56 in its display orientation between a pair hinged panels;
FIG. 58 is a perspective view of a further embodiment of a mass production method for making pop-up units, which units each include a pop-up element of the general nature of those shown in FIGS. 55-57, which method uses a single printed web and an underlying carrier web;
FIG. 59 is a perspective view, slightly enlarged in scale, showing one of the pop-up units made by the mass production method of FIG. 58 after it has been removed from the carrier web and as it is being readied for use by exposing the pressure-sensitive adhesive regions;
FIG. 60 is a perspective and schematic view of still another mass production method for making pop-up elements, utilizing a pair of continuous webs each printed on one surface;
FIG. 61 is a schematic perspective view showing how groups of the pop-up elements made by the mass production method of FIG. 60 might be handled for distribution;
FIG. 62 is fragmentary perspective view showing one of the pop-up elements made by the mass production method of FIG. 60 in display position between a pair of hinged panels;
FIG. 63 is a schematic perspective view showing yet another mass production method for making pop-up units from a pair of printed webs, which method incorporates a transparent film which is employed to distribute the pop-up element in its flattened form;
FIG. 64 is a view showing the pop-up units manufactured by the mass production method of FIG. 63 on a carrier web, with one being shown as it is removed from the web;
FIG. 65 is a side view of the pop-up unit shown in FIG. 64 which was removed from the carrier web;
FIG. 66 is a fragmentary perspective view showing the pop-up element that formed the main part of the pop-up unit of FIG. 65 in its eventual display orientation between a pair of hinged panels;
FIG. 67 is a perspective view of another alternative embodiment of a pop-up element which can be made by various of the illustrated mass production methods and which is shown in its upstanding display orientation affixed to a pair of hinged panels;
FIG. 68 is an end view, enlarged in size, of this pop-up element looking generally along the line 68--68 of FIG. 67;
FIG. 69 is a perspective view showing the flag section of the pop-up element of FIGS. 67 and 68 after it has been removed from the remainder of the pop-up element and as the release liner portion is being separated from the adhesive-carrying main body;
FIG. 70 is a perspective and schematic view of yet another embodiment of a mass production method for making pop-up elements which is designed to create a stack of single-sheet pop-up elements, one atop another, which can be removed one at a time for use;
FIG. 71 is a view showing one of the pop-up elements after its removal from the stack shown in FIG. 70;
FIG. 72 is a perspective view showing the pop-up element of FIG. 71 in its display condition between adjacent panels of a sheet-like item, such as a letter, pamphlet, menu or the like;
FIG. 73 is a schematic and perspective view showing one more embodiment of a mass production method for making folded pop-up elements embodying various features of the invention, which method produces a fan-folded stack of pop-up elements attached to one another via lines of perforation;
FIG. 74 is a fragmentary perspective view showing one pop-up element removed from the fan-folded stack of FIG. 73 and mounted in display position between a pair of hinged-together panels of sheet material;
FIG. 75 is a perspective and schematic view of one more embodiment of a mass production method for making pop-up elements from a single sheet of web material which utilizes a carrier web;
FIG. 76 is a perspective view of one pop-up element as produced by the method illustrated in FIG. 75, which has been removed from the carrier web;
FIG. 77 is a perspective view similar to FIG. 76 showing the pop-up element after it has been folded to ready it for application to an article with which it will be distributed to a recipient; and
FIG. 78 is a fragmentary perspective view showing the pop-up element of FIG. 77 mounted in display position between a pair of hinged-together panels of sheet material.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a continuous web 11 as it may be running on a web-printing press or being unrolled from a preprinted roll, depicting a series of structurally identical printed blanks which could, if desired, be appropriately preliminarily die-cut; the blanks are designed to, following fabrication, form a series of promotional pieces such as that illustrated in FIGS. 5 and 8. Each blank is aligned laterally across the continuous web 11, the direction of movement of the web being shown by the arrows in the FIGURE. The dot-dash lines illustrate the transverse lines along which each blank, following folding, will be severed from the next adjacent blank to complete fabrication of an individual piece.
In the blanks illustrated in FIG. 1, a pair of basepieces 13 and 15 are arranged next to one another with a pair of pop-up panels 17, 19 located laterally next to the edge of the basepiece 15. Also shown in FIG. 1 are printed, longitudinally extending, parallel lines that divide each blank into four panels. Some or all of these lines could actually be formed as lines of weakness in the web, as for example, by pressing, scoring or slightly perforating; alternatively, they may be omitted and simply left to be formed as a result of the subsequent folding operations performed on the web. It is generally satisfactory to simply rely upon the natural resiliency of the paper web to effect appropriate bending of the pop-up elements as a result of the particular placement of an adjacent line of adhesive without actually providing a line of weakness; however, lines of weakness within the regions of the pop-up panels can be employed to create a neater appearance in the final product. As a part of the manufacturing operation, the same die-cutting, adhesive-applying and folding steps are effected with respect to each of these successive blanks of the continuous, sheet material web, which is preferably made of a suitable paper or paperboard material, glossy or matte finish as desired, but which might possibly be an appropriate plastic sheet material.
As a part of an adhesive application step, a glue pattern 21 of generally triangular form is applied so that it covers portions of both pop-up panels 17 and 19, which pattern is eventually used to join the pop-up panels to the interior surfaces of the basepieces 13, 15. If desired, such a glue pattern could instead be applied to the appropriate locations on the basepieces 13, 15. Although these are commonly referred to in the trade as glue patterns, any suitable adhesive, e.g., hot-melt or solvent-based, can be used in such a fabrication process. Such permanent-type adhesive is understood to be such as to have a bond strength that is generally higher than the tear strength of the fibers. Other such adhesive arrangements, such as detailed in the aforementioned patents, including heat, ultrasonic or RF-activated or micro-encapsulated adhesives, can alternatively be used. If desired, co-adhesive patterns of a material that will only adhere to itself can be applied to the appropriate locations of both surfaces, as is known in this art.
Following the application of the glue pattern 21, the web is folded upon itself along the longitudinal line between the panels 15 and 17, as depicted in FIG. 2, thereby joining together triangular portions of the panels 13 and 19 and of the panels 15 and 17, respectively, in the region of the glue pattern 21. Following the folding operation, the upper surface of the folded web constituting the basepiece panels 13 and 15 is substantially completely coated with pressure-sensitive adhesive 23. Next, a web 25 of liner material of appropriate width is brought into association with the upper surface of the folded web so as to completely cover the pressure-sensitive adhesive surface. The undersurface of the liner material web 25 depicted in FIG. 2 is appropriately precoated with a silicone or some other suitable release agent so as to allow it to be stripped cleanly from the basepieces exposing the pressure-sensitive adhesive, as is well known in the art. As an alternative to first creating the folded web of superimposed pairs of basepiece panels and pop-up panels and then applying pressure-sensitive adhesive and a liner sheet, it would be acceptable to purchase sheet material in roll form in the form of a ply of blank paper joined by pressure-sensitive adhesive to a release liner and thereafter print the interior surfaces of the basepiece panels 13 and 15 onto the blank paper ply. Thereafter, through the appropriate application of the glue patterns 21, this two-ply web could be associated with a continuous printed web of suitable width to constitute the pop-up panels 17, 19.
As a further alternative, if desired, instead of folding the web onto itself as illustrated in FIG. 2, the web could be longitudinally severed along the line between panels 15 and 17 and the left-hand portion of the web moved into superimposed position atop the right-hand portion. Similarly, two different webs, which could be of similar widths or slightly different widths, could be used to produce the basepiece panels and the pop-up panels, respectively, and such an arrangement would likely be employed should it be desired to form the basepiece panels, for example, of heavier stock material or of a material having different surface characteristics from that of the pop-up panels. In all of these embodiments, the basepieces 13, 15 are preferably fabricated from a single sheet so as to be integral with each other, being connected along a common foldline.
As a still further alternative, it would be possible to first coat one surface of the left-hand portion of the web 11 of FIG. 1 with pressure-sensitive adhesive and then apply the continuous web of liner material 25 in association therewith to cover the adhesive before the web is either folded onto itself or severed and laterally displaced so as to associate the other surface of the left-hand half of the web with the right-hand half which constitutes the pop-up panels.
As depicted in FIG. 3, the composite web consisting of the folded over web 11 and the liner material 25 is preferably rotated 180.degree. to facilitate the application of adhesive patterns 31 to the regions of the pop-up panels 17, 19, which would then be located at the upper surface of the composite continuous web. Although such rotation is preferable, it is not necessary, and the glue patterns could be applied to the undersurface of the web without such 180.degree. rotation. Next, as depicted in FIG. 3, both lateral edges of the composite web are trimmed by the use of suitable knife blades 33 or the like, and the trim material 35 is discarded. Alternatively, the trimming of the lateral edges could take place prior to the application of the glue patterns 31. Moreover, instead of applying glue patterns 31 to both of the pop-up panels 17, 19, a single glue pattern could be applied to just one of the panels.
Following the trimming operation, the web is again folded upon itself along the longitudinal line between the panels 17 and 19 to the orientation 37, depicted in FIG. 4, so that the glue patterns 31 interconnect the pop-up panels to each other and so that the interconnected pop-up panels are sandwiched between the basepieces 13, 15 which constitute a folder, the outer surface of which is covered by the pressure-sensitive adhesive 23 and the liner material 25. Thereafter, there are alternative ways of treating the finally-folded web 37 depending upon how it is intended that the pop-up pieces are to be stored and distributed. As well known in the art, it is often preferable to run the finally-folded web 37 through a set of compression rolls so as to assure a strong adhesive bond is created at the desired points. Likewise, a further trimming operation could be carried out along the right-hand edge of FIG. 4, if desired, and only such a trimming operation might be also used instead of trimming both edges, as depicted in FIG. 3.
If the pop-up pieces are to be delivered as single individual units, a transverse severing of the web is then effected using a suitable knife blade mechanism 39 or the like, which could be part of a rotating device, to create the individual, structurally identical units 41. Should it be desired to maintain the pop-ups in strip form, instead of using a knife 39 to completely sever adjacent units, an appropriate line of perforations could be imposed at this point; thereafter, the continuous web could be wound in roll form or could be fan-folded at each of the lines of perforation to create a strip of interconnected pop-up pieces.
A further alternative is shown in FIG. 6 wherein the finally-folded, continuous web 37 is associated with a web of carrier material 43, the upper surface of which is either precoated or coated at that time with a weak-bond, pressure-sensitive adhesive; the carrier web 43 may be slightly wider than the finally-folded composite web 37. Thereafter, as depicted in FIG. 7, a "kiss-cut" die-cutting operation is effected to cut through all of the thicknesses of the composite web 37 but not to cut into the continuous carrier web 43. The result of such die-cutting is to create a plurality of individual pop-up containing units 41' at uniformly spaced locations along the carrier web 43, and the die-cut scrap material formed as a part of the kiss-cut operation, as indicated by the reference numeral 45, is stripped from the web using state of the art techniques. Thereafter, as depicted in FIG. 7, the carrier web and its series of structurally identical pop-up carrying pieces 41' can be conveniently wound into a roll form for storage and/or shipping, either by rolling the web in the direction shown or in the opposite direction. When it is desired to distribute the items, because of the relatively weaker bond between the carrier 43 and the liner 25, the individual units 41' can be removed therefrom without detaching the liner material 25 from the basepieces.
By reference to FIG. 8, it can be seen that opening the folder, by pivoting the basepieces 13 and 15 along their straight foldline of interconnection, causes the pair of pop-up panels which constitute the central pop-up element to be stressed (as a result of their interconnections to the basepieces in the triangular regions provided by the glue pattern 21) and causes them to rise up out of the planes of the basepieces and assume a three-dimensional, attention-attracting configuration guided also by the interconnection at the glue pattern 31. By stripping all or a part of the liner material 25 from the exterior surfaces of the basepieces 13 and 15, the pressure-sensitive adhesive 23 becomes exposed and allows the open piece to be easily and quickly affixed to an appropriate supporting surface, such as the upper surface of a horizontal shelf 47 or the like. This attachment to the shelf surface resulting from the pressure-sensitive adhesive bond assures that the piece 41 remains affixed in the open position with the pop-up element prominently displayed in its three-dimensional configuration.
Should it be desirable to provide a piece that can be temporarily fixed in one location and then removed and later affixed in a different location, it might be preferable to die-cut the liner sheet 25 so as to facilitate only partially exposing the pressure-sensitive adhesive surface, as shown for example in FIGS. 9 and 10. Depicted is a modified piece 41" in which the liner material has been kiss-cut or otherwise suitably die-cut to leave short links that easily rupture so as to create a hinged panel 49 at an appropriate, e.g., a central, location in the liner sheet portion covering the exterior surface of each of the basepieces 13, 15. By stripping the hinged panel 49 from the adhesive surface and folding it rearward onto the remainder of the liner 25, as depicted in FIG. 10, less than 20% of the pressure-sensitive adhesive surface area is exposed. The central location arrangement assures that the pop-up can still be securely mounted; yet as a result, the piece might be removed from one surface and firmly re-affixed to a second suitable supporting surface after removing the entire liner sheet 25. Instead of hinging the panel 49 to the remainder of the liner panel 25, it can be left connected along a line of perforations or completely severed therefrom to facilitate its complete removal.
Should it be desired to distribute the pop-up pieces in piggyback form in combination with an intermediate substrate, a process generally as depicted in FIG. 7 could be employed so as to create a series of structurally identical pop-up pieces 41' located in spaced arrangement along a continuous web 51, as depicted in FIG. 11, using a web 51 of a suitable material to serve as a piggyback substrate. Thereafter, the web 51 is transversely severed into a series of individual units each of which constitutes a pop-up piece 41' attached to an intermediate substrate 53 in piggyback fashion. These units are then applied to a carrier web 55 upon which has been applied a suitable, releasable, adhesive pattern 57, or the undersurface of the web 51 could have a suitable adhesive applied to it, preferably prior to its being severed. Alternatively, the folded web 37 as carried by the substrate web 43, as shown in FIG. 6, might also be affixed directly to an adhesive-bearing web 55 or to a plain web after having an adhesive pattern applied to the undersurface of the web 43; thereafter, kiss-cutting is performed to fashion the individual piggyback units. As another alternative, a composite web having a layer of adhesive sandwiched between two continuous webs could be used instead of the webs 51 and 55, and a first kiss-cutting step would be used to create the individual pieces 41 followed by a second kiss-cutting step to create the substrates 53. As a further alternative, the individual pieces 41 could be produced as depicted in FIG. 5 and then placed individually onto the web 51 in alignment with adhesive patterns applied thereto using commercially available state-of-the-art equipment. The characteristics of the various adhesives used can be such as taught in U.S. Pat. No. 4,479,838, the disclosure of which is incorporated herein by reference. More particularly, the adhesive pattern 57 should be the weakest so that when the piggyback unit is ready for removal from its "storage" location on the carrier web 55, it can be easily peeled from the carrier 55, using automated equipment if desired, and placed in its distribution location. For example, it may be desired to distribute the piggyback items on the exterior surface of a package, attached to a stand-alone promotional folder or by insertion into a magazine or a book.
In such an instance, it might be desirable to use a thin transparent material, e.g., thin thermoplastic material, for the web 51 from which the intermediate substrates 53 would be cut. In this manner, the transparent substrate 53 can be allowed to ultimately remain in place where it is located following removal of the pop-up piece 41' because it will not obscure any underlying printing. Furthermore, in order to facilitate its ultimately remaining in place, the adhesive which is used to attach the piece 41' to the web 51 should preferably be a "dry residue" adhesive that is also transparent, as is known in the art. This dry residue adhesive should have a greater adherence strength than the adhesive pattern 57, but it should have a lower adhesive strength than the pressure-sensitive adhesive with which the basepieces are bonded to the liner material 25 so that the piece 41' can be stripped from the intermediate substrate 53 by the ultimate recipient, leaving only the transparent substrate which would likely be bonded by a substantially permanent, transparent adhesive in the location on a package or folder or the like where distribution occurs. It is contemplated that the webs 55 of carrier material with the attached piggyback arrangements would then be rolled for storage and shipping purposes, as described hereinbefore.
Disclosed in FIGS. 12-14 is a method for making pop-up elements 71 without the attached basepieces in flat-folded condition, which pop-up elements can be distributed as novelty items or the like. More particularly, a continuous web 61, which is preferably printed or otherwise suitably designed to form a series of pop-up elements each including two pop-up panels 62a and 62b. To the web 61 there is applied a central strip 63 of pressure-sensitive adhesive, as by coating with adhesive from a suitable source, as shown in FIG. 12. Alternatively, the central strip of adhesive can be applied via the use of transfer tape which includes a strip of pressure-sensitive adhesive disposed upon a slightly wider strip of liner material. A continuous liner 65 is then brought into superimposed relationship atop the pressure-sensitive adhesive strip to completely cover it, and the composite strip is preferably rotated 180.degree. in order to reach the orientation shown in FIG. 13 where the liner web 65 is lowermost. In some operations, it may be suitable to apply the strip of pressure-sensitive adhesive to the undersurface of the moving web and then to apply the liner material strip below it. A continuous pattern 67 of permanent adhesive is then applied generally along one edge (or both edges, if desired) of the web 61, and the composite web is then folded in half onto itself along its longitudinal centerline so that the adhesive pattern 67 permanently interconnects the two lateral edges of the original web 61 that will constitute the pop-up panels, as depicted in FIG. 14. Should it be desired to have one portion of the pop-up element, e.g. the panel 62a extend past the end of the other panel, e.g. 62b, then the line of adhesive is located spaced accordingly from the edge and the fold line is offset accordingly from the longitudinal centerline. The folded web is then severed by a knife blade 69 or the like to create a plurality of structurally identical pop-up elements 71.
If desired for distribution, these units 71 can be mated to a continuous carrier web 73, as depicted in FIG. 15, to which a suitable adhesive pattern 75 is applied using an adhesive that will have a lower bond strength than the adhesive 63 so that the pop-up elements 71 can be readily removed from the web by the recipient when ready for use without peeling the liner 65 from the pop-up panels 62. Thereafter following removal, as shown in FIG. 16, the liner 65 is stripped from the outer surface of the pop-up panels 62a and 62b, exposing the pressure-sensitive adhesive pattern 63. By handling the pop-up element 71 near its upper edge where the pop-up panels 62a and 62b are permanently interconnected by the adhesive pattern 67, the recipient can mount the pop-up element directly onto a flat, supporting surface 81, as depicted in FIG. 17, by moving the element 71 perpendicular to the surface so that it opens after the foldline between the panels 62a 62b engages the surface and lower portions of the panels carrying the pressure-sensitive adhesive 163 become affixed to the surface 81.
Alternatively, as depicted in FIGS. 18 and 19, following removal of the liner 65, the pop-up element 71 can be inserted between a pair of facing sheets or panels 85, 87 that are associated with each other in generally hinged relationship thereto along a straight hinge line 89. They may, for example, be sections of the same page of a letter folded along a crease line 89. They could also be facing pages of a larger paperboard folder or menu, or they could be adjacent pages of a magazine or book having a common backbone As illustrated in FIG. 18, the pop-up element 71 is located so that the panel 62a becomes attached to the surface of the panel 87, and when the panel 85 is folded into superimposed relationship along the hinge line 89, it becomes attached to the other pop-up panel 62b by the exposed pressure-sensitive adhesive which it carries. Thereafter, when the panels 85 and 87 are opened, pivoting along the hinge line 89, the pop-up 71 automatically opens and assumes a three-dimensional configuration similar to that depicted in FIG. 17.
Disclosed in FIGS. 20-26 is an alternative method for making pop-up units wherein a single pop-up panel is employed and wherein one of the liner panels is fashioned from the continuous web of paper material by the application of appropriate release coating thereto. Shown in FIG. 20 is a continuous web 111, the direction of movement of which is shown by the associated arrow. The web is suitably printed to depict a series of structurally identical blanks, each of which contains four separate panels arranged side by side across the width of the web. A pair of basepiece panels 113 and 115 are located along the two lateral edges of the continuous web 111. A single pop-up panel 117 is arranged adjacent the basepiece panel 115, and a liner panel 125 is located between the basepiece panel 113 and the pop-up panel 117. The basepiece panel 113 is coated with an overall pattern of pressure-sensitive adhesive, as illustrated in FIG. 20, whereas a release coating (not shown) is preferably applied to the region of the web which constitutes the liner panels 125. The portion of the web which constitutes the pop-up panels 117 is preferably scored, perforated, or otherwise suitably treated so as to create a transverse line of weakness 118 and is also die-cut to create a tab 119. A second transverse line of weakness 118a is located in each of the basepieces 115. An adhesive pattern 121 is applied to the upper surface of the panels 117 in the region between the line of weakness 118 and the adjacent edge of the blank.
As illustrated in FIG. 21, the first folding step folds the lateral edge of the web 111, which constitutes the basepieces 113, onto the release-coated liner panels 125. As also illustrated, a ribbon is severed from the main portion of the web, which ribbon is that part of the web which constitutes the basepieces 115 lying along the other lateral edge thereof.
Following severing of the ribbon, the portion of the web constituting the pop-up panels 117 is folded onto the once-folded web so that the pop-up panels are superimposed atop the basepiece panels 113, with the adhesive pattern 121 creating a joinder between the respective panels along the trailing edges thereof. Following folding, adhesive patterns are applied to the upper surface of the twice-folded web in the form of a transverse strip of adhesive 123 and a generally rectangular spot 124 of adhesive which is positioned on the die-cut tab 119. The transverse strip 123 extends across the panel in a region which corresponds to the region between the trailing edge of the blank and the transverse line of weakness 118a and covers a surface area equal to about half of the area of the region between the trailing edge of the pop-up blank and the line of weakness 118.
Following the application of these adhesive patterns, the severed ribbon containing the basepiece panels 115 is superimposed upon the twice-folded ribbon, as shown in FIG. 23, and if desired, suitable compression can be applied to the composite ribbon to assure good adhesive bonds are created between the pop-up panels 117 and the flanking basepieces 113 and 115 through the adhesive patterns 121, 123 and 124. Then a pressure-sensitive adhesive pattern 127 is applied to the upper surface of the basepieces 115.
Following application of the overall pressure-sensitive adhesive pattern 127, the composite web is then inverted by rotation 180.degree. so that the basepiece panel 115 constitutes the lower surface and the liner panel 125 constitutes the upper surface. As depicted in FIG. 24, the lateral edges of the composite ribbon are trimmed to eliminate the folded interconnections in the twice-folded web, and the composite web is suitably transversely severed into structurally identical individual units or pieces 128.
As depicted in FIG. 25, the units 128 are located in spaced-apart positions along a continuous strip 129 of release-coated paper or the like. Alternatively, the blanks can be appropriately sized, and the composite strip, following trimming, can be severed into individual units 128 by kiss-cutting, as shown in FIG. 11. The strip 129 can be unwound from a roll and can be re-rolled after application of the individual units 128. Alternatively, the strip 129 carrying the individual units 128 can be fan-folded if desired. It is contemplated that it may be desirable to market such pop-up pieces 128 in groups of 10 or 20 or the like, and fabrication in this fashion would facilitate distribution in this manner.
As best seen perhaps in FIG. 26, the adhesive patterns 121 and 123 create a false backbone region between the basepieces 113 and 115 and the pop-up panel 117 allowing the basepiece 115 to be pivoted relative to the basepiece 113, generally along the line of weakness 118a, after the completed unit has been removed from the continuous strip 129 and affixed to an appropriate supporting surface, such as upon the upper surface of a horizontal shelf or the like, where the pressure-sensitive adhesive pattern on a basepiece holds it firmly thereto. For example, after the liner panel 125 is stripped from the basepiece 113, the piece 128 can be opened to the position shown in FIG. 26 wherein the pop-up panel 117 is displayed in a three-dimensional configuration between the two basepieces, which results from its attachment via the wide, adhesive pattern 121 to the basepiece 113 and its attachment in the region of the die-cut tab 119 to the basepiece 115. The pressure-sensitive adhesive pattern on the basepiece 113 that was exposed by the stripping of the liner panel 125 and the pressure-sensitive adhesive pattern 127 allow the pop-up piece 128 to be mounted in a fully open three-dimensional configuration by completing the pivoting of the basepiece 115 as depicted by the arrow in FIG. 26. Alternatively, if the piece 128 was affixed to a wall or other vertical surface via the adhesive pattern on the basepiece 113, gravity could be relied upon to maintain it in the open position. Of course, it should be understood that the die-cut pop-up panel 117 could be die-cut to different configurations than that illustrated, which would likewise assume a three-dimensional configuration upon the pivoting of the basepieces.
Disclosed in FIGS. 27 through 29 is a method for making single sheet pop-up elements without attached basepieces which, as a result of their pressure-sensitive adhesive patterns, are adapted to be placed individually between the pages of a pamphlet or book or at the foldline between panels of a personal letter, as generally hereinbefore illustrated with respect to the item fabricated in FIGS. 12-15, as shown in FIGS. 18 and 19. Illustrated in FIG. 27 is a continuous web 131 which is preferably printed in the form of a series of structurally identical pop-up elements 133, each having a line of weakness 135 impressed along the left hand edge to provide attachment panels in that region. Pressure-sensitive adhesive patterns 137 are first applied to the upper surface of each of the individual blanks 133 in these regions along both the leading and trailing edges of each of the individual blanks 133, and, if desired a release coating can be applied in the region therebetween. Following application of the adhesive patterns 137, the continuous web 131 is rotated 180.degree. to facilitate the application of adhesive patterns 139 to the opposite surface; again, if desired, release coatings could be applied in the regions between the adhesive patterns 139 along the edge of the web. However, depending upon the manufacturing equipment available, the adhesive patterns 139, which are shown as being subsequently applied to the opposite surface of each individual blank in a generally central region of the attachment panels, could instead be applied to the underside of the continuous web.
Following the application of the pressure-sensitive adhesive patterns 137, 139 to both surfaces, the web is die-cut to provide a pair of slits 141 extending inward from this lateral edge past the line of weakness 135 thereby providing, in each individual blank, three separate attachment subpanels 142a, b & c in the region laterally outward of the line of weakness 135. If desired, additional die-cutting could be carried out at the same time in the region of the printed pattern in the remainder of each of the blanks 133 in order to contour this edge (which becomes the upper edge of the pop-up) to render it more attractive. The continuous web 131 is then severed by a reciprocating or rotary knife blade 143 or the like, as are well known in this art, into a plurality of structurally identical individual pop-ups 145 which are collated into stacks of a desired number, as represented by the reference numeral 147 in FIG. 28. One or more of the edges of the stack 147 can then be trimmed, as by a knife 149 as depicted in FIG. 28, so as to present a stack with a neat edge appearance. Moreover, instead of die-cutting the continuous web, as depicted in FIG. 27, it is also possible to die-cut the completed stack 147 to produce the pair of parallel slits 141 in each individual pop-up element 145.
Adjacent pop-up elements 145 in the stack are held in face-to-face contact with one another by the adhesive patterns 137 and 139 on the opposite surfaces of each individual element. However, if desired, the stack 147 can be made into a more formal pad by the application of padding adhesive along one end surface of the stack, for example either along the upper edge in FIG. 28 where the trimming is shown or along any one of the other edges. The formation of such pads is well known in this art, and if desired, a base sheet could be applied to the undersurface of the stack 147 prior to the application of the padding adhesive.
The individual pop-up elements 145 can then be peeled one by one from the stack 147 and can be used in substantially the same way as the pop-up elements 71, depicted in FIGS. 16-19. If, for example, the pop-up element 145 is inserted between panels or sections of the same page of a letter, generally along a crease line between panels 151a and 151b, when the letter is opened by the recipient, the pop-up element 145 will assume the three-dimensional configuration shown in FIG. 29, as a result of the joinder of the attachment subpanels 142 of the pop-up to opposite panels 151. More specifically, the central attachment subpanel 142b is attached to one panel 151a of the letter by the adhesive pattern 139, and the two flanking attachment subpanels 142a and 142c are attached by the adhesive patterns 137 to the adjacent panel 151b of the letter.
Depicted in FIGS. 30-34 is still another method for making pop-up elements that can be distributed as novelty items without attached basepieces. Shown is a continuous web 155 which is preferably printed in the form of a series of rectangular blanks 157 that will create structurally identical pop-up elements, each in the form of two hinged-together pop-up panels 159. A continuous adhesive pattern is applied along both lateral edges of the continuous web 155, with the pattern along the left hand edge carrying the reference numeral 161a and the pattern along the right hand edge carrying the reference numeral 161b. The adhesive is pressure-sensitive adhesive that will adhere strongly to the paperboard or other sheet material which constitutes the web 155 and that will only lightly adhere to itself. Such adhesives are readily available from adhesive formulators throughout the U.S. Following the application of the two pressure-sensitive patterns, the web 155 is folded in half along a centerline depicted, for reference purposes, by the dot-dash line 163 in FIG. 30. This line thereafter constitutes the foldline 163 between the separate panels 159.
The folded web is then die-cut to remove generally rectangular sections which are given the reference numeral 165 in FIG. 30 and which are located just laterally inward from the adhesive patterns 161 that were applied along the two edges of the continuous web. Each of the die-cut regions extends forward and rearward into adjacent blanks 157.
As depicted in FIG. 31, following the die-cutting operations, the once-folded web is then fan-folded so as to create stacks of individual pop-up elements 167, each having the appropriate number of individual units that it is desired to market as a composite stack or pad. For example, one way of accomplishing this end is to sever the continuous web transversely in sections of 25 units each, and fan-fold these 25-unit strips as shown in FIG. 31 to create a vertical stack 169. As depicted in FIG. 32, the completed stack 169 is then trimmed along both side edges by a suitable trimming knife means 171 to eliminate the interconnections along the trailing and leading edges of the adjacent blanks 159 and to thereby create a stack of 25 individual pop-up elements 167. Each of the elements remains detachably joined to the adjacent element through the face-to-face contact of the adhesive patterns 161a and 161b. If desired, a padding adhesive can be applied, preferably along the edge surface of the stack 169 where the adhesive patterns 161 are located, as explained hereinbefore with respect to the stack 147, depicted in FIG. 28.
When an individual pop-up element 167 is peeled from the stack 169, it constitutes a pair of hinged-together panels 159, each of which has a depending subpanel 172 carrying the pressure-sensitive adhesive pattern 161, which subpanel is connected thereto by a narrow neck 173 formed by the die-cutting operation that removed the rectangular sections 165. The pop-up element 167 is ready for insertion between the facing surfaces of two hinged-together pages 175a and 175b of a pamphlet or the like or between adjacent panels of a folded personal or business letter; attachment is made upon contact with the depending attachment panels via the pressure-sensitive adhesive patterns 161 which retain sufficient tack to strongly adhere to the usual paper materials. As depicted in FIG. 34, when the hinged-together panels 175a and 175b are spread apart, the pop-up element 167 assumes three-dimensional configuration with the panels 159 pivoting relative to each other along the hinge line 163.
Shown in FIG. 35 is a continuous web 181 which is preferably printed in the form of a series of rectangular blanks that will each create two structurally identical pop-up elements each in the form of hinged-together pop-up panels. The web is folded along a pair of foldlines 183 so that each of the edge portions is folded over into superimposed relationship with the underlying adjacent central portion of the web. Upon completion of this first folding step, a pair of parallel lines 185 of pressure-sensitive adhesive are applied to the upper surface of the folded portions in flanking relationship to the centerline of the web.
Following the application of these two adhesive strips 185, the web is rotated 180.degree., and an additional two parallel strips 187 of pressure-sensitive adhesive are applied to what was the original undersurface of the web, again flanking the centerline. A second folding operation is then effected so as to further fold web 181 along its centerline to create an assemblage that is four layers thick. The pressure-sensitive adhesive that is used is similar to that used in the method described with respect to FIGS. 30-34 which adheres strongly to the sheet material but only lightly to itself. The web is then die-cut to remove generally rectangular sections given the reference numeral 189 in FIG. 35. Thereafter, the web is then fan-folded as depicted in FIG. 36 to create a stack 191 of these individual pop-up elements 192, with each blank of the original continuous web providing two such elements.
Once a stack 191 of the desired number of elements have been formed, the final cutting operation is effected, as depicted in FIG. 37, using suitable knives 193 and 195. Cutting along both side edges of the stack 191 by the knives 193 eliminates the interconnection of adjacent pop-up elements 192 along the foldlines that were created by the fan-folding operation, and the trimming along the bottom edge by the knife 195 eliminates the original foldline along the centerline of the web along which one panel of each of the two elements from each blank were originally joined. Once the trimming operation depicted in FIG. 37 is completed, the stack of pop-up elements is substantially indistinguishable from that produced in FIG. 32.
Shown in FIG. 38 is an alternative method of making the pop-up elements of single sheet thickness of the type generally depicted in FIGS. 27-29. A generally similar continuous web 201 of sheet material, printed on both sides, is provided which is printed to constitute a series of individual blanks 203 that will form structurally identical pop-up elements. Pressure-sensitive adhesive patterns 205a are first applied on one surface of the web to the regions of the web which will constitute a pair of attachment subpanels. The web is then rotated 180.degree., and adhesive patterns 205b are applied to the opposite surface in the region of the single attachment subpanel. Instead of then die-cutting the web 201 as was done in the method depicted in FIG. 27, the web 201 is laid atop a continuous web 209 of carrier material to which patterns of pressure-sensitive adhesive 210 are strategically applied to coincide with the center of each blank. In some instances, depending upon the size of the pop-up element 211, the additional adhesive pattern 210 may be unnecessary, for it may be possible to rely upon the patterns 205a to secure the elements in place on the carrier web 209.
A kiss-cutting operation is then carried out similar to that depicted in FIG. 7. As a result of this kiss-cutting operation, the entire outline of the desired pop-up element 211 is effected by cutting through the single thickness of the printed web material 201 but not cutting into the liner material web 209. At the same time, parallel die-cuts 213 which extend upward from the base of the pop-up element 211 are simultaneously created. Thereafter, the scrap portion 215 of the continuous printed web is stripped therefrom, leaving a plurality of spaced-apart individual pop-up elements 211 attached by the pressure-sensitive adhesive patterns 210 and 205a to the underlying continuous web of liner material 209. The liner material 209 might then be severed to create strips of predetermined length each containing the desired number of pop-up elements 221 which are to be marketed as a unit; such strips can then be rolled so that the pressure-sensitive adhesive patterns 205b on the upper surface of the pop-up elements 211 are protected by the adjacent undersurface of the liner material strip. Thus, such rolled strips carrying the desired number of pop-up elements can be packaged and marketed in this fashion.
FIG. 40 illustrates composite web material 221 which is commercially available and which consists of two individual sheets 223, 225 with a relatively thick layer 227 of pressure-sensitive adhesive sandwiched therebetween. If desired, such composite 3-layer web material could be formed as a part of an overall operation. The adhesive 227 preferably adheres equally to both of the facing surfaces, and in such an instance, when a portion of either sheet is removed, a partial layer of pressure-sensitive adhesive will adhere to the surface of the removed portion as well as to the now-exposed surface of the underlying sheet. Alternatively, for the construction of certain pop-up elements, it may be desirable that one of the sheets, e.g. the sheet 225 be treated with a release coating so the adhesive will preferentially adhere to the other sheet, e.g. sheet 223. If such a composite is not readily available, it can be fabricated as mentioned above. Moreover, it is feasible that a single web of suitable width could be split in half, with one-half being coated with a release material and dried before mating with the other one-half to which the pressure-sensitive adhesive is applied.
As depicted in FIG. 41, a continuous web of such material 221 is printed so as to provide a series of rectangular blanks, each of which constitutes a pop-up element in the form of a pair of panels which will ultimately remain hinged together along a line of weakness down the longitudinal centerline of the web. A die-cutting operation is effected so as to die-cut the image of a circular head 229 completely through the entire composite web. At the same time, a line of weakness 231 is created in the region of the blank along the centerline of the web, which is interrupted by the neck of each die-cut head. Optionally, one or two parallel lines of weakness 233 can be created in the web near the lateral edges thereof to create distinct subpanels if desired. In addition, a kiss-cutting operation is carried out on the web so as to create a removable rectangular panel 235 in the upper sheet 225 in the region of one of the subpanels and to create a straight-line cut 237 through the upper sheet to define a second removable rectangular cover panel 238 adjacent the opposite edge of the moving web, which can be in addition to or in lieu of creating a line of weakness at the same location. If the sheet material from which the sheet 225 is formed is relatively thick, it may be desirable to kiss-cut a pair of straight-line cuts 237 rather than one and a rectangular panel. Thereafter, the web is folded along the centerline so that the pop-up element panels are superimposed upon each other, and the folded web is then severed transversely to create individual pop-up units 239 (see FIG. 42).
As depicted in FIG. 42, manual removal of the cover panel 235 created by the kiss-cutting exposes the pressure-sensitive adhesive region on the underlying surface of the interior sheet 223, and removal of the cover panel 238 likewise exposes the adhesive-covered subpanel of the sheet 223. These exposed adhesive regions allow the pop-up unit 239 to be readily secured between the surfaces of a pair of facing panels of a letter or the pages of a book, as explained hereinbefore with respect to the pop-up unit 167 illustrated in FIG. 33.
Disclosed in FIG. 43 is a continuous web 241 of sheet material that has been printed so as to constitute a series of blanks each in the form of a pair of pop-up panels located on opposite sides of the centerline of the web. A die-cutting operation is first performed so as to create perforations 243, 245 in regions to eventually define subpanels, which perforations extend along lines parallel to the direction of travel of the web. The upper surface of each pop-up element panel along the upper half of the web (FIG. 43) is then coated overall with a layer of pressure-sensitive adhesive 247; alternatively a smaller pattern of adhesive could be applied to cover key regions. The web is then folded to superimpose the panels upon each other and sandwich the layer of pressure-sensitive adhesive between the folded web. The pressure-sensitive adhesive is such that some of the adhesive will adhere to both facing surfaces of the folded web so that, as in the material depicted in FIG. 40, when a portion of one sheet is removed, there will be pressure-sensitive adhesive remaining, now exposed, on the surface of the underlying portion of the pop-up element.
Following the folding operation, a die-cutting operation is carried out so as to die-cut the FIG. 249 of a flag and flagpole along one edge of the folded web creating a strip of waste 252 and to die-cut a pair of parallel lines 251 transverse to the direction of travel of the web extending inward from the opposite edge of the web 241. Waste 252 from the die-cutting of the flag figures is stripped away using any suitable state-of-the-art method of waste removal, and the web is then severed to create individual pop-up elements 253, as depicted in FIG. 44. If it should be desired to balance waste removal for manufacturing efficiency, a waste strip could also be used along the opposite lateral edge of the folded web. The pair of die-cut lines 251 and the perforations 243 create a single removable panel 255 on the rear surface of the unit, and the die-cut lines and the perforations 245 create two removable panels 257 on the front surface of each element, as seen in FIG. 43. Removal of these three panels exposes the pressure-sensitive adhesive and readies the pop-up element 253 for insertion between facing surfaces of a pair of hinged panels, for example, the folded portions 259a,b of a business letter or the like. When the letter is opened, as depicted in FIG. 45, the pop-up element 253 automatically assumes its three-dimensional display orientation.
Illustrated in FIG. 46 is a continuous web 261 of sheet material that has been printed or otherwise suitably designed so as to constitute a series of rectangular blanks, each in the form of a pair of pop-up panels located on opposite sides of the centerline 263 of the web, which blanks are preferably designed to form single pop-up elements of generally structurally identical construction, which could however be printed with different designs or die-cut in slightly different fashion, if desired. Preferably, a pair of lines of weakness 265 are impressed in the continuous web, spaced inward from its lateral edges, to create subpanels 267. At about the same time, a strip of permanent adhesive 269 is preferably laid down adjacent the centerline, which adhesive is designed to cause permanent adherence between the facing portions of the two hinged panels. The web is then folded along the centerline 263 to bring the pop-up panels into superimposed position, creating this permanent adhesive bond.
Following the folding step, strips of pressure-sensitive adhesive 271 are applied to the outer surfaces of both subpanels 267. The application can be made simultaneously upon the upper and lower surfaces of the continuously moving web. Alternatively, the adhesive strip 271 can be applied to the upper surface of the web, and the web then rotated 180.degree. before a similar adhesive strip is applied to the upper surface of the other subpanels 267. As a further alternative, a pressure-sensitive adhesive strip could be applied initially along both edges of the continuous web 261, and the web could then be rotated 180.degree. prior to the application of the permanent adhesive strip 269.
Following the application of the pressure-sensitive adhesive strips 271, the web can be severed into individual units 273 which are then applied to a carrier web as generally illustrated in FIG. 15, or accumulated in a stack as described hereinbefore with respect to the embodiments shown in FIGS. 27 and 28, or handled in any other way as described hereinbefore; alternatively, the web can be cut into multiple unit lengths that are fan-folded, as previously described in detail with respect to FIG. 31, and then severed into individual units by trimming. The pressure-sensitive adhesive should be such that it will adhere strongly to the web material but will only adhere lightly to itself when it is intended that the pop-up elements 273 are to be distributed in a stack. When one of the pop-up elements is removed from such a stack and placed between facing panels 275a, 275b of a business letter or the like, the pressure-sensitive adhesive 271 attaches the pop-up element subpanels 267, respectively, to one of the facing panels of the letter, and when the letter is opened, as shown in FIG. 47, the pop-up element 273 automatically assumes its three-dimensional display orientation.
Illustrated in FIG. 48 is a continuous web 279 of sheet material that has been printed or otherwise designed to constitute a series of rectangular blanks, each in the form of a pair of pop-up panels located on opposite sides of the centerline 281, which panels are designed to form pop-up elements generally similar to that depicted in FIG. 47 but of a slightly different construction. They could also be die-cut in slightly different configurations if desired. A pair of lines of weakness 283 are preferably impressed in the web 279 in flanking relationship to the centerline 281, and a strip of permanent adhesive 285 is preferably applied along one edge of the web. The lines of weakness create subpanels 287 lying on opposite sides of the centerline 281. The web is then folded in half along the centerline 281 so as to superimpose one panel of each blank atop the other, using a "banana finger" as known in this art to achieve folding precisely along the longitudinal centerline. As a result of the folding, the lateral edges of the web become adhered to each other via the permanent adhesive strip 285. Thereafter, strips of pressure-sensitive adhesive 289 are applied to the upper and lower surfaces of the web in the regions of the subpanels 287. As explained with respect to FIG. 46, the strips 287 can be applied simultaneously to the upper and lower surfaces of the moving web, or one can be applied first before the other, with a 180.degree. rotation of the web taking place in between. They might possibly be applied to the undersurface of the web prior to the folding operation. The folded and glued web can then be cut into individual units 291 or can be cut into multiple units, as explained hereinbefore, which units may be distributed as a stack or in some other suitable arrangement.
When one of the pop-up elements 291 is peeled from such a stack and placed between the panels 293a, 293b of a letter, or between the pages of a pamphlet, a book or the like, the subpanels 287, which remain hinged together along a foldline that was originally the centerline 281 of the web, become adhered to the facing panels 293a, 293b via the pressure-sensitive adhesive patterns 289. When the letter is opened, as depicted in FIG. 49, the pop-up element 291 automatically assumes its three-dimensional display orientation.
Illustrated in FIG. 50 is a continuous web 301 of sheet material that has been printed so as to constitute a series of rectangular blanks, each of which blanks includes one pop-up element and one basepiece, on opposite sides of the centerline 303 of the web. A peripheral pressure-sensitive adhesive pattern 305 is applied in the form of three separate spaced locations located generally along the periphery of the basepiece panel 307 of each blank. A single adhesive pattern 309 is applied to the pop-up element panel 311 of the web at a location generally adjacent the centerline 303 which is preferably of permanent adhesive but could be of pressure sensitive adhesive that would create a strong bond. Die-cutting is carried out so as to die-cut a series of spaced pentagons 313 along the centerline of the web, to create a pair of parallel lines 315 between these pentagons, and to create a contoured edge 317 inward of the upper edge of the web, as depicted in FIG. 50, defining a series of pop-up elements 318 therein. Following the die-cutting operation, the die-cut pentagons 313 and the upper edge portion 319 of the web may be removed as scrap before the die-cut upper half of the web is folded along the centerline 303 so as to lie upon the lower half of web which carries the peripheral pressure-sensitive adhesive pattern 305. Alternatively, the folding step may be carried out before the removal of the die-cut pentagons to facilitate folding; however, so long as the pentagon die-cuts are spaced about an inch or more from the centerline 303, it should be possible to fold without difficulty using state-of-the-art methods. Once the folding operation is completed, the permanent adhesive pattern 309 aids in retaining the folded web in this condition.
Following folding, pressure-sensitive adhesive patterns 321 are applied to what is now the upper surface of the folded pop-up element 318 in the regions just flanking the die-cut lines 315 and generally adjacent the centerline 303. The adhesive 321 preferably is such as to create a stronger bond than the peripheral adhesive pattern of the pressure-sensitive adhesive 305 which lies outward of the boundary of the die-cut pop-up element 318. The folded web can be then severed by a knife blade 324 into individual units 323 each including one basepiece 307 and a superimposed pop-up element 318. The units 323 can be distributed attached to a carrier web similar to the arrangement shown in FIG. 15, or a web of release-coated material could be superimposed onto the individual units as they are severed using the pressure-sensitive adhesive patterns to effect joinder. They may also be distributed arranged in a stack or in any other suitable manner as hereinbefore described. Alternatively, it might be most efficient to apply the folded web to a carrier web and then carry out the severing into individual units by kiss-cutting as shown in FIG. 7.
The pop-up unit 323 can be applied to any suitable supporting surface, for example to the front panel of an envelope 325, as depicted in FIG. 51. When the recipient opens the unit by grasping the upper edge and pulling it downward, the weaker pressure-sensitive adhesive pattern 305 is broken, allowing the basepiece 307 to be folded downward, pivoting along the hinge line that was originally the centerline 303 of the web. The pressure-sensitive adhesive patterns 321, which most preferably have a semi-permanent bond which is stronger than the adhesive 305, remain attached to the front surface of the envelope 325, as depicted in FIG. 52. Thus, the patterns 321 and the permanent adhesive bond 309 between the central portion of the pop-up element and the basepiece 307 causes the pop-up element 318 to assume an upstanding three-dimensional configuration.
Illustrated in FIG. 53 is a continuous web 331 of sheet material that has been printed so as to constitute a series of side-by-side rectangular blanks, each of which includes a single basepiece and a pair of panels that will constitute a pop-up element. The continuous web, which is moving in the direction of the arrow, is first die-cut to produce a series of spaced-apart die-cuts 333 which are located in the blank at the junction between the basepiece panel 335 and the remainder of the blank which constitutes the pop-up element. The lower or left hand portion of the web, as viewed in FIG. 53, is then folded along the centerline of the pop-up element portion of the blank to create pop-up panels 337 and 339 of substantially equal dimension which are superimposed one atop the other. An adhesive pattern 341 of permanent-type adhesive is then applied to the pop-up panel 339 generally along its free edge.
The web 331 is then folded again along a longitudinal line defined by the series of die-cuts 333 to superimpose the pop-up element portion atop the basepiece portion of the web. The twice-folded web is then kiss-cut so as to cut through only the two thicknesses of the pop-up element portion thereof along parallel lines 343 that are spaced apart a distance equal to the length of the die-cuts 333 and aligned therewith. The generally rectangular, folded, scrap portions 345 created by the kiss-cutting are suitably removed using state of the art methods. A pressure-sensitive adhesive pattern 347 of relatively strong bond strength is then applied to the upper surface of the pop-up portion of the web, and an adhesive pattern 349 of pressure-sensitive adhesive having a weaker bond strength is applied to the portions of the basepiece which become exposed by the removal of the rectangular kiss-cut sections. Finally, the web is cut along parallel lines between the individual blanks using a suitable knife blade 351 or its equivalent to create individual pop-up units 353. Alternatively, these individual pop-up units 353 which are created from the continuous web 331 can be severed from one another, handled and distributed in any of the ways described above with respect to the pop-up units illustrated in FIGS. 50-52.
The individual pop-up units 353 may be designed to be applied to the front of an envelope 355 or the like with the hinge line at the top and with the free edge of the basepiece 335 at the bottom. When the free edge of the basepiece is lifted, the weaker bonds of the pressure-sensitive adhesive patterns 349 part, releasing the basepiece 335 from direct contact with the outer surface of the envelope 355. The bond strength of the stronger pressure-sensitive adhesive pattern 347 secures the pop-up panel 337 to the face of the envelope along its upper edge, causing the basepiece 335 to pivot along the fold line created between the spaced-apart die-cuts 333. The permanent adhesive bond created by the adhesive pattern 341 between the facing surface of the basepiece and the pop-up panel 339 pulls one-half of the folded pop-up element toward it, causing the pop-up element to assume a three-dimensional configuration. If desired, lines of weakness can be impressed or otherwise added to the continuous web at an appropriate time, for example at about the time of the die-cutting step, in locations adjacent the edges of the adhesive patterns 341 and 347 so as to create more distinct subpanels and provide a sharper, overall appearance.
Illustrated in FIGS. 55-57 is an alternative mass production method for making pop-up elements 401 having some similarity to those made by the method of FIG. 48. Shown is a continuous web of sheet material 403 that has been printed on one side or otherwise suitably designed to constitute a series of rectangular blanks, each of which is designed to form a structurally identical pop-up element 401 generally similar to that shown in FIG. 49. FIG. 56 shows the normal orientation in which the method might likely be run, and FIG. 55 is a view of the same method as seen from below which better illustrates certain features. As best seen in FIG. 57, the mass production method is designed to produce a pop-up element 401 having an upper flag section 405, which is the attention-getting portion of the pop-up element and which is of only a single thickness for most of its area. The flag section is supported by a base section 407 in the form of a plurality of subpanels 409a and b and 411a and b, the lowermost two of which carry pressure-sensitive adhesive so as to adhere to a supporting surface. As indicated previously, the supporting surface can be adjacent panels 413a and 413b of a folded letter, the pages of a book, or any relatively flat surface from which it might be desired to have the pop-up element 401 extend upwardly in attention-attracting fashion.
A plurality of lines of weakness are preferably impressed in the continuous web 403 as it travels through the press. These lines of weakness include a center line 415, which will become the folded bottom edge of the series of pop-up elements, and two pairs of spaced-apart lines which flank the center line of weakness and define what will become the individual hinged-together subpanels 409, 411 of the supporting base. More specifically, lines 417a and b are spaced closest to and equally apart from the center line 415 and define the pair of lowermost or bottom subpanels 411 which will, in the completed environment, carry the pressure-sensitive adhesive. The two lines 417a and 419a and the two lines 417b and 419b respectively define the intermediate or oblique subpanels 409a and b which interconnect the bottom panels 411 and the flag section 405 of the pop-up element 401. In addition, there is defined, between the line 419a and the edge of the web, a flange or joinder panel 421 that will become affixed to the rear surface of the flag section 405 of the pop-up element and thus create a lower, double thickness section in the flag panel.
Pressure-sensitive adhesive is efficiently applied to the appropriate surfaces of the pair of adjacent bottom subpanels 411 by means of laminating a thin continuous strip of transfer tape 423 to the undersurface of the continuous web 403 (FIG. 55 showing this step in inverted orientation). The transfer tape 423, carrying a desired adhesive pattern 425 on one surface, is aligned so that its centerline is precisely positioned so as to be in alignment with the center line of weakness 415, and it is of such a width that its total width is equal to the width of the pair of subpanels 411 which constitute the bottom two subpanels of the supporting base 407. The transfer tape 423 is made of sheet material that is coated with a release coating so that the pressure-sensitive adhesive which it carries will preferentially adhere to the surface of the continuous web 403; accordingly, when the transfer tape 423 is removed from contact with the web (in the eventual pop-up element 401), the pressure-sensitive adhesive remains, precisely positioned as desired to support the pop-up element 401 in its intended attention-attracting orientation. Alternatively, if desired, the lines of weakness are not impressed in the continuous printed web 403 until the lamination with the transfer tape 423 has been effected; in such instance, when the lines of weakness are impressed in the web 403, the central line 415 is simultaneously impressed in the transfer tape 423. Moreover, the width of the transfer tape 423 can, if desired, be just slightly greater than the pressure-sensitive adhesive pattern which, as indicated above, preferably matches the width of the pair of subpanels 411 to which it is intended to transfer; however, a slightly narrower transfer tape is preferably employed which carries a pressure-sensitive adhesive pattern 425 completely across its width, thus eliminating any uncoated short edge regions.
Following the impression of the lines of weakness, a strip of bonding adhesive 427 is applied (see FIG. 56) to the upper surface of the web 403 in the region between the line 419a and the edge of the continuous web, i.e., onto the region of the web which constitutes the flange panel 421 that becomes bonded to the flag section 405 of the pop-up element. Following application of the bonding adhesive 427, the continuous web 403 and the laminated strip 423 carrying the pressure-sensitive adhesive 425 is folded along the line 415 so as to superimpose one-half of the base section 407 upon the other and to superimpose the flange panel 421 on the rear surface of the flag section 405 of the pop-up. The folding of the continuous web assembly can be done using a plow-banana finger combination or the like as known in the art to achieve precise folding along the desired line.
The continuous web is then die-cut along a contour line 429 to create the individual pop-up elements 401 each including an upper flag section 405 and a lower base section 407. In the illustrated embodiment, the die-cutting is such as to constitute a perforation cut which leaves the pop-up element 401 still connected to the remainder of the web by a plurality of short easily broken bridges of fibrous material.
The folded and die-cut web can then be handled in any of the manners hereinbefore illustrated. For example, it could be fan-folded as illustrated in FIG. 36 and then optionally trimmed to create a stack of individual units; it could be rolled into a coil of a predetermined number of pop-up elements; or it might be cut into strips of a plurality of units, for example 5 each, which are distributed in that form. Individual pop-up elements 401 could also be removed totally from the remainder of the web and applied to a carrier web as illustrated with respect to FIG. 25.
A pop-up element 401 is removed from the web by breaking the short bridges remaining in the lines of perforation to prepare it for use. The remaining portion of the folded transfer tape 423 is peeled from the pressure-sensitive adhesive bearing subpanels 411, thus exposing the adhesive which remains adhered to the continuous web, having transferred thereto. With the pressure-sensitive adhesive 425 on the subpanels 411 now exposed, the pop-up element 401 is placed in the crease between the folded panels 413 of a letter, and the letter is closed so that the opposite-facing subpanels 411 adhere to the hinged panels of the letter. When the letter is opened, as depicted in FIG. 57, the pop-up element 401 automatically assumes a 3-dimensional display orientation with the flag section 405 supported in attention-getting orientation. Alternatively, once the release liner 423 has been removed, the pop-up element 401 can be applied to any essentially flat surface or the like by pressing it transversely against the surface at the foldline 415; such action will cause the bottom subpanels 411 to adhere to the surface and support the pop-up element in its intended 3-dimensional orientation.
Depicted in FIG. 58 is an alternative method of mass production for making individual pop-up units 431 generally resembling those shown in FIG. 57. A continuous printed web 433, substantially the same as the web 403, is employed which is printed on both surfaces and is designed to produce a series of structurally identical pop-up elements 431 from the individual blanks provided in the continuous web. Instead of using a relatively narrow strip of transfer tape, in this embodiment, a continuous web 435 of release-coated transparent material having a width substantially greater than the width of the printed web 433 is employed. This transparent continuous web contains a pair of elongated adhesive patterns 437 of pressure-sensitive adhesive which align with the portions on the continuous web which will constitute a pair of bottom subpanels 439. Following lamination of the two webs, a plurality of lines of weakness 441 are impressed upon the laminated material generally as described hereinbefore, or alternatively, the lines of weakness can be impressed upon the continuous printed web 433 prior to the lamination. Thereafter, a strip of bonding adhesive 443 is applied along one edge of the continuous printed web 433 which constitutes a flange panel 445, and a separate line of bonding adhesive 447 is applied along one edge of the transparent web material 435.
The two laminated webs 433 and 435 are then folded along the longitudinal centerline 441a so as to superimpose the portion of the continuous printed web containing two subpanels of the base and the flange panel 445 upon the corresponding subpanel portion of the web on the other side of the fold line and to also fold the release-coated web essentially in half, with the line of adhesive 447 bonding one edge of the transparent material web 435 to the facing surface of the other lateral edge.
Prior to folding the printed web 433 and the transparent web 435, the flag portion is die-cut to create a distinctive shape if it is desired for the flat portion to have a contour. In such an instance, if desired, the remainder of the web along the right-hand edge as shown in FIG. 58 can be stripped therefrom; however, the remaining matrix can also be simply left in place so as to resemble the uncut version that is shown.
At some time during the manufacturing process, either before or after, but preferably after the folding, the folded assembly is laminated to an underlying continuous carrier web 449. The carrier web 449 is provided with a suitable adhesive pattern (not shown) so as to secure it to the undersurface of the transparent web for a purpose to be explained hereinafter.
Following the folding of the two webs, the folded web assembly is die-cut using a kiss-cutting arrangement that will cut through the upper transparent film layer, both layers of the printed web, and the lower transparent film layer, but stopping short of the carrier web 449. The kiss-cutting operation is such as to cut rectangular panel outlines 451, each of which constitutes a single pop-up element unit. The remaining matrix 453, having a generally ladder-like form, which is created following this kiss-cutting operation, is then stripped from the top of the carrier web to leave a series of spaced-apart pop-up element units 455 in place on the carrier web 449.
As best seen in FIG. 59, each of the resultant units 455 includes the pop-up element 431 sandwiched between a pair of transparent rectangular panels 457. The pop-up adhesive patterns 437 secure the transparent panels to the pop-up element along the left-hand edge, and the strip of bonding adhesive 447, which preferably extends downward to just contact the right-hand edge portion of the printed web 433, secures this sandwich or envelope along its right-hand edge. The carrier web arrangement can be rolled, as described with regard to the FIG. 7 arrangement, or, if desired, folded in a zigzag fashion. The individual pop-up units 455 will often be manually removed from the carrier web 449; however, this arrangement also lends itself to feeding the units for placing of the individual units by some suitable automatic apparatus. In this respect, the carrier web 449 can have a release coating on its upper surface, and the adhesive pattern which is applied can be of a light-strength pressure-sensitive adhesive that will transfer to the undersurface of the transparent layer 435. Then, when such automatic equipment grasps the individual pop-up unit 455 and removes it from the carrier web, it will be removed cleanly from the carrier web 449 along with the pressure-sensitive adhesive, which will be in place and ready to adhere the pop-up unit 455 to an appropriate item for distribution.
When it is ready to employ the pop-up unit 455, the user simply peels the two rectangular transparent panels 457 apart beginning at the left-hand edge as depicted in FIG. 59 to expose the pop-up element 431. If the flag section is die-cut and particularly if the bonding adhesive pattern 447 extends down slightly over the right-hand edge of the printed web 433, the waste from the die-cut will remain with the two transparent panels when the pop-up element 431 is removed. In any event, the pressure-sensitive adhesive 437 will be exposed on the two bottom base subpanels 439; although as a result of the die-cutting, these two subpanels 439 will not be interconnected to each other by a hinge line, as was the case for the pop-unit element 401 manufactured by the process shown in FIG. 55, it will function equally as well when inserted between a pair of facing pages or panels of a folded letter, essentially as shown in FIG. 47 with respect to the pop-up element 273.
Shown in FIG. 60 is still another method for mass production of pop-up elements 461 wherein a pair of printed webs 463 are laminated to each other so that the flag section 465 of the pop-up element 461 contains printed indicia on both surfaces. Each printed web 463 is designed so that each blank will form two pop-up elements 461, located base-to-base along a centerline 467 which is preferably perforated. More specifically, the mass production process employs an upper printed continuous web 463a and a lower printed continuous web 463b with one of the webs, preferably the lower web having a bonding adhesive pattern 469 located along both of its upper surface edges in the regions which will constitute the flag sections 465 of the pop-up. A pair of lines of weakness 471 are preferably provided in the lower printed web 463b and are located so as to define the hinge line between each flag section 465 and the uppermost base subpanel 472. Such lines 471 are preferably impressed in the lowermost web because comparable lines are omitted from the uppermost web so that the flag section 465 will not stand straight up but will be preferentially tilted slightly rearward for a particular effect. Although additional lines of weakness 473 could also be impressed in the lowermost printed web before lamination, this is optional. These lines 473 are preferably simultaneously impressed in both webs after lamination of the two webs, and either before or after a pair of continuous strips 475 of transfer tape bearing pressure-sensitive adhesive 477 are applied respectively to the undersurface and the top surface of the two-web lamination. Alternatively, a strip of transfer tape 475 could be applied to each of the printed webs before lamination to each other, if desired. The transfer tape 475 provides pressure-sensitive adhesive 477 in the region of the bottom or lowermost subpanels 479 of the support section for each pop-up element, and the adhesive pattern preferably stops just short of each edge of the transfer tape, i.e. so that the edge of the adhesive pattern essentially extends only to the two parallel lines of weakness that are impressed in the pair of laminated webs, which define the lowermost base subpanels 479.
Following application of the two strips of transfer tape 475, the entire laminated assembly is die-cut to provide outlines 481 of a pair of base-to-base pop-up elements 461 in each blank and to also provide a longitudinal line of perforations at the centerline 467 along which each pop-up element is separable from its mate in the series of blanks. The resultant die-cut assembly can be rolled as described before, but it is preferably fan-folded in the form of sheets 483 containing groups of, for example, five blanks each, as shown in FIG. 61. To facilitate such fan-folding, a transverse line of perforations 484 is preferably cut in the web perpendicular to the central line of perforations 467 so as to mark off groups 483 of five blanks each.
When such an arrangement is employed, these pop-up elements 461 can be distributed in small sheets 483 of ten pop-up elements each. The die-cutting that is used to create the individual pop-up elements 461, which in the illustrated arrangement are in the form of an unfurled flag flying from a supporting flag pole, utilizes a nick die which leaves a plurality of short bridges of fibrous material interconnecting each pop-up element 461 with the surrounding matrix material 485. The user simply breaks these easily severable bridges to remove the pop-up element which is then ready to use upon exposing the pressure-sensitive adhesive 477 by the subsequent removal of the liner subpanels which were die-cut from the upper and lower strips 475 of transfer tape. As before, the pressure-sensitive adhesive 477 from the transfer tape 475 remains on the printed web material 463, and thus the pop-up element is ready for insertion between the pages of a pamphlet or between the folded panels 487 of a letter. The lowermost pressure-sensitive adhesive-carrying subpanels 479 of the base support are not joined to each other along a hinge line, but again the pop-up element 461 functions as generally shown in FIG. 47 when located, for example, near the fold line between the facing panels 487 of a letter or other paperboard circular, as shown in FIG. 62.
Illustrated in FIG. 63 is yet another mass production process for making pop-up elements 501 generally similar to that shown in FIG. 60. In this arrangement, a lowermost carrier web 503 is employed having an overall coating of clear, transparent, pressure-sensitive adhesive 505 disposed atop its upper surface, which surface is coated with a silicone-release coating or the like so that the adhesive 505 will transfer from this carrier or liner onto the undersurface of a web 507 of clear transparent film which is then laminated thereatop. Next, a dry residue adhesive formula 515 is applied across the entire upper surface of the transparent film web 507; a dry residue adhesive such as that disclosed in U.S. Pat. No. 4,479,838 (the disclosure of which is incorporated herein by reference) may be employed. A first printed web 517, printed side down, is then laminated atop the dry residue adhesive layer 515. This continuous web 517 is printed to have a series of blanks designed to produce structurally identical pop-up elements 501 each having an upstanding flag section 519 and a lower supporting base portion 521. Thereafter, a bonding adhesive pattern 523 is applied to the flag portion region of the upper surface of continuous web 517, and then a second printed continuous web 525 preferably of co-equal width, is laminated atop the first continuous web, printed side up. Once these laminations are completed, the laminated web is kiss-cut from the bottom to create a rectangular die-cut 511 in the region of the lower subpanel of the base section that extends upward through the carrier web 503 and the transparent film web 507. This rectangular die-cut creates a release liner panel from the carrier layer which protects the pressure-sensitive adhesive on this subpanel.
If desired, three parallel lines of weakness 527 can be impressed in the pair of laminated printed webs to define the subpanels which will constitute the supporting base 521 of each pop-up element 501. These lines of weakness can be impressed either before or after a strip of transfer tape 529 carrying pressure-sensitive adhesive 531 is applied atop the upper printed surface of the printed web in the region of the lowermost subpanels, so as to provide the pressure-sensitive adhesive carried by this strip which transfers to the upper surface of these bottom subpanels 533.
Following the application of the transfer tape 529, a final die-cutting operation is carried out to produce a contour outline 535 in each flag section, which is a kiss-cutting operation from the top which extends through the transfer tape 529, the two laminated printed webs 517, 525 and through the clear transparent film web 507, but stops short of the lowermost carrier web 503. If desired, thereafter the matrix material 537 can be stripped from around the individual pop-up elements, which matrix will consist of the ladder-like portion remaining from the three thicknesses of printed web and transparent film plus the transfer tape, leaving a series of pop-up elements 501 adhering via pressure-sensitive adhesive 505 to the underlying carrier web 503. The pop-up elements 501 can be distributed in any form using any of the rolling, fan-folding or other procedures as hereinbefore described.
They can be removed from the carrier web 503 via automatic equipment if desired. When each pop-up element 501 is removed from the web, a parting occurs at the light-strength pressure-sensitive adhesive layer 505, which adhesive has transferred to the undersurface of the transparent film 507 because the carrier web 503 is coated with a release-coating material; however, the die-cut liner panel covering one base subpanel 533 is removed from the web with the element (see FIGS. 64 and 65). Thereafter, the pressure-sensitive adhesive 505 which has transferred onto the undersurface of the lowermost transparent layer across the entire region of the flat section allows the composite pop-up element to be affixed to a suitable surface for distribution, for example, the exterior of a box or a cover or interior surface of a pamphlet, letter or the like, because this pressure-sensitive adhesive will bond strongly to a fibrous or paperboard surface or the like that does not carry a silicone release coating.
Upon receipt of the distributed item, the recipient can remove it from this surface, which can be a printed surface, and parting will occur at the dry adhesive bond between the transparent film 507 and the printed web 517 because the strength of the dry residue adhesive is less than that of the pressure-sensitive adhesive 505. As a result, the transparent film 507 remains in place on the distribution surface, but because of its transparency and that of the adhesive 505, does not obscure any writing or graphics that might be beneath. Likewise, because of the nature of the dry residue adhesive, there is no residue that is left that would be unsightly or troublesome. The pop-up element 501 is then ready for use in the manner of the pop-up element 461 described hereinbefore.
To affix the pop-up element in display orientation, the remainder of the transfer tape 529 which covers the lowermost subpanel 533 on the front surface is removed to expose the pressure-sensitive adhesive 531 which has transferred thereto. Likewise, the die-cut rectangular portion of the release-coated carrier web 503 is peeled therefrom, and this exposes the pressure-sensitive adhesive 505 on the undersurface of the panel of transparent film 507 that remains attached thereto. With these two liner panels removed, the pop-up element 501 is ready for placement between the pages of a pamphlet, at the fold line of the panels 541 of a letter or the like, as illustrated in FIG. 66, where it is shown in its 3-dimensional display orientation.
Depicted in FIG. 67 is a perspective of a pop-up element 551 generally similar to those which have been hereinbefore described; however, it is constructed to include a line of perforations 553 at the junction between the lower boundary of the flag section 555 and the oblique subpanels 557 of the supporting base. This arrangement allows the pop-up element 551 to be used as a distribution system for a sticker or the like that is formed as the flag section 555. This pop-up element is made using a pair of webs which are laminated to each other, and the mass production method shown in FIG. 60 can be used for this purpose. However, instead of utilizing a permanent adhesive as the bonding adhesive between the halves of the flag sections 555 of the pop-up 551, a pressure-sensitive adhesive 559 is used, and one of the facing surfaces of the webs, preferably the upper surface of the lower web as shown in FIG. 60, is provided with a silicone-release coating or the like. As a result, the pressure-sensitive adhesive 559 will adhere strongly to the undersurface of the flag section of the upper web (555a in FIGS. 68 and 69) and will release from the lower web (555b). Accordingly, the pop-up element 551 is distributed between the panels of a folded letter or the like, and pops up in attention-attracting orientation upon the opening of the letter. Thereafter, the recipient of the letter can detach the flag portion 555 along the line of perforations 553. As shown in FIG. 69, the recipient then simply peels the rear liner layer 555b from the detached flag portion, leaving the graphic flag portion sticker 555a with its pressure-sensitive adhesive pattern 559 ready to be affixed to a telephone, the exterior of a refrigerator, or in some other desired location.
Illustrated in FIG. 70 is still another alternative embodiment of a mass production method for making individual pop-up elements of a type resembling those depicted in FIGS. 27-29, which method results in the production of a stack of such individual pop-up elements. More specifically, a single continuous web 601 is employed which may be printed on both sides, printed on one side, or unprinted, as desired. However, to ease description, the web is shown as being printed on both sides with the lines along which die-cutting and the impression of the lines of weakness will eventually take place, as well as lines demarcating the series of individual blanks which are designed to create structurally identical pop-up elements. Sometime during the mass production method, a line of weakness 605 is preferably impressed parallel to and spaced inward from the left-hand edge of the web as illustrated in FIG. 70. Each blank 603 is intended to be eventually cut with a pair of die-cut lines along the lines 607 which are transverse to the line of weakness 605 and divide the base portion of each pop-up element into three panels which may be of essentially equal dimension. Alternatively, if desired, a single die-cut line 607 could be used that would divide the support section of the blank into two base panels of preferably equal dimensions. The line of weakness 605 then forms three lower subpanels 609a, 609b and 609c within these three base panels. The surfaces of two of the subpanels, the panels 609a and 609c, on one surface of the web are coated with a release coating pattern 611 so that pressure-sensitive adhesive coming in contact with this coated surface will release therefrom. A similar release coating pattern 613 is applied to the opposite surface of centrally located subpanel 609b. Thereafter, a pattern of pressure-sensitive adhesive 615 (in actuality a continuous strip as shown) is laid down to cover the entire region between the left-hand edge of the continuous web 601 and the line of weakness 605. Following application of the pressure-sensitive adhesive pattern 615, two transverse slits are cut along the lines 607. Thereafter, the continuous web 601 is severed by a reciprocating or rotary knife blade, as explained hereinbefore, to create a plurality of structurally identical individual pop-up elements 621 which are collated into a stack 617 with one element being stacked atop another. The stack 617 can be continuously compressed, or periodically substacks of a desired length can be removed and compressed. Following compression, individual pads each including a desired number of individual pop-up elements are split therefrom, for example, from the lower end of a continuously growing stack. These pads can then be trimmed, if desired, on one or more of the edges for neatness and then individually wrapped for distribution.
Shown in FIG. 71 is a pop-up element 621 which has been peeled or removed from such a pad of pop-up elements. The upper surfaces of the subpanels 609a and 609c carry pressure-sensitive adhesive 615 whereas the undersurface of the central subpanel 609b carries the pressure-sensitive adhesive 615. What has occurred is that, in the compressed stack of pop-up elements, because of the release coating pattern 613 that was applied to the upper surface of the central subpanel 609b, the pressure-sensitive adhesive 615 that was originally laid down upon that panel transfers to the undersurface of the central subpanel 609b of the next adjacent pop-up element 621 in the stack. If only two panels are employed, then one of the two subpanels 609 would carry the release coating beneath the pressure-sensitive adhesive. Because of the release coating patterns 611 that were applied to the undersurfaces of the subpanels 609a and 609c, the pressure-sensitive adhesive pattern 615 that was applied to those subpanels remains in place thereupon and does not transfer in the stack.
After one individual pop-up element 621 has been peeled from the stack, as illustrated in FIG. 71, it is used in substantially the same way as described and illustrated previously; for example, the pop-up element 621 is inserted between the panels 623 of the same page of a letter, generally along a crease line, so that, when the letter is opened by the recipient, the pop-up element 621 assumes the 3-dimensional attention-attracting configuration shown in FIG. 72.
Illustrated in FIG. 73 is yet another alternative embodiment of a mass production method for making individual pop-up elements which have a folded form generally resembling the pop-up elements comprised by the hinged panels 17, 19 of FIG. 8. The illustrated method results in the production of a stack of such individual pop-up elements in fan-folded configuration. More specifically, a single continuous web 631 is employed which may be printed on both sides, printed on one side, or unprinted, as desired. As in the previously described embodiment, the web 631 is designed to produce structurally identical pop-up elements from the series of adjacent blanks which are located next to one another along the longitudinal length of the web; however, each of the pop-up elements is formed with a pair of flag panels 635, 637 that are hinged together to provide a folded configuration which spreads apart in the display orientation.
The continuous web 631 has a longitudinal centerline 633 which separates right-hand flag panels 635 from left-hand flag panels 637 as shown in FIG. 73. A pressure-sensitive adhesive pattern 639 of generally triangular shape is applied near the leading edge of each blank of the web on each side of the longitudinal centerline 633. The adhesive patterns 639 are located in the regions which become base-subpanels and which support the pop-up element in its display orientation. Oblique lines of weakness 641 are preferably impressed in each of the blanks, located along the trailing edges of the adhesive patterns 639 to provide a clean fold at this point in the ultimate construction. If desired, the lines of weakness 641 can be impressed in the web prior to the application of the adhesive, or the lines of weakness can be omitted if desired.
A release coating pattern 643 is applied to the trailing region of each of the blanks, which may be a standard silicone base coating material that prevents pressure-sensitive adhesive from strongly adhering thereto. Following the application of the release coating patterns 643, the web 631 is folded along the longitudinal centerline 633, and the folded web is then perforated at the junctions between adjacent blanks so that each is separated from the next blank by a line of perforations 645. Thereafter, the folded perforated web is manipulated to form a stack 647 by fan-folding each of the pop-up units 649 in the opposite direction. The pressure-sensitive adhesive patterns 641 adhere only lightly to the release-coated flag portions 635, 637 of the adjacent pop-up elements 649 in the stack, but thereby serve to maintain the integrity of the folded stack 647. At the same time, the pressure-sensitive adhesive 639 is protected by the facing release-coated region and thus preserves its tack for ultimate use.
The pop-up elements 649 are generally distributed in groups of a desired number in this fan-folded stack form, and these groups may be conveniently overwrapped with a suitable wrapping material which also would adhere only lightly to the pressure-sensitive adhesive and thus also serves a protective function. When a pop-up element is desired to be employed, the pop-up element 649 at the end of the stack is detached along the line of perforations 645, and it is inserted generally along the fold line of a pair of hinged-together panels or sheets 651, for example, the facing pages of a menu or business advertisement. When the sheets 651 are opened, the pop-up element 649 assumes a 3-dimensional orientation with the flag panels 637 and 635 prominently displayed in attention-attracting fashion. If desired, the side edges of the stacks could be trimmed, generally as illustrated in FIG. 32, and the perforations 645 could be replaced by lines of weakness to facilitate folding.
Illustrated in FIG. 75 is one more alternative embodiment of a mass production method for making a plurality of individual pop-up elements of a type resembling those shown in FIGS. 70-72. The method produces these pop-up elements in the form of a continuous strip which could, if desired, be fed through a laser printer or the like so as to imprint a personalized message onto the flag portion of each individual pop-up element. Such a strip could be provided with flanking rows of pin-holes to facilitate feeding to a printer and could be distributed in roll form, if desired, as is known in this art. The continuous web may be preprinted with the reference indicia shown in FIG. 76. If desired, a background could be printed as a part of each flag section, or such background printing could be omitted, in which case plain white pop-up elements would be produced upon which the entire message would then be imprinted through a computer-operated laser printer or the like.
More specifically, a single continuous web 701 is employed for the pop-up elements, and a carrier web 703 of the same or a slightly wider width is employed. The web 701 is designed to provide a series of blanks each of which will be die-cut to form a structurally identical pop-up element. Shown on the web 701 is a reference line A which is spaced from the left-hand edge B of the web a distance such that it indicates the dividing line in the base section of each pop-up element that defines the lowermost subpanels that will become adhered to the supporting surface. The carrier web 703 has an undersurface 705 that is preferably coated with a release coating of a suitable silicone-based compound and an upper surface 707, the left-hand edge region of which is also preferably coated with a release coating in the region where a pressure-sensitive adhesive pattern 709 is provided. The width of the pressure-sensitive adhesive pattern 709 is such that it extends about to the reference line A when the lamination of the two webs is effected, and thus the pattern 709 generally occupies the region between the reference lines A and B. A strip of pressure-sensitive adhesive 711 is also provided along the right-hand edge region of the upper surface 707 of the carrier web 703. A release coating 713 is applied to the surface 715 of the web 701 in the region generally between a reference line C and the right-hand edge D of the web, which region is generally aligned with and has about the same width as the pressure-sensitive adhesive pattern 711.
Following lamination of the two webs, a pair of lines of weakness 721a and 721b are preferably impressed in the web, and then a die-cutting operation is effected to create the individual pop-up elements 723. The line 721b might optionally be omitted. A kiss-cutting technique is employed which cuts through just the upper web 701 and does not cut through the carrier web 703 to produce the series of generally rectangular pop-up elements 723 which remain in place on the carrier web, being held thereto by the pressure-sensitive adhesive patterns 709 and 711. The illustrated die-cutting produces a generally rectangular perimeter or profile for the element 723 with two transverse lines 724; i.e. transverse and preferably perpendicular to the line of weakness 721a. If desired, the lines of weakness 721a and 721b could be impressed at the same time as the kiss-cutting operation is effected.
As best seen in FIG. 76, each of the individual pop-up elements 723 has a flag section 725 and a supporting base section 727 in the form of three panels 729a, 729b and 729c of approximately equal dimensions (although unequal dimensions might be employed if desired), which panels are hinged to the flag section along the line of weakness 721b. The line of weakness 721a creates subpanels 731 which form the lowermost portions of each of these 3 panels. Alternatively, two rather than three panels 729 could be used.
After the individual pop-up elements 723 have been appropriately imprinted with a desired message while they are a part of the strip, an individual pop-up element 723 is removed from the carrier web layer as shown in FIG. 76. Because of the release coating 713 that was applied in the region of the undersurface 715 of the web 701 that becomes the flag section 725, the adhesive remains with the carrier web in this region; thus, the flag section 725 has no adhesive on its surface. Because the carrier web 703 carried a release coating on its upper surface 707 beneath the pressure-sensitive adhesive pattern 709, this pressure-sensitive adhesive transfers to the undersurface of each of the pop-up elements 723 in the region of all 3 subpanels 731. As a result, the undersurfaces of the 3 subpanels 731a, 731b and 731c in FIG. 76 carry pressure-sensitive adhesive 709.
To ready the pop-up element 723 for ultimate application, the central subpanel 731b is bent upward 180.degree. so that it lies against the remainder of the panel 729b with its adhesive pattern 709 facing upward; alternatively the two flanking subpanels 731a and 731c could be folded upward. With the subpanel 731b in this position, the pop-up element 723 is inserted between a pair of panels 741 of the same page of a letter or like, so that the lowermost edges of the subpanels 731a and 731c are aligned adjacent a crease line between panels; then the panels 741 are folded about the pop-up element so that the respective pressure-sensitive adhesive patterns 709 adhere to the facing surfaces of the letter panels 741. When the letter is opened by the recipient, the pop-up element 723 assumes the 3-dimensional, attention-attracting configuration shown in FIG. 78.
If desired, the entire surface 707 of the carrier web 703 could be coated with pressure-sensitive adhesive instead of only using the limited pattern 711 illustrated in FIG. 75, in which case, the entire region of the surface 715 of web 701 from reference line A through edge D would be coated with a release coating. Also, instead of using a pressure-sensitive adhesive pattern 711 on the upper surface 707 of the carrier web 703, a dry-residue adhesive, as described hereinbefore, could alternatively be employed in the region other than that covered by the pressure-sensitive adhesive pattern 709. With such a dry-residue adhesive, the use of the release coating pattern 713 could be omitted if desired from the web 701. As a still further alternative, instead of placing the pressure-sensitive adhesive pattern 709 on the surface 707 and having it transfer to the surface 715 of the web 701, the pressure-sensitive adhesive pattern 709 might be applied directly to the surface 715 in the region of the subpanels 731, in which case a release coating would still be applied onto the corresponding region on the surface 707 of the carrier web as described. Instead of producing a single strip of such printable pop-up elements, a wider web could be used to produce columns of pop-up elements three-abreast which could be appropriately cut into 81/2.times.11 inch sheets or the like for printing, if desired.
Although the invention has been described with regard to certain preferred embodiments, it should be understood that various changes and modifications as would be obvious to one having the ordinary skill in this art may be made without departing from the scope of the invention which is set forth in the claims appended hereto. For example, the pop-up elements can be made in various forms from a single sheet that is die-cut to form a plurality of subpanels, and instead of the pop-up elements 145 or 621 being formed with three base panels, only two base panels may be used, one having adhesive on one surface and the other having adhesive on the opposite surface. In addition, a single sheet can be folded upon itself to create an interconnected subpanel along the base of a pop-up element which carries adhesive on the exterior surface while a die-cut subpanel portion of the pop-up element carries adhesive on the opposite surface. Instead of folding the web 155 along the centerline 163 as depicted in FIG. 30, a line of weakness could be impressed at this location, and the pop-up element 167 could be distributed flat, relying on the pressure-sensitive adhesive patterns 161 to interconnect adjacent units in the stack.
Although fabrication from a continuous roll is often preferred, cut sheets containing multiple pop-up elements have advantages in some cases. Instead of die-cutting one blank at a time, two or more blanks might be die-cut as a group, which would allow for the creation of pop-up elements of different shapes within the same cut sheet; in such a case, the pop-up elements which result might have a different appearance but would be structurally identical in that the fold lines would be in precisely the same locations. Instead of applying a single liner web 65 in FIG. 12, a pair of webs might be applied parallel to each other. Moreover, if desired for a particular web-handling operation, an illustrated folding step may be replaced by severing and manipulating the severed portion of the web. Instead of employing pressure sensitive adhesive patterns to attach the pop-up elements to a carrier web or the like, one might protect the adhesive pattern by covering it with a release liner and then use separate pressure sensitive adhesive patterns, that leave no residue upon detachment, to position the pop-up elements for distribution. Adhesive patterns may also be applied to the corresponding surface portion of the web from that illustrated when surface-to-surface contact will subsequently be achieved. Furthermore, the adhesive patterns can be applied in any suitable manner; for example, instead of applying liquid adhesive in FIGS. 27 or 30, strips of double-faced adhesive material, similar to carpet-laying tape, might be used.
Although the term "pop-up" element is used throughout to refer to the illustrated sheet material structures, it is intended to broadly encompass any flat sheet material structures that are easily displayable in three-dimensional form as a result of pressure-sensitive adhesive carried thereupon.
Particular features of the invention are emphasized in the claims that follow.

Number	Name	Date
2131448	Lowen	Sep 1938
2360973	Pedersen	Oct 1944
3945870	Johnsen	Mar 1976
4479838	Dunsirn et al.	Oct 1984
4657612	Schoenleber	Apr 1987

	Number	Date
Parent	817281	Jan 1992
Parent	463118	Jan 1990
Parent	381047	Jul 1989

Methods of making pop-up promotional items

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