GB2420740A

GB2420740A - Printable laminated article

Info

Publication number: GB2420740A
Application number: GB0523348A
Authority: GB
Inventors: Mark Peter Morrish; John Morrish
Original assignee: Individual
Current assignee: Individual
Priority date: 2004-11-19
Filing date: 2005-11-16
Publication date: 2006-06-07
Also published as: GB0523348D0

Abstract

A printable laminated article (10, 27), kit and methods for making and modifying the same, the laminated article comprising a top sheet laminated with a backing sheet. The top sheet is printable and cut to define a removable shaped element (14, 54, 84, 19, 21) and at least one waste element (16, 86, 23). In one embodiment the removable shaped element is formable into a predetermined body form, such as a hat, bib, mask, box, novelty item etc., after removal from the backing sheet and waste element. In another embodiment the removable shaped element is an insertion element that may be inserted into an item of stationary such as a desktop calendar, notebook, diary etc.

Description

1 2420740

PRINTABLE LAMINATED ARTICLE

The present invention relates to printable laminated articles. It relates particularly, but not exclusively, to printable products that are subsequently formable into body forms such as hats, bibs, masks, boxes, decorations novelty items and point of sale and sales promotion items, and to articles of stationery such as a wire- or plastic-bound desktop calendars, notebooks, diaries or the like. The present invention may be used, for example, to personalise such an article, or a plurality of such articles.

Card hats, facemasks, bibs, boxes, other novelty products and stationery are known. For example, known card hats are available that are customised with logos for businesses as promotional hats. These may be used in particular as children's hats. Such products may be used for marketing and advertising. Alternatively, they may be used as souvenirs and at party events.

Typically, products such as those described above are formed as follows. The required text and/or image is printed onto card. The card is then cut to a desired two dimensional shape. The two dimensional shape may include an arrangement of slits or slots to allow the card to be formed into the desired body form (a three dimensional shape) . Typically, the product is only formed into the desired body form at the point of use, since the flat form of the product is useful for storage and transport of large quantities of the products.

As another example, wire bound desktop calendars are known. In particular, the easel type of desktop calendar is of the type where the calendar sits upright on a surface. The tops of the pages are bound using looped wire binding through small square apertures in the pages.

When the pages of the calendar are turned, the apertures are guided around the binding so as to fully expose the entirety of the next page. The binding is normally (but not exclusively) a comb shape, the teeth of the comb extending from the spine of the comb. The pages are bound by first punching the apertures. Then the teeth of the comb are pushed through the apertures. The teeth are curved so that they meet the spine of the comb so as to prevent the pages from being removed from the binding.

Typically, the comb is formed from bent wire, plastic- coated bent wire or from plastics.

Other items of stationery employing similar binding are also known, e.g. notebooks and diaries.

Such stationery items may be used for marketing and advertising. Alternatively, they may be used as souvenirs. In the case of desktop calendars, the required images and/or text for marketing, advertising or souvenir purposes is usually applied to a card support which is folded to form a supporting easel. This card support is incorporated into the calendar before binding of the pages.

The present inventor has realised that the above manufacturing processes can work well for large volumes of novelty items. However, it is very expensive per item to have a relatively small number (e.g. tens or several hundreds) of such novelty or stationary articles manufactured. Furthermore, the time taken for manufacture and delivery of such novelty or stationary articles can be quite long. For small businesses, other small enterprises and families, the cost and delay in obtaining these novelty articles can be prohibitive.

The present inventor has realised that it would be advantageous to provide a system that allows small numbers of such products to be produced using printing equipment that need not be specific to the task of printing such products.

One way to apply suitable text and/or images to printable surfaces is to use a digital printing technique, e.g. using a desktop printer or digital printing machine or photocopier. However, the present inventor has realised that the article to be printed might require a relatively complex shape to allow it to form a useful body shape or to be inserted into an item of stationary. Such complex shapes do not work well with desktop printers, or indeed with other printing technologies that require feeding of the sheet to be printed.

Additionally, the present inventor has realised that it is possible to add a customised insert carrying images and/or text for marketing, advertising or souvenir purposes to an article of stationery such as a desktop calendar after the other pages have been bound. In this way, it is possible to add an insert of a desired design to an otherwise standard article of stationery. The advantage of this is that the standard article of stationery can be prepared, e.g. as described above, but that the insert can be prepared later and then inserted into the article. In this way, the overall cost of preparing relatively small numbers of bespoke stationery articles can be significantly reduced.

It is possible to provide an adhesive strip that has the required shape to allow insertion into the binding. Such an adhesive strip can be affixed to an additional sheet (e.g. with the required image on it) and then inserted into the binding. However, this solution is not preferred since it is difficult and time- consuming to fix the adhesive strip onto the additional sheet in a straight manner. Furthermore, this approach tends to bulk up the binding side of the product, which is undesirable.

Further problems with the required shape of such products are that the cutting operation to form the shape tends to be difficult to perform on more than a few sheets at a time, and that it is difficult subsequently to remove the waste material that is generated by the cutting operation.

The present invention has been devised in order to address one or more of the above problems, preferably to ameliorate, avoid or even overcome one or more of the above problems.

Accordingly, in a first aspect, the present invention provides a printable laminated article having a top sheet laminated with a backing sheet, the top sheet being printable and being cut to define a removable shaped element having a perimeter and at least one waste element, the removable shaped element being in flat form when laminated with the backing sheet and being formable into a predetermined body form after removal from the backing sheet and waste element, wherein the removable shaped element has at least one concave cut feature at its perimeter or a cut feature wholly or partly disposed within its perimeter, said cut feature defining first and second cut surfaces that move relative to each other to accommodate the shape change from the flat form to the body form.

In this way, the invention allows a user to personalise the pre-cut removable shaped element of the top sheet as required before removal from the backing sheet and waste element and then remove the shaped element from the backing sheet and waste element to form the shaped element into the required body form.

In this way, the overall cost of preparing relatively small numbers of bespoke printed body form articles can be significantly reduced.

Preferred and/or optional features are set out below.

These are applicable to any of the aspects of the invention, either independently or in any combination.

Preferably, the at least one cut feature forms all or part of a cut pattern in the removable shaped element.

In this case, the cut pattern may open to accommodate the shape change from the flat form to the body form. The cut feature may be at least one slit that is closed in the flat form and open in the body form. Most preferably, the cut feature is a pattern of spiral slits interposed between a central portion and a rim portion, the central portion being moveable out of plane from the rim portion by opening of the spiral slits.

The removable shaped element may include attachment formations that cooperate to attach to each other in the body form to retain the shaped element in the body form.

In this way, the shaped element may be locked into the body form. There may be a range of attachment formations that are present for use on the shaped element.

Preferably, the body form of the shaped element is adjustable in size by adjusting the selection of the attachment formations used to retain the shaped element in the body form. The attachment formations may include, for example, at least one tab and/or at least one slot.

In some embodiments, the body form may be achieved in part by folding of the shaped element. This folding may be achieved using pre-formed lines of weakness in the shaped element. Preferably, the lines of weakness are scored or perforated lines. In this way, the lines of weakness may be formed into the shaped element as part of the process of manufacturing the laminate, and before printing of the desired images onto the top sheet.

Preferably, the body form of the article is selected from one of: a hat, a cap, a bib, a mask and a children's party product.

In a second aspect, the present invention provides a printable laminated article having a top sheet laminated with a backing sheet, the top sheet being printable and being cut to define a removable shaped element and at least one waste element, the removable shaped element being in flat form when laminated with the backing sheet and being formable into a predetermined container form having a base and walls.

In this way, the invention may be applied specifically to the case where the body form of the shaped element is a container. Customisation of such containers (e.g. a box), particularly at small scale, is difficult to achieve using conventional techniques.

Preferably, the removable shaped element is foldable along boundaries between the base and/or walls. This folding may be achieved along preformed lines of weakness in the shaped element. Most preferably, these lines of weakness are scored lines or lines of perforations formed in the removable shaped element.

Preferably, the removable shaped element includes a portion shaped to be an integral lid of the container.

Alternatively or additionally, the top sheet further includes a second removable shaped element, the second removable shaped element being shaped to be a separable lid for the container.

The following preferred and/or optional features are intended to be equally applicable to either of the first or second aspects, and may also be applied to any other aspect of the invention.

Preferably, the printable laminated article has at least one straight edge and preferably two, three or four straight edges. This allows the printable laminated article to be more easily fed through a printer than would otherwise be the case. Preferably, the article is of a standard stationary size such as A4, A3, etc. Such sizes are particularly applicable to desktop printers.

Preferably, the shaped element, after removal from the backing sheet, is non-adhesive. As explained below, the backing sheet, after removal of the shaped element, may be adhesive or non-adhesive.

Preferably, the printable article is formed from laminated card, typically dry laminated card. The backing sheet may be a siliconised sheet of thin craft paper. Typically, the top sheet is a sheet of paper, thin card or synthetic material such as plastic that can be easily and permanently printed, for example by an inkjet or laser printer. The printable article may be of the form of laminated product known as "dry peel". Such a product allows the top sheet to be peeled off the backing release paper without leaving an adhesive or sticky deposit on the rear of the face paper.

As an alternative, the printable article may be formed from a modified conventional laminated sheet. Such sheets are typically used to create printable adhesive labels. Conventionally, the label side of the laminate is cut to the desired shape, and has an adhesive applied.

Conventionally, the backing sheet is not cut. In use in the present invention, such a sheet may be modified so that what would normally be considered to be the backing sheet is actually the top sheet and the adhesive sheet is actually the backing sheet. The surface of the top sheet not contacting the adhesive sheet is printable and typically is made thicker than a conventional backing sheet. Furthermore, the top sheet may be cut to the desired shape to provide the shaped element. In use, the shaped element is peeled from the adhesive sheet, leaving the waste element and the adhesive sheet behind. This modified embodiment therefore is effectively the same as the dry peel embodiment above, except that the "backing sheet", after removal of the shaped element, is adhesive, rather than non-adhesive. In both preferred embodiments, the shaped element is non-adhesive.

Preferably, the removable shaped element is formed in one piece.

Preferably, the shaped element is formed by cutting the top sheet of the printable article (to form the shaped element and the waste element from said top sheet) but without cutting the backing sheet, so that the backing sheet remains in one piece.

In a third aspect, the present invention provides a kit including one or more printable laminated articles according to the first or second aspect, the kit further including instructions for printing onto the top sheet of the laminate before removal of the removable shaped element from the backing sheet.

In this way, it is envisaged that the printable laminated inserts may be sold as a kit, so that a user can create several customised body forms according to need.

Preferably, the kit further includes a software product for managing the printing of the printable laminated article.

In a fourth aspect, the present invention provides a method of producing a printable laminated article including the steps of: providing a laminate of a printable top sheet and a backing sheet; and cutting a shaped removable element of a desired shape into the top sheet, leaving the shaped removable element, a waste element and the backing sheet still laminated and in flat form, said shaped removable element having a perimeter and being formable into a predetermined body form after removal from the backing sheet and waste element wherein the removable shaped element has at least one concave cut feature at its perimeter or a cut feature wholly or partly disposed within its perimeter, said cut feature defining first and second cut surfaces that move relative to each other to accommodate the shape change from the flat form to the body form.

In a fifth aspect, the present invention provides a method of producing a printable laminated article including the steps of: providing a laminate of a printable top sheet and a backing sheet; and cutting a shaped removable element of a desired shape into the top sheet, leaving the shaped removable element, a waste element and the backing sheet still laminated and in flat form, said shaped removable element being formable into a predetermined container form having a base and walls after removal from the backing sheet and waste element.

Preferably, the shaped removable element is formed by cutting the top sheet but without cutting the backing sheet, a process known as "kiss cutting", so that the backing sheet remains in one piece.

In a sixth aspect, the present invention provides a method of customising a printable laminated article including the steps of: providing a printable laminated article according to the first or second aspect; and then printing a customising image or customising text onto the top sheet of the laminated article; and then removing the printed removable shaped element from the backing sheet and the waste element; and then forming the printed removable shaped element from a flat form to a body form.

Preferably, the printing step prints at least part of the customising image onto the waste element. In this way, it can be ensured that the image extends substantially to the perimeter of the removable shaped element.

Preferably, the printing step is carried out using a desktop printer.

In a seventh aspect, the present invention provides a printable laminated article having a top sheet laminated with a backing sheet, wherein the top sheet is a thin substrate with a printable surface, the top sheet being cut to define a removable shaped element having a perimeter and at least one waste element, said at least one waste element abutting against the removable shaped element at its perimeter, the removable shaped element being in flat form when laminated with the backing sheet and being foldable or bendable into a predetermined body form after removal from the backing sheet and waste element, wherein the removable shaped element has at least one inward cut feature at its perimeter or a cut feature wholly or partly disposed within its perimeter, said cut feature defining first and second cut surfaces that move relative to each other to accommodate the shape change from the flat form to the body form, the body form having concave or convex cross-sections in each of two or more orthogonal directions.

In an eighth aspect, the present invention provides a printable laminated article having a top sheet laminated with a backing sheet, the top sheet being printable and being cut to define a removable shaped element and at least one waste element, the removable shaped element being in flat form when laminated with the backing sheet and being formable into a predetermined container form having a base and walls, opposing walls being spaced apart from each other.

In a ninth aspect, the present invention provides a method of producing a printable laminated article including the steps of: providing a laminate of a top sheet and a backing sheet, wherein the top sheet is a thin substrate with a printable surface; and cutting a shaped removable element of a desired shape into the top sheet, leaving the shaped removable element, a waste element and the backing sheet still laminated and in flat form, said shaped removable element having a perimeter, said at least n one waste element abutting against the removable shaped element at its perimeter, and said removable element being formable into a predetermined body form after removal from the backing sheet and waste element, wherein the removable shaped element has at least one inward cut feature at its perimeter or a cut feature wholly or partly disposed within its perimeter, said cut feature defining first and second cut surfaces that are moveable relative to each other to accommodate the shape change from the flat form to the body form, the body form having concave or convex cross-sections in each of two or more orthogonal directions.

In a tenth aspect, the present invention provides a method of producing a printable laminated article including the steps of: providing a laminate of a printable top sheet and a backing sheet; and cutting a shaped removable element of a desired shape into the top sheet, leaving the shaped removable element, a waste element and the backing sheet still laminated and in flat form, said shaped removable element being formable into a predetermined container form having a base and walls after removal from the backing sheet and waste element, opposing walls in the body form being spaced apart from each other.

In an eleventh aspect, the present invention provides a method of customising a printable laminated article including the steps of: providing a printable laminated article according to the seventh or eighth aspect; and then printing a customising image or customising text onto the top sheet of the laminated article; and then removing the printed removable shaped element from the backing sheet and the waste element; and then forming the printed removable shaped element from the flat form to the body form.

Preferably, the printing step prints at least part of the customising image onto the waste element, so that the image extends to the edge of the shaped removable element.

In a twelfth aspect, the present invention provides a stationery article kit including an article of stationery having a plurality of pages bound by a binding that extends through apertures in the pages, the apertures being guided around the binding when the pages are turned, and a printable insert for insertion into the / binding of said article after binding of said pages, said printable insert being a laminate of a top sheet and a backing sheet, said top sheet being cut to define an insertion element and a waste element, the backing sheet retaining the insertion element and the waste element of the top sheet together.

The kit allows a user to personalise the insertion element as required and then fit it to the stationery article to provide a personalised stationery article.

Preferred and/or optional features applicable to any of the aspects of the invention either independently or in any combination are set out below.

It is preferred that the printable insert has straight edges in order to allow it to be printed on easily using conventional laser, inkjet and/or digital printers.

Furthermore, the size of the printable insert is preferably a standard paper size such as A4, A3, etc., for ease of feeding through such printers.

Preferably, the binding includes looped binding elements extending through the apertures. Such loops allow the pages to be turned so as to expose the entirety of the next page. Typically, the binding is a comb or spiral binding.

Preferably, the apertures in the pages of the article of stationery are closed holes. This allows for firmer securing of the pages in the article. However, the insertion element of the top sheet preferably includes open apertures. This allows the insertion element to be inserted into the binding easily. Preferably, the open apertures have fingers extending between them, the fingers being for insertion between elements of the binding. Furthermore, the fingers preferably have barbs formed at their free ends for retaining the insertion element in the binding. These barbs typically do not particularly hinder the insertion of the insertion element into the binding but they assist in preventing the removal of the insertion element from the binding.

Preferably, the insertion element has at least eight, preferably twelve or more, aperatures for engagement with the binding.

It is contemplated that the insertion element could be inserted at the top of the stationery article, i.e. as a cover sheet. However, it is preferred that the insertion element itself is covered during use of the stationery article. A cover element such as a transparent or translucent sheet, or a sheet (formed, e.g. from stiffer material than the insertion element) having a window through it, may be bound with the other leaves in the article for this purpose. In this way, the insertion element is protected by the cover sheet, whilst still being (at least partially) visible through it.

Preferably, the kit further includes an insertion tool having a shape corresponding to spaces between elements of the binding. Preferably, the insertion tool is comb shaped, the teeth of the comb being for inserting corresponding fingers of the insertion element into the binding. Preferably, the insertion tool is (or at least the teeth of the insertion tool are) stiffer than the insertion element so as to allow the easy insertion of the insertion element into the binding.

Preferably, the kit further includes instructions for printing onto the insertion element of the top sheet before removal of the insertion shape from the backing sheet and the waste element. The kit may include software to allow suitable formatting for such printing.

Typically, the article of stationery is a calendar, a notebook or a diary. It may be preferred to personalise the article of stationery, e.g. with images and/or information relating to a business (as a marketing device), a particular person (as a greeting) or a particular place (as a souvenir) The kit may include a plurality of articles of stationery and a plurality of printable inserts. In this way, a user may modify a set of such articles as desired, either with the same design or with different designs such as personalised designs.

Preferably, the insertion element, after removal from the backing sheet, is non-adhesive. As explained below, the backing sheet, after removal of the insertion element, may be adhesive or non-adhesive.

Preferably, in any aspect of the invention, the backing sheet has substantially the same shape as the top sheet.

For example, the backing sheet may be coterminous with the top sheet.

Preferably, the printable insert is formed from laminated card. The backing sheet may be a siliconised sheet of thin craft paper. Typically, the front sheet is a sheet of paper, thin card or synthetic material such as plastic that can be easily and permanently printed, for example by an inkjet or laser printer. The printable insert may be of the form of laminated product known as "dry peel".

Such a product allows the front sheet to be peeled off the backing release paper without leaving an adhesive or sticky deposit on the rear of the face paper.

As an alternative, the printable insert may be formed from a modified conventional laminated sheet. Such sheets are typically used to create printable adhesive labels. The label side of the laminate is conventionally cut to the desired shape, and has an adhesive applied.

The backing sheet is conventionally not cut. In use in the invention, such a sheet may be modified so that what would normally be considered to be the backing sheet is actually the top sheet and the adhesive sheet is actually the backing sheet. The surface of the top sheet not contacting the adhesive sheet is printable and typically is made thicker than a conventional backing sheet.

Furthermore, the top sheet may be cut to the desired shape to provide the insertion element. In use, the insertion element is peeled from the adhesive sheet, leaving the waste element and the adhesive sheet behind.

This modified embodiment therefore is effectively the same as the dry peel embodiment above, except that the "backing sheet", after removal of the insertion element, is adhesive, rather than non-adhesive. In both preferred embodiments, the insertion element is non-adhesive.

It is most preferred for the insertion element formed from the printable insert to be formed in one piece.

Preferably, the insertion element is formed by cutting the top sheet of the printable insert (to form the insertion element and the waste element from said top sheet) but without cutting the backing sheet, so that the backing sheet remains in one piece.

In a thirteenth aspect, the present invention provides an article of stationery having a plurality of pages bound by a binding that extends through apertures in the pages, the apertures being guided around the binding when the pages are turned, and a printed insertion element inserted into the binding of said article after binding of said pages, said printed insertion element being part of the top sheet of a printable insert, being a laminate of said top sheet and a backing sheet.

In a fourteenth aspect, the present invention provides a printable insert being a laminate of a top sheet and a backing sheet, said top sheet being cut to define an insertion element and a waste element, the backing sheet retaining the insertion element and the waste element of the top sheet together, wherein the insertion element has a shape to allow it, once removed from the backing sheet and the waste element, to be inserted into the binding of an article of stationery.

Preferably, the article of stationery has a plurality of pages bound by a binding that extends through apertures in the pages, the apertures being guided around the binding when the pages are turned.

In a fifteenth aspect, the present invention provides a method of producing a printable insert including the steps of: providing a laminate of a printable top sheet and a backing sheet; and cutting an insert element of a desired shape into the top sheet, leaving the insert element, a waste element and the backing sheet still laminated, wherein the insertion element has a shape to allow it, once removed from the backingsheet and the waste element, to be inserted into the binding of an article of stationery.

In a sixteenth aspect, the present invention provides a method of modifying an article of stationery, the article having a plurality of pages bound by a binding that extends through apertures in the pages, the apertures being guided around the binding when the pages are turned, the method including the steps of: providing a printable insert being a laminate of a top sheet and a backing sheet, said top sheet being cut to define an insertion element and a waste element, the backing sheet retaining the insertion element and the waste element of the top sheet together; peeling the insertion element from the backing sheet and the waste element; and inserting the insertion element into the binding of said article.

The method preferably further includes the step of printing text and/or an image onto the printable insert, before peeling the insertion element from the backing sheet and waste element.

Preferably, the printing step is carried out using a desktop printer (e.g. inkjet or laser printer) The step of inserting the insertion element is preferably carried out using an insertion tool, e.g. as set out above.

Preferred embodiments of the invention will now be set out by way of example, with reference to the accompanying drawings, in which: Fig. 1 shows an embodiment of the invention before printing and folding into a body form; Fig. 2 shows an embodiment of the invention before printing and folding into a body form; Fig. 3 shows an embodiment of the invention before printing and forming into a body form; Fig. 4 is a schematic view of a desktop calendar for use with an embodiment of the invention; Fig. 5 is a perspective view of a blank printable insert according to an embodiment of the invention; Figs. 6 and 7 are perspective views of the printable insert of Fig. 5 after printing.

Fig. 8 is a schematic enlarged plan view of part of an insertion element according to an embodiment of the invention.

The printable laminated article of each of the embodiments is a "drypeel" laminated sheet. Examples of laminated sheets suitable for forming body shapes are shown in Figs. 1-3, which each show the printable laminated article in plan view from above, with the removable shaped element cut into the top sheet.

A4 sheets of dry peel laminated sheet are available from companies that manufacture printable labels. In many respects, the dry-peel laminated sheet is similar to a sheet of printable labels, except in that the printable top sheet of the dry-peel sheet is formed from card and in that the top sheet, when peeled from the backing paper, is non-sticky.

The cutting operation (known as "kiss cutting") to form the removable shaped element and the waste element from the top sheet of the laminate is known, except in this case the shape of the tool to form the required shape is new. It will be readily apparent to the person skilled in the art, given the desired shape, how to cut the desired shapes.

Peeling of the removable shaped element from the backing sheet leaves the waste element in place on the backing sheet. Thus, the method of forming the complex shape of the removable shaped element does not give rise to the production of waste material that might clog up the cutting machine. Instead, the waste material is retained, in one piece, on the backing sheet.

Before peeling of the removable shaped element from the backing sheet and waste element, it is possible to print onto the surface of the removable shaped element (and, optionally, onto the surface of the waste element) Desired images and/or text may be printed using a desktop printer, for example, because the shape of the printable laminated article is one which is suitable for feeding through such printers (the shape is typically rectangular, e.g. A3, A4 or A5) In an alternative embodiment, after removal of the removable shaped element, the backing sheet of the laminated article is adhesive. Such a printable laminated article is a modified version of a conventional printable label laminate. However, in this embodiment, the label sheet of the laminate is, in effect, the backing sheet and is not cut. The top sheet is printable on the surface that does not contact the label sheet.

Furthermore, the top sheet is made thicker than in conventional label laminates. The top sheet is cut to desired shape to form the shaped removable element and the waste element. The shaped removable element is non- adhesive after removal from the backing sheet.

Fig. 1 shows a printable laminated article 10 being a sheet of dry laminated card having a top sheet 12 and a backing sheet (not shown) . A pattern is cut into the top sheet 12 to form a removable shaped element 14 and a waste element 16. The perimeter shape of the shaped removable element is a complex one. The shape includes concave cut features 18, 20. These concave cut features allow the different parts (e.g. side portion 22 and bonnet portion 24) of the shaped removable element to move relative to each other after removal from the backing sheet.

Lines 26, 28 represent slots cut into the shape of the shaped removable element. These slots are intended to receive tabs 30, 31, respectively.

Lines 34, 36 represent lines of weakness formed into the shaped removable element. These are typically formed as scored lines or microperforations in a way known to the skilled person.

As will be clear, the shaped removable element, once removed from the backing sheet and waste element, may be folded into the form of a toy car. Prior to removal from the backing sheet and waste element, however, the shaped removable element may be printed using a conventional printer to give appropriate car-like decoration.

Fig. 2 shows a simpler design than Fig. 1. In this case, printable laminated article has cut into its top sheet 52 a shaped removable element 54 for folding into the shape of a container (here, a box) . Concave cut features 58, allow folding of the different sides of the container towards each other. Lines of weakness 74, 76, generated by scoring or by the forming of microperforations, permit this folding.

Fig. 3 shows a design for a novelty hat. Printable laminated article 80 has cut into its top sheet 82 a shaped removable element 84 and waste element 86. Cut features 88, 90 are wholly contained within the perimeter of the shaped removable element. The cut features are arranged in a spiral pattern. On removal of the removable shaped element 84 from the backing sheet and waste element, the cut features allow the flat form of the shaped element to form into the body form (a hat shape) by opening up of the cut features. In this way, the central hub portion 92 of the hat is able to move out of plane with the rim portion 94 so as to define a space to receive the wearer's head. Peak portion 96 remains substantially in-plane with the rim portion 94.

Again, the hat of Fig. 3 may be printed before removal from the backing sheet.

Fig. 4 shows the general form of a desktop calendar 9 of the type that is known. The calendar has a cardboard fold-out easel 11, the two ends of the easel meeting at the apex of the calendar, where they are bound together by a wire comb binding 13. The wire binding 13 extends through holes (not shown) in the cardboard in a known fashion. Also included in the calendar binding are calendar sheets 15. Typically, there will be twelve such sheets, each displaying information relating to one month of the year. Optionally, there is an additional cover sheet. Each of the calendar sheets has holes (not shown) for the wire binding to extend through, in a similar way to the cardboard easel.

The holes in the calendar sheets and in the easel for the wire binding are closed. This provides more secure fixing of the sheets and easel with the binding.

The mass production of calendars such as that shown in Fig. 4 requires that the calendar sheets are printed, arranged and then punched to give the holes. Optionally, the easel may be punched in the same operation. Then, the binding is inserted to bind the sheets together in the calendar. It is not practicable to carry out short production runs for a small number (e.g. tens or hundreds) of bespoke printed calendars.

It is preferred instead to personalise a standard calendar with a personalisation sheet. The personalisation sheet might contain, for example, business details (in the case of a small business sending calendars to its customers) or it might contain a personal message for the recipient.

It will be noted that the length of the inclined face of the easel is greater than that of the calendar sheets in the calendar of Fig. 1. Thus, there is a gap 17 at the base of the calendar sheets.

A suitable blank printable insert for the calendar of Fig. 4 is shown in Fig. 5. Printed versions of the same insert are shown in Figs. 6 and 7. The printable insert consists of insertion elements 19, 21, a waste element 23 and a backing sheet 25 (not shown but its position is illustrated in Fig. 5 using a dotted line) The printable insert is a "drypeel" laminated sheet.

The printable insert shown in Fig. 5 is formed from a known product - an A4 sheet of dry peel laminated sheet available from companies such as Averytm, or other companies that manufacture pintable labels. In many respects, the dry-peel laminated sheet is similar to a sheet of printable labels, except in that the printable top sheet of the dry-peel sheet is formed from card and in that the top sheet, when peeled from the backing paper, is non-sticky.

The shape cut into the top sheet of the printable insert is relatively complex. The complex part is shown in Fig. 8, which shows an enlarged portion of one side of one of the insertion elements, after peeling from the backing sheet. As can be seen in Fig. 8, a series of open apertures 29 is formed at one side of the insertion element. The open apertures are separated by barbs 31.

It is possible to insert the insertion element into the binding 13 of the calendar by pushing the barbed portions 31 between the wire binding elements of the binding 13 using a tool (not shown) having teeth spaced at the same pitch as the barbed elements, pressing on the barb elements. Once inserted, the barb elements spring back (at least partially) to hold the wire binding elements in place in the apertures 29.

The cutting operation (known as "kiss cutting") to form the insertion elements and the waste element from the top sheet of the laminate is known, except in this case the shape of the tool to form the required shape is new. It will be readily apparent to the person skilled in the art, given the desired shape, how to cut that shape.

Peeling of the insertion element from the backing sheet leaves the waste element in place on the backing sheet.

Thus, the apertures 29 are open on the insertion element and the waste element retained by the backing sheet has a corresponding shape. Thus, the method of forming the apertures in the insertion element does not give rise to the production of waste material that might clog up the cutting machine. Instead, the waste material is retained, in one piece, on the backing sheet.

The advantage of providing a kit containing the pre-cut printable insert is that the printing of that insert can be carried out easily on a conventional desktop printer.

Thus, the desired information and/or images can be printed on the printable insert by the person or business who wishes to offer the calendar. After printing, the insertion element can be peeled from the backing sheet and inserted into the calendar as described above, to give a personalised calendar.

As shown in Figs. 6 and 7, the personalisation information is printed towards the base of the insertion elements. Thus, once inserted into the calendar binding, this information will be visible at space 17 of the calendar.

In an alternative embodiment, after removal of the insertion element, the backing sheet of the printable insert is adhesive. Such a printable insert is a modified version of a conventional printable label laminate. However, in this embodiment, the label sheet of the laminate is, in effect, the backing sheet and is not cut. The top sheet is printable on the surface that does not contact the label sheet. Furthermore, the top sheet is made thicker than in conventional label laminates. The top sheet is cut to desired shape to form the insertion element and the waste element. The insertion element is non-adhesive after removal from the backing sheet.

It is noted that, usually, such stationary articles will require the insertion elements to be located at the front of the article, optionally under a cover through which the insert is visible.

The invention is not limited to the embodiments described above. Further embodiments can be envisaged, e.g. in the form of masks and the other novelty items described earlier, or printable insertion elements for stationary articles such as notebooks, diaries and the like.

Modifications of the present embodiments, further embodiments and modifications thereof will be apparent to the skilled person on reading this disclosure, and as such these are within the scope of the present invention.

In particular, it is possible that means other than tabs and slots (as described with reference to Fig. 1) may be used to hold the shaped removable element in a body form.

For example, press studs or other connectors may be provided (e.g. as part of a kit) to attach parts together or to provide anchor points for other connectors such as elastic fasteners. Additionally, in relation to insertion elements for stationary articles, it may be possible to locate one or more insertion element within an article, and at any position within that article.

Claims

CLPIMS: 1. A printable laminated article having a top sheet laminated with

a backing sheet, the top sheet being printable and being cut to define a removable shaped element having a perimeter and at least one waste element, the removable shaped element being in flat form when laminated with the backing sheet and being formable into a predetermined body form after removal from the backing sheet and waste element, wherein the removable shaped element has at least one concave cut feature at its perimeter or a cut feature wholly or partly disposed within its perimeter, said cut feature defining first and second cut surfaces that move relative to each other to accommodate the shape change from the flat form to the body form.
2. A printable laminated article according to claim 1 wherein the at least one cut feature forms all or part of a cut pattern in the removable shaped element and the cut pattern opens to accommodate the shape change from the flat form to the body form.
3. A printable laminated article according to claim 1 or claim 2 wherein the cut feature is at least one slit that is closed in the flat form and open in the body form.
4. A printable laminated article according to any one of claims 1 to 3 wherein the cut feature is a pattern of spiral slits interposed between a central portion and a rim portion, the central portion being moveable out of plane from the rim portion by opening of the spiral slits.
5. A printable laminated article according to any one of claims 1 to 4 wherein the removable shaped element includes attachment formations that cooperate to attach to each other in the body form to retain the shaped element in the body form.
6. A printable laminated article according to claim 5 wherein the body form of the shaped element is adjustable in size by adjusting the selection of the attachment formations used to retain the shaped element in the body form.
7. A printable laminated article according to claim 5 or claim 6 wherein the attachment formations include at least one tab and at least one slot.
8. A printable laminated article according to any one of claims 1 to 7 wherein the removable shaped element is foldable along scored or perforated lines. )
9. A printable laminated article according to any one of claims 1 to 8 wherein the body form of the article is selected from one of: a hat, a cap, a bib, a mask and a children's party product.
10. A printable laminated article having a top sheet laminated with a backing sheet, the top sheet being printable and being cut to define a removable shaped element and at least one waste element, the removable shaped element being in flat form when laminated with the backing sheet and being formable into a predetermined container form having a base and walls.
11. A printable laminated article according to claim 10 wherein the removable shaped element is foldable along the boundaries between the base and/or walls along scored lines or lines of perforations formed in the removable shaped element.
12. A printable laminated article according to claim 10 or claim 11 wherein the removable shaped element includes a portion shaped to be an integral lid of the container.
13. A printable laminated article according to claim 10 or claim 11 wherein the top sheet further includes a second removable shaped element, the second removable shaped element being shaped to be a separable lid for the container.
14. A printable laminated article according to any one of claims 1 to 13 having straight edges.
15. A printable laminated article according to claim 14 of a standard stationary size.
16. A printable laminated article according to any one of claims 1 to 15 wherein the laminate is formed from dry laminated card.
17. A printable laminated article according to any one of claims 1 to 16 wherein said removable shaped element is formed in one piece.
18. A kit including one or more printable laminated articles according to any one of claims 1 to 17, the kit further including instructions for printing onto the top sheet of the laminate before removal of the removable shaped element from the backing sheet.
19. A kit according to claim 18 further including a software product for managing the printing of the printable laminated article.
20. A method of producing a printable laminated article including the steps of: providing a laminate of a printable top sheet and a backing sheet; and cutting a shaped removable element of a desired shape into the top sheet, leaving the shaped removable element, a waste element and the backing sheet still laminated and in flat form, said shaped removable element having a perimeter and being formable into a predetermined body form after removal from the backing sheet and waste element wherein the removable shaped element has at least one concave cut feature at its perimeter or a cut feature wholly or partly disposed within its perimeter, said cut feature defining first and second cut surfaces that move relative to each other to accommodate the shape change from the flat form to the body form.
21. A method of producing a printable laminated article including the steps of: providing a laminate of a printable top sheet and a backing sheet; and cutting a shaped removable element of a desired shape into the top sheet, leaving the shaped removable element, a waste element and the backing sheet still laminated and in flat form, said shaped removable element being formable into a predetermined container form having a base and walls after removal from the backing sheet and waste element.
22. A method of customising a printable laminated article including the steps of: providing a printable laminated article according to any one of claims 1 to 17; and then printing a customising image or customising text onto the top sheet of the laminated article; and then removing the printed removable shaped element from the backing sheet and the waste element; and then forming the printed removable shaped element from a flat form to a body form.
23. A method according to claim 22 wherein the printing step prints at least part of the customising image onto the waste element.
24. A printable laminated article having a top sheet laminated with a backing sheet, wherein the top sheet is a thin substrate with a printable surface, the top sheet being cut to define a removable shaped element having a perimeter and at least one waste element, said at least one waste element abutting against the removable shaped element at its perimeter, the removable shaped element being in flat form when laminated with the backing sheet and being foldable or bendable into a predetermined body form after removal from the backing sheet and waste element, wherein the removable shaped element has at least one inward cut feature at its perimeter or a cut feature wholly or partly disposed within its perimeter, said cut feature defining first and second cut surfaces that move relative to each other to accommodate the shape change from the flat form to the body form, the body form having concave or convex cross-sections in each of two or more orthogonal directions.
25. A printable laminated article having a top sheet laminated with a backing sheet, the top sheet being printable and being cut to define a removable shaped element and at least one waste element, the removable shaped element being in flat form when laminated with the backing sheet and being formable into a predetermined container form having a base and walls, opposing walls being spaced apart from each other.
26. A method of producing a printable laminated article including the steps of: providing a laminate of a top sheet and a backing sheet, wherein the top sheet is a thin substrate with a printable surface; and cutting a shaped removable element of a desired shape into the top sheet, leaving the shaped removable element, a waste element and the backing sheet still laminated and in flat form, said shaped removable element having a perimeter, said at least one waste element abutting against the removable shaped element at its perimeter, and said removable element being formable into a predetermined body form after removal from the backing sheet and waste element, wherein the removable shaped element has at least one inward cut feature at its perimeter or a cut feature wholly or partly disposed within its perimeter, said cut feature defining first and second cut surfaces that are moveable relative to each other to accommodate the shape change from the flat form to the body form, the body form having concave or convex cross-sections in each of two or more orthogonal directions.
27. A method of producing a printable laminated article including the steps of: providing a laminate of a printable top sheet and a backing sheet; and cutting a shaped removable element of a desired shape into the top sheet, leaving the shaped removable element, a waste element and the backing sheet still laminated and in flat form, said shaped removable element being formable into a predetermined container form having a base and walls after removal from the backing sheet and waste element, opposing walls in the body form being spaced apart from each other.
28. A method of customising a printable laminated article including the steps of: providing a printable laminated article according to claim 24 or claim 25; and then printing a customising image or customis.ing text onto the top sheet of the laminated article; and then removing the printed removable shaped element from the backing sheet and the waste element; and then forming the printed removable shaped element from the flat form to the body form.
29. A method according to claim 28 wherein the printing step prints at least part of the customising image onto the waste element, so that the image extends to the edge of the shaped removable element.
30. A stationery article kit including an article of stationery having a plurality of pages bound by a binding that extends through apertures in the pages, the apertures being guided around the binding when the pages are turned, and a printable insert for insertion into the binding of said article after binding of said pages, said printable insert being a laminate of a top sheet and a backing sheet, said top sheet being cut to define an insertion element and a waste element, the backing sheet retaining the insertion element and the waste element of the top sheet together.
31. A stationery article kit according to claim 30 wherein the binding includes looped binding elements extending through the apertures.
32. A stationery article kit according to claim 30 or claim 31 wherein the apertures in the pages of the article of stationery are closed holes.
33. A stationery article kit according to claim 32 wherein the insertion element includes open apertures for allowing the insertion element to be inserted into the binding.
34. A stationery article kit according to claim 33 wherein the open apertures have fingers extending between them, the fingers being for insertion between elements of the binding. )
35. A stationery article kit according to claim 34 further including an insertion tool having a shape corresponding to spaces between elements of the binding.
36. A stationery article kit according to claim 34 or claim 35 wherein the fingers have barbs formed at their free ends for retaining the insertion element in the binding.
37. A stationery article kit according to any one of claims 30 to 36 wherein the printable insert is formed from dry laminated card.
38. An article of stationery having a plurality of pages bound by a binding that extends through apertures in the pages, the apertures being guided around the binding when the pages are turned, and a printed insertion element inserted into the binding of said article after binding of said pages, said printed insertion element being part of the top sheet of a printable insert, being a laminate of said top sheet and a backing sheet.
39. A printable insert being a laminate of a top sheet and a backing sheet, said top sheet being cut to define an insertion element and a waste element, the backing sheet retaining the insertion element and the waste element of the top sheet together, wherein the insertion element has a shape to allow it, once removed from the backing sheet and the waste element, to be inserted into the binding of an article of stationery.
40. A printable insert according to claim 39 wherein the article of stationery has a plurality of pages bound by a binding that extends through apertures in the pages, the apertures being guided around the binding when the pages are turned.
41. A method of producing a printable insert including the steps of: providing a laminate of a printable top sheet and a backing sheet; and cutting an insert element of a desired shape into the top sheet, leaving the insert element, a waste element and the backing sheet still laminated, wherein the insertion element has a shape to allow it, once removed from the backing sheet and the waste element, to be inserted into the binding of an article of stationery.
42. A method of modifying an article of stationery, the article having a plurality of pages bound by a binding that extends through apertures in the pages, the apertures being guided around the binding when the pages are turned, the method including the steps of: providing a printable insert being a laminate of a top sheet and a backing sheet, said top sheet being cut to define an insertion element and a waste element, the backing sheet retaining the insertion element and the waste element of the top sheet together; peeling the insertion element from the backing sheet and the waste element; and inserting the insertion element into the binding of said article.
43. A method according to claim 42 further including the step of printing text and/or an image onto the printable insert, before peeling the insertion element from the backing sheet and waste element.
44. A method according to claim 42 or claim 43 wherein the printing step is carried out using a desktop printer.
45. A method according to any one of claims 41 to 44 wherein the step of inserting the insertion element is carried out using an insertion tool.