Multi-layer web and method for making automation-compatible multipage inserts

Abstract

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.

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.