Multi-layer web and method for making automation-compatible multipage inserts
A multi-layer web and method for making an automation-compatible multi-layer web from a continuous web, where the multi-layer web can be separated into a plurality of inserts, such as booklets. The multi-layer web is constructed with adhesive and perforations such that it can be conveniently fed through an automated machine commonly known in the art to rapidly separate perforations and secure the resulting booklet to a printed publication.
The present invention relates, generally, to systems and methods for dynamic insertion and attachment of booklets into printed material such as periodicals and, more particularly, to a high-speed method for making convenient, automation-compatible booklet inserts for printed publications such as newspapers, magazines and the like.
BACKGROUNDIn the printing industry, magazines, newspapers and other publications often have special advertising inserts that include business reply cards, coupons and the like. Advertising is a particularly effective way for companies to promote new products and revive older brands. To be effective, advertising inserts need to be attractive to the consumer, and in addition, they must also be convenient to use and access. To make such inserts worth the investment for an advertiser, the inserts must be relatively inexpensive to manufacture. An advertiser must be able to supply a large quantity to be inserted into a publication in a short amount of time.
Many printers face the problem of how to place response cards, newsnotes, Post-it® or other adhesive note products, coupons, order forms, or other promotional pieces on press-finished products without adding another off-line finishing operation. A card application machine such as the Hurletron® ElectroCard® 3G (hereinafter a “Hurletron-type machine”) is commonly known among those skilled in the art and is disclosed in U.S. Pat. No. 5,968,307 and U.S. Pat. No. 6,006,669. Such a Hurletron-type machine can apply 100,000 pieces per hour to a moving web on high-speed gravure, offset or newspaper presses. The machine places these pieces with plus or minus one eighth of an inch accuracy on a designated page of a printed publication without disrupting the printing operation or adding off-line operations. The Hurletron-type machine attaches cards, Post-it® or adhesive products, coupons, samples, etc. to a moving web at press speed. These pieces are generally only single-ply. The promotional pieces are often supplied in a continuous card stream separated by “weak links” or perforations, or they can be supplied as loose, individual pieces via a carrier web. The Hurletron-type machine has a vacuum drum which runs at press speed. It also has a register cylinder which runs at approximately one-third press speed. This causes the perforations connecting the promotional pieces to “burst” between a nip wheel and the register cylinder, releasing the pieces to a vacuum drum. When required, a thin stream of hot-melt adhesive is applied as the promotional pieces are transported to the register cylinder. From the register cylinder, the Hurletron-type machine goes on to secure the promotional piece to the printed publication at press speed.
When securing booklet inserts into printed publications, advertisers generally supply the finished, loose, individual booklet inserts to be secured to the publication. Applying such loose, individual booklet inserts can be difficult and time-consuming to align, feed into a machine, and secure.
Consequently, a need exists for advertising inserts that are attractive and convenient. In addition, a need exists for an inexpensive method to manufacture such inserts rapidly and in a way that is compatible with existing web printing presses equipped with in-line card application capabilities.
SUMMARYIn one embodiment, a high speed method for making automation-compatible, multi-page inserts includes providing a continuous web of paper with a longitudinal edge. An adhesive area is formed adjacent the longitudinal edge and a multi-layer web is formed from the continuous web such that each layer is bound by adhesive to an adjacent layer along the longitudinal adhesive area. The multi-layer web is perforated along a continuous longitudinal line and along a plurality of latitudinal lines to define individual pages of the multi-page inserts. The multi-layer web is configured for automated insertion of the multi-page inserts into printed publications.
In another embodiment, a perforated, continuous multi-layered web includes a first continuous web with a top longitudinal edge, and a bottom longitudinal edge. A longitudinal area of adhesive resides along the top longitudinal edge such that the paper is divided into a longitudinal adhesive area and a non-adhesive area. At least one additional continuous web is provided congruent to the first continuous web, where each continuous web is bonded to the adjacent continuous web at the longitudinal adhesive area to create a multi-layer web. A longitudinal perforation extends through the multi-layer web along a continuous longitudinal line. A plurality of latitudinal perforations extend through the multi-layer web along a plurality of latitudinal lines defined adjacent each latitudinal adhesive area and extending from the top longitudinal edge to the bottom longitudinal edge.
In yet another embodiment, a high speed method for making automation-compatible multi-page inserts includes providing a continuous web with a top side, a bottom side, a top longitudinal edge, and a bottom longitudinal edge. The web is fed into a master pull roller, where the master pull roller controls the speed at which the web moves. A longitudinal area of adhesive is applied to the paper along the top longitudinal edge such that the paper is divided into a longitudinal adhesive area and a non-adhesive area. A plurality of evenly spaced latitudinal areas of adhesive are applied to the continuous web between the top longitudinal edge and the bottom longitudinal edge such that a plurality of latitudinal adhesive areas are formed and a plurality of non-adhesive areas are defined by the rectangular boundaries having edges along the longitudinal adhesive area, the bottom longitudinal edge, and the latitudinal adhesive areas. The continuous web of paper is bound to itself along the longitudinal adhesive area and the plurality of latitudinal adhesive areas to create a multi-layer web. A longitudinal perforation is created by perforating the multi-layer web along a continuous longitudinal line defined parallel to the boundary between the longitudinal adhesive area and the non-adhesive areas. A plurality of latitudinal perforations are created by perforating the multi-layer web along a plurality of latitudinal lines defined adjacent each latitudinal adhesive area and extending from the top longitudinal edge to the bottom longitudinal edge such that the plurality of latitudinal adhesive areas are positioned to act as a bindings for multi-page inserts defined by the latitudinal perforations. The multi-layer web is configured for automated insertion of the multi-page inserts into printed publications.
It will be appreciated that for simplicity and clarity of illustration, machine elements illustrated in the Figures have not necessarily been drawn to scale. For example, the dimensions of some of the elements are exaggerated relative to others for clarity. Further, where considered appropriate, reference numerals have been repeated among the Figures to indicate corresponding elements.
DETAILED DESCRIPTIONThe present invention provides a high-speed method for making convenient, automation-compatible inserts for printed publications such as newspapers, magazines, or other printed media. The present invention further provides a perforated, continuous multi-layered web that can be fed into an automated machine for inserting booklets into printed publications, such as a Hurletron-type machine. Because of the continuous nature of the multi-layered web produced by the present method, it is compatible with the high-speed Hurletron-type machines, which can separate perforations and secure the resulting multi-layered booklet inserts into printed publications. Hurletron-type machines are well known in the art. Although the exemplary embodiments of the invention described below generally relate to making automation-compatible booklet inserts, those skilled in the art will appreciate that the method and product of the invention can equally be utilized and incorporated into a variety of printing methods.
Illustrated in
In
The next step in the illustrative embodiment is for the continuous web of paper 11 to be processed by the infeed device 20. The infeed device 20 manages the amount of tension in the web, and controls amount of paper supplied to rest of line to allow for consistent feeding throughout the process. Such a device is well known to those skilled in the art. The infeed device 20 supplies the continuous web of paper 11 to the master pull roller 30.
The master pull roller 30 is generally designed to inform the rest of the servo driven line what speed to operate based on a repeat mark found on the printed, continuous web of paper 11. This device is also well known by those of skill in the art.
In another embodiment, illustrated in
As depicted in
The continuous web 11 with a strip of longitudinal adhesive is next fed into the first plow station 50, which, in this embodiment, folds the continuous web 11 in half along a longitudinal line parallel with the top longitudinal edge 16 and half way between the top longitudinal edge 16 and the bottom longitudinal edge 17. It should be noted that in alternative embodiments, many variations are possible as the plow station 50 could fold the continuous web more than once and in a number of locations. Furthermore, the hot melt gluer 40 could apply more than one strip of adhesive that would eventually align with the top longitudinal edge of the insert. In addition, it should be noted that although the illustrative embodiment has two plow stations, more plow stations can be used to create inserts with more layers.
After exiting the first plow station 50, the continuous web 11 has become a multi-layer web of paper 12, which has been folded in half and the two layers are bound together along the longitudinal adhesive area 42, illustrated in
As in the first plow station 50, the second plow station 60 folds the web that enters. In this embodiment, the web entering the second plow station 60 is a two-layer web of paper with an area of exposed longitudinal adhesive on the top side 2. The second plow station 60 folds the web in half as in the first plow station 50, thus binding one two-layer web to the other two-layer web to create a four-layer web, which is referred to as a multi-layer web 12.
It should be noted that in this embodiment, the multi-layer web of paper 12 has been folded. To create a booklet-style insert the folds must be slit to enable the booklet to have loose pages. As illustrated in
In an alternative embodiment, the final inserts are booklets with a binding near the left edge 18. In order to create such a binding, a plurality of latitudinal adhesive areas must be applied to the multi-layer web. This application of latitudinal adhesive can take place within the plow stations. In the illustrative embodiment depicted in
As illustrated in
As in the first plow station 50, the second plow station 60 has a metering roller 65 which again applies a latitudinal area of adhesive just before the folding process. As such, the multi-layer web of paper 12 has a plurality of evenly spaced latitudinal adhesive areas 44 which are created as the web progresses through the plow stations. The latitudinal adhesive and the layers of paper between them will be collectively referred to as the latitudinal adhesive areas 44.
In another embodiment depicted in FIG., ribbon shifters can be placed where the first and second plow stations 50 and 60 are located to accomplish the task of creating a multi-layer web of paper 12, 13 by cutting or slitting the web and shifting two or more layers upon each other instead of folding the layers upon each other. Ribbon shifters are commonly known by those of skill in the art.
In another embodiment, the hot melt gluer 40 can apply adhesive in locations such that portions of one web layer can be completely glued to another web layer to form a resulting layer of increased thickness. This can be useful for an embodiment where the desired result is to combine two pages of the final booklet insert in order to increase their thickness to seven thousandths of an inch to comply with the thickness required for the mailing of post cards, business reply mail and the like.
As depicted in
In another embodiment illustrated in
It should be noted that the preferred embodiment produces inserts with a maximum length of 8.5 inches and a minimum length of 3 inches. The preferred width is in the range having a maximum of 6 inches and a minimum of 3 inches. In the preferred embodiment, it should also be noted that the perforated, continuous multi-layer web 13 has a preferred maximum thickness of 0.040 inches. To conform to some of the standard equipment in the field, the preferred embodiment has a length of 5.9167 inches between each latitudinal perforation 74.
From the rotary die cutter 70, the perforated, continuous multi-layer web of paper 13 goes to a fan folder 80 in the embodiment illustrated in
In the rewinding embodiment, the perforated, continuous multi-layer web of paper 13 is fed into the rewinding machine 90 where it rewinds the perforated, continuous multi-layer web of paper 13 into a wound roll 92. This wound roll 92 is another convenient delivery system which can be fed into a Hurletron-type machine at a later time. In yet another alternative embodiment, the perforated, continuous multi-layer web of paper 13 can be fed directly into a Hurletron-type machine without being stacked or wound.
Thus it is apparent that there has been described a method for making automation-compatible booklet inserts for printed publications that fully provides the advantages set forth above. Those skilled in the art will recognize that numerous modifications and variations can be made without departing from the spirit of the invention. For example, the perforated, continuous multi-layer web can be configured to be fan folded or wound for convenient feeding into a Hurletron-type machine. The multiple layers of the web, for example, can come from folding, shifting or starting with multiple webs. Accordingly, all such variations and modifications are within the scope of the appended claims and equivalents thereof.
Claims
1. A high speed method for making automation-compatible, multi-page inserts comprising the steps of:
- providing a continuous web of paper with a longitudinal edge;
- forming an adhesive area adjacent the longitudinal edge;
- forming a multi-layer web from the continuous web such that each layer is bound by adhesive to an adjacent layer along the longitudinal adhesive area;
- perforating the multi-layer web along a continuous longitudinal line;
- perforating the multi-layer web along a plurality of latitudinal lines to define individual pages of the multi-page inserts; and
- configuring the multi-layer web for automated insertion of the multi-page inserts into printed publications.
2. The method of claim 1 further comprising the step of forming a plurality of spaced latitudinal areas of adhesive on the continuous web such that the multi-layer web is bound together along the longitudinal adhesive area and the plurality of latitudinal adhesive areas.
3. The method of claim 1 wherein configuring the multi-layer web comprises winding the multi-layer web around a cylinder to create a roll.
4. The method of claim 1 wherein configuring the multi-layer web comprises fan folding the multi-layer web along the latitudinal perforations to create a continuous stack of inserts.
5. The method of claim 1 further comprising the step of feeding the multi-layer web into a machine for automated insertion of the multi-page inserts into printed publications.
6. The method of claim 5 further comprising the step of separating the latitudinal perforations of the multi-layer web to create individual inserts.
7. The method of claim 5 further comprising the step of securing the multi-page inserts to the printed publications with an adhesive.
8. The method of claim 1 further comprising the step of feeding the continuous web through a printing press before forming the adhesive area adjacent the longitudinal edge.
9. The method of claim 8 wherein desired content is printed onto the continuous web in the printing press.
10. The method of claim 2 wherein forming a plurality of spaced latitudinal adhesive areas comprises applying glue with a metering roller.
11. The method of claim 1 wherein forming the multi-layer web comprises folding the multi-layer web along at least one fold line parallel to the longitudinal edge.
12. The method of claim 11 wherein the method further comprises separating folded layers of the multi-layer web with a slitting device.
13. The method of claim 1 wherein forming a multi-layer web comprises slitting the continuous web and shifting the resulting layers onto each other.
14. The method of claim 1 wherein forming a multi-layer web comprises providing more than one continuous web initially.
15. The method of claim 1 wherein the method further comprises die cutting the continuous web to form a plurality of slots to enable adhesive to bind one layer to a non-adjacent layer through the slot.
16. The method of claim 1 further comprising the step of bonding one or more layers of the multi-layer web together to form at least one thicker layer within the multi-layer web.
17. The method of claim 1 further comprising the step of kiss cutting one or more layers of the multi-layer web to create a flap that can be opened to reveal content on an adjacent layer.
18. The method of claim 1 further comprising the step of creating one or more removable labels by kiss cutting a first layer of the multi-layer web in an enclosed pattern, applying adhesive to one side of the multi-layer web within the enclosed pattern, applying a release coating on an adjacent second layer of the multi-layer web, and bonding the first and second layers together.
19. The method of claim 1 further comprising the step of creating one or more removable envelopes within the multi-page inserts by applying a remoistenable glue to the continuous web, applying adhesive to the continuous web and folding the web onto the adhesive such that a pocket is formed.
20. A high speed method for making automation-compatible multi-page inserts comprising the steps of:
- providing a continuous web with a top side, a bottom side, a top longitudinal edge, and a bottom longitudinal edge;
- feeding the web into a master pull roller, wherein the master pull roller controls the speed at which the web moves;
- applying a longitudinal area of adhesive to the paper along the top longitudinal edge such that the paper is divided into a longitudinal adhesive area and a non-adhesive area;
- applying a plurality of evenly spaced latitudinal areas of adhesive to the continuous web between the top longitudinal edge and the bottom longitudinal edge such that a plurality of latitudinal adhesive areas are formed and a plurality of non-adhesive areas are defined by the rectangular boundaries having edges along the longitudinal adhesive area, the bottom longitudinal edge, and the latitudinal adhesive areas;
- binding the continuous web of paper to itself along the longitudinal adhesive area and the plurality of latitudinal adhesive areas to create a multi-layer web;
- creating a longitudinal perforation by perforating the multi-layer web along a continuous longitudinal line defined parallel to the boundary between the longitudinal adhesive area and the non-adhesive areas;
- creating a plurality of latitudinal perforations by perforating the multi-layer web along a plurality of latitudinal lines defined adjacent each latitudinal adhesive area and extending from the top longitudinal edge to the bottom longitudinal edge such that the plurality of latitudinal adhesive areas are positioned to act as a bindings for multi-page inserts defined by the latitudinal perforations;
- configuring the multi-layer web for automated insertion of the multi-page inserts into printed publications.
21. A perforated, continuous multi-layered web comprising:
- a first continuous web with a top longitudinal edge, and a bottom longitudinal edge;
- a longitudinal area of adhesive along the top longitudinal edge such that the paper is divided into a longitudinal adhesive area and a non-adhesive area;
- at least one additional continuous web, congruent to the first continuous web, wherein each continuous web is bonded to the adjacent continuous web at the longitudinal adhesive area to create a multi-layer web;
- a longitudinal perforation extending through the multi-layer web along a continuous longitudinal line; and
- a plurality of latitudinal perforations extending through the multi-layer web along a plurality of latitudinal lines defined adjacent each latitudinal adhesive area and extending from the top longitudinal edge to the bottom longitudinal edge.
22. The product of claim 21 further comprising a plurality of evenly spaced latitudinal areas of adhesive on the first continuous web between the top longitudinal edge and the bottom longitudinal edge such that a plurality of latitudinal adhesive areas are defined, and a plurality of non-adhesive areas are defined by the rectangular boundaries having edges along the longitudinal adhesive area, the bottom longitudinal edge, and the latitudinal adhesive areas;
23. The product of claim 21 wherein the multi-layer web comprises a continuous roll of webbing wound around a cylinder.
24. The product of claim 21 wherein the multi-layer web comprises a stack of continuous webbing fan folded along the latitudinal perforations.
25. The product of claim 22 wherein the longitudinal perforation comprises a continuous longitudinal line defined parallel to the boundary between the longitudinal adhesive area and the non-adhesive areas.
26. The product of claim 22 wherein the multi-layered web further comprises desired content printed on at least one of the non-adhesive areas.
27. The product of claim 21 further comprising adhesive underneath the longitudinal adhesive area of the multi-layer web such that the individual inserts can be secured to printed publications with the adhesive.
28. The product of claim 22 wherein the latitudinal adhesive is positioned to act as a binding for a booklet formed by the multiple layers of the multi-layer web.
29. The product of claim 21 wherein one or more layers of the multi-layer web are bonded together to form a thicker layer.
30. The product of claim 22 wherein one layer of the multi-layer web includes a flap that can be opened up to reveal content on the layer below.
31. The product of claim 22 wherein the multi-layer web includes one or more removable labels comprising a first layer in an enclosed pattern having adhesive on one side within the enclosed pattern, a release coating on an adjacent second layer, and a bond between the first and the adjacent second layer.
32. The product of claim 22 wherein the multi-layer web further comprises one or more removable envelopes comprising a remoistenable glue to the web during the printing process, applying adhesive and folding such that a pocket is formed.
Type: Application
Filed: Apr 2, 2007
Publication Date: Oct 2, 2008
Inventor: Peter R. Hudetz (Plainfield, IL)
Application Number: 11/732,266
International Classification: B65D 65/28 (20060101);