[0001]    This patent is a continuation of allowed U.S. Ser. No. 09/697,070 filed Oct. 26, 2000, which is a continuation of U.S. Ser. No. 09/470,374 filed Dec. 22, 1999, now U.S. Pat. No. 6,158,778, which is a continuation of U.S. Ser. No. 09/305,966 filed May 6, 1999, now U.S. Pat. No. 6,068,300, which is a continuation of U.S. Ser. No. 09/031,191 filed Feb. 26, 1998, now U.S. Pat. No. 5,909,899, which is a continuation of U.S. Ser. No. 08/492,213 filed Jun. 19, 1995, now U.S. Pat. No. 5,813,700, which is a continuation-in-part of U.S. Ser. No. 08/324,350 filed Oct. 17, 1994, which is a continuation-in-part of U.S. Ser. No. 08/264,181 filed Jun. 22, 1994, now U.S. Pat. No. 5,458,374, which is a continuation of U.S. Ser. No. 08/037,294 filed Mar. 26, 1993 and a continuation-in-part of U.S. Ser. No. 08/264,181 filed Jun. 22, 1994, which is a continuation of U.S. Ser. No. 08/037,294 filed Mar. 26, 1993. All of the patent applications and patents identified in this paragraph are incorporated by reference herein in their entirety. 
     
    
     
       BACKGROUND  
         [0002]    This patent relates to methods of folding informational items which have printed information, such as instructions and/or warnings, relating to pharmaceutical products.  
           [0003]    Informational items, such as outserts, are used to convey information to purchasers and users of pharmaceutical products. The information printed on an outsert typically includes instructions for use of a pharmaceutical product and medical warnings relating to the product. The outsert typically accompanies the product, such as by being affixed directly to the container in which the pharmaceutical product is provided or by being enclosed within a cardboard carton in which the pharmaceutical container is packaged.  
           [0004]    A method of forming outserts is disclosed in U.S. Pat. No. 4,812,195 to Michael Vijuk. In that patent, outserts are manufactured by folding a relatively long sheet a number of times in a direction perpendicular to the length of the sheet and then cutting the folded sheet a number of times in a direction perpendicular to the folding direction to make a number of individual outserts. The result of the folding and cutting steps is a “ribbon” style outsert like the one shown in FIG. 1B.  
           [0005]    [0005]FIG. 1A illustrates an example of an outsert  10  constructed in accordance with the prior art which has open edges  12  about its periphery. FIG. 1B illustrates a conventional ribbon style outsert  14  constructed in accordance with the prior art. The outsert  14  has a tail portion  16  which, prior to opening of the outsert by the purchaser of the associated pharmaceutical product, is glued to an interior portion of the outsert. The tail portion  16  consists of a single sheet having an unfolded, exterior sheet edge which lies in a direction parallel to the folding direction.  
         SUMMARY OF THE INVENTION  
         [0006]    In one aspect, the invention is directed to a method of folding a sheet having printed information thereon to form an outsert for providing information to the user of a product. The method comprises (a) folding the sheet by making a first fold in the sheet, the first fold being parallel to a first direction; (b) folding the sheet by making a second fold in the sheet, the second fold being parallel to the first direction; (c) folding the sheet by making at least one additional fold in the sheet, the additional fold being parallel to the first direction and being made to form a first folded article having a first end and a second end, each of the first and second ends of the first folded article having unfolded exterior sheet edges which lie in a direction perpendicular to the first direction; (d) after completion of (a) through (c), folding the first folded article by making a first fold in the first folded article in a second direction perpendicular to the first direction to form a second folded article, the second folded article having a first end and a second end, the first end of the second folded article having no unfolded exterior sheet edges; (e) making at least one additional fold in a direction parallel to the second direction to form a third folded article, the third folded article having a sheet portion; (f) depositing an adhesive on the sheet portion of the third folded article; and (g) folding the third folded article by making a final fold in a direction parallel to the second direction to form the outsert, the final fold being made so that the second end of the second folded article is covered by one of the sheet portions of the outsert and so that there are no unfolded exterior sheet edges which lie in a direction parallel to the second direction, the thickness of the sheet being such that when the folds in the first and second directions are made, the folds will cause the outsert to have a thickness of 0.25 inches or greater.  
           [0007]    In another aspect, the invention is directed to a method of producing a folded item having printed information thereon to provide information to the user of a product. The method comprises (a) forming a first article having a first end, a second end, a length along a first direction, and a width along a second direction perpendicular to the first direction, the first article having a plurality of first elongate sheet portions and a plurality of second elongate sheet portions, each of the first elongate sheet portions having a first end and a second end, and each of the second elongate sheet portions having a first end and a second end, each of the first ends of the first elongate sheet portions being joined to a respective one of the first ends of the second elongate sheet portions at a respective fold coinciding with the first end of the first article so that the first end of the first article has no exterior unfolded sheet edges, each of the respective folds being parallel to the second direction; (b) folding the first article by making a first transverse fold in the first article to form a second article, the first transverse fold being parallel to the second direction and being made so that the second end of the first article is disposed between the first end of the first article and the first transverse fold; (c) depositing an adhesive on a portion of the second article; and (d) folding the second article by making a second transverse fold in the second article to form the folded item, the second transverse fold being parallel to the second direction so that the folded item has no exterior unfolded sheet edges which lie in a direction parallel to the second direction, the thickness of the sheet being such that when the folds in the first and second directions are made, the folds will cause the folded item to have a thickness of 0.25 inches or greater. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0008]    [0008]FIG. 1A illustrates an example of an outsert having open edges about its periphery constructed in accordance with the prior art;  
         [0009]    [0009]FIG. 1B illustrates a ribbon style outsert constructed in accordance with the prior art;  
         [0010]    [0010]FIG. 2A is a perspective view of a first embodiment of an outsert;  
         [0011]    FIGS.  2 B- 1  through  2 B- 5  illustrate the method of forming the outsert illustrated in FIG. 2A;  
         [0012]    [0012]FIG. 3A is a perspective view of a second embodiment of an outsert;  
         [0013]    FIGS.  3 B- 1  through  3 B- 6  illustrate the method of forming the outsert illustrated in FIG. 3A;  
         [0014]    [0014]FIG. 4A is a perspective view of a third embodiment of an outsert;  
         [0015]    FIGS.  4 B- 1  through  4 B- 7  illustrate the method of forming the outsert illustrated in FIG. 4A;  
         [0016]    [0016]FIG. 5 is a perspective view of an outsert applied to the outside of a container for a pharmaceutical product;  
         [0017]    [0017]FIG. 6A is a perspective view of a fourth embodiment of an outsert;  
         [0018]    FIGS.  6 B- 1  through  6 B- 10  illustrate the method of forming the outsert illustrated in FIG. 6A;  
         [0019]    [0019]FIG. 7A is a perspective view of a fifth embodiment of an outsert;  
         [0020]    FIGS.  7 B- 1  through  7 B- 10  illustrate the method of forming the outsert illustrated in FIG. 7A; and  
         [0021]    [0021]FIG. 8 is a perspective view of an outsert applied to the top of a container for a pharmaceutical product. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0022]    [0022]FIG. 2A is a perspective view of a universal, nonjamming, multi-ply outsert  20  having multiple folds, which is manufactured from an integral sheet of stock. FIGS.  2 B 1 - 1  through  2 B- 5  illustrate the method of forming the outsert  20  depicted in FIG. 2A. Referring to FIGS. 2A and 2B, the method starts with web stock that is directly fed to an in-line cutter, where the stock is cut into separate individual sheets (or, alternatively, starting with individual sheet stock which is automatically stacked and fed). The size of the individual sheet stock is variable. For example, it has been demonstrated that starting with a commercial grade sheet stock having an overall length (L) of approximately 8.375 inches, and an overall width (W) of approximately 4.125 inches, an outsert can be manufactured having a total of four folds, twelve total ply thickness, and an overall size of approximately 2.438 inches wide, approximately 1.5 inches high, and approximately 0.125 inches thick (depending on the thickness of the individual sheet stock used).  
         [0023]    To manufacture the outsert depicted in FIG. 2A, starting at FIG. 2B- 1 , and with the individual sheet stock  21  traveling in a predetermined first direction, an initial fold  22  is made across the entire length of the sheet stock and is at a right angle from the point of origin (see FIG. 2B- 2 ). This initial fold may be an even fold or an uneven fold (i.e., may be folded over to less than all of the adjoining section of sheet stock). This initial fold results in the sheet stock having a top panel (W 1 ) and an adjoining bottom panel (W 2 ). If the initial fold is an even fold, the resulting width will be ½ of the initial width (i.e., W 1 =W 2 =½ W). Following completion of this initial fold, the sheet stock will have an overall thickness of two plies.  
         [0024]    At FIG. 2B- 3 , and following the re-orientation of the individual sheet stock  21  to a different predetermined second direction (i.e., re-oriented substantially 90 degrees from the first direction), a second fold  24  is then made across the entire width of the sheet stock at a designated location and is at a right angle from the point of origin. This second fold may be an even fold or an uneven fold (i.e., may be folded over to less than all of the adjoining section of the sheet stock). This second fold will result in the sheet stock having a top panel length (L 1 ) and an adjoining bottom panel length (L 2 ).  
         [0025]    If the second fold is an even fold, the resulting length will be ½ of the initial length (i.e., L 1 =L 2 =½ L). Following completion of this second fold, the sheet stock will have an overall thickness of four plies. Also, after completion of this second fold, the resulting folded sheet stock will have two ends of orientation, one end being a folded closed-end, and the other end being an open-edge end, not having any fold.  
         [0026]    At FIG. 2B- 4 , a third fold  26  is made across the entire width of the sheet stock at a right angle from the point of origin, the third fold being located at the open-edge end of the folded sheet stock. This third fold is equal to approximately ⅓ of the total panel length and will result in the sheet stock now having a resulting top panel length (L 1 ) and a resulting adjoining bottom panel length (L 2 ) (i.e., L 1 =⅓ L and L 2 =⅔ L). Following completion of this third fold, the sheet stock will have an overall thickness of eight plies for the resulting top panel length, and four plies for the resulting bottom panel length.  
         [0027]    Following the third fold (see FIG. 2B- 4 ), at a designated location on the resulting top panel length, a single glue spot  25  (or glue spots) is made thereon, with a suitable adhesive. If desired, the gluing step may be omitted.  
         [0028]    At FIG. 2B- 5 , a fourth fold  28  is made to complete the outsert. The fourth fold is made across the entire width of the sheet stock at a right angle from the point of origin, the fourth fold being located at the closed-end of the folded sheet stock. This fourth fold is equal to approximately ½ of the total panel length and will result in the sheet stock now having a resulting top panel length (L 1 ) and a resulting adjoining bottom panel length (L 2 ) (i.e., L 1 =½ L and L 2 =½ L). This fourth fold is made in a manner whereby the adhesive will maintain the outsert in a more or less fixed and compact relationship with respect to the top and bottom panel lengths of the folded sheet stock. Following completion of this final fold, the outsert will have an overall thickness of twelve plies.  
         [0029]    [0029]FIG. 3A is a perspective view of a universal, non-jamming, multi-ply outsert  30  having multiple folds, which is manufactured from an integral sheet of stock. FIGS.  3 B- 1  through  3 B- 6  illustrate the method of forming the outsert  30  depicted in FIG. 3A. Referring to FIGS. 3A and 3B, the method starts with web stock that is fed to an in-line cutter, where the stock is cut into separate individual sheets (or, alternatively, starting with individual sheet stock which is automatically stacked and fed). The size of the individual sheet stock is variable. For example, it has been demonstrated that starting with a commercial grade sheet stock having an overall length (L) of approximately 12 inches, and an overall width (W) of approximately 11 inches, an outsert can be manufactured having a total of eight folds, forty total ply thickness, and an overall size of approximately 2.25 inches wide, approximately 1.5 inches high, and approximately 0.3125 inches thick (depending on the thickness of the individual sheet stock used).  
         [0030]    To manufacture the outsert depicted in FIG. 3A, starting at FIG. 3B- 1 , and with the individual sheet stock  31  traveling in a predetermined first direction, an initial fold  32 , which consists of a number of substantially parallel folds (consisting of a series of tandem folds  32 ( a ),  32 ( b ),  32 ( c ) and  32 ( d ) comprising a four-fold accordion fold), is made across the entire length of the sheet stock and is at a right angle from the point of origin (see FIGS.  3 B- 2 A through  3 B- 2 D). This initial fold  32  may be an even fold or an uneven fold (i.e., may be folded over to less than all of the adjoining section of sheet stock).  
         [0031]    If the initial fold  32  is an even fold, the resulting width will be ⅕ of the initial width (i.e., W 1 =W 2 =W 3 =W 4 =W 5 =⅕ W). This initial fold is a four-fold tandem accordion fold and, assuming the initial fold has equal panels, each panel will consist of the four-fold tandem accordion fold that is equal to ⅕ the original width (i.e., W 1 =⅕ W). This initial fold results in the sheet stock having a tandem series of substantially equally-sized adjoining panels, with accordion folds (running length-wise) being positioned between adjacent panels. Following completion of this initial fold, the sheet stock will have an overall thickness of five plies.  
         [0032]    At FIG. 3B- 3 , and following the re-orientation of the individual sheet stock  31  to a different predetermined second direction (i.e., re-oriented substantially 90 degrees from the first direction), a second fold  33  is then made across the entire width of the sheet stock at a designated location and is at a right angle from the point of origin. This second fold may be an even fold or an uneven fold (i.e., may be folded over to less than all of the adjoining section of the sheet stock). This second fold will result in the sheet stock having a top panel length (L 1 ) and an adjoining bottom panel length (L 2 ).  
         [0033]    If the second fold is an even fold, the resulting length will be ½ of the initial length (i.e., L 1 =L 2 =½ L). Following completion of this second fold, the sheet stock will have an overall thickness of ten plies. Also, after completion of this second fold, the resulting folded sheet stock will have two ends of orientation, one end being a folded closed-end, and the other end being an open-edge end, not having any fold.  
         [0034]    At FIG. 3B- 4 , a third fold  34  is made across the entire width of the sheet stock at a right angle from the point of origin, the third fold being located at the open-edge end of the folded sheet stock. This third fold is equal to approximately ¼ of the total panel length and will result in the sheet stock now having a resulting top panel length (L 1 ) and a resulting adjoining bottom panel length (L 2 ) (i.e., L 1 =¼ L and L 2 =¾ L). Following completion of this third fold, the sheet stock will have an overall thickness of twenty plies for the resulting top panel length, and ten plies for the resulting bottom panel length.  
         [0035]    At FIG. 3B- 5 , a fourth fold  35  is made across the entire width of the sheet stock at a right angle from the point of origin, the fourth fold being located at the section of folded sheet stock that is adjacent to the open-edge end portion of the folded sheet stock. This fourth fold is equal to approximately ⅓ of the total panel length and will result in the sheet stock now having a resulting top panel length (L 1 ) and a resulting adjoining bottom panel length (L 2 ) (i.e., L 1 =⅓ L and L 2 =⅔ L). Following completion of this fourth fold, the sheet stock will have an overall thickness of thirty plies for the resulting top panel length, and ten plies for the resulting bottom panel length.  
         [0036]    At FIG. 3B- 5 , following the fourth fold, at a designated location on the resulting bottom panel length, a single glue spot  36  (or glue spots) is made thereon, with a suitable adhesive. If desired, the gluing step may be omitted.  
         [0037]    At FIG. 3B- 6 , a fifth fold  37  is made to complete the outsert. The fifth fold is made across the entire width of the sheet stock at a right angle from the point of origin, the fifth fold being located at the section of folded sheet stock that is next to the adjacent section previously discussed (i.e., the adjacent section being next to the open-edge end portion of the folded sheet stock). This fifth fold is equal to approximately ½ of the total panel length and will result in the sheet stock now having a resulting top panel length (L 1 ) and a resulting adjoining bottom panel length (L 2 ) (i.e., L 1 =½ L and L 2 =½ L). This fifth fold is made in a manner whereby the adhesive will maintain the outsert in a more or less fixed and compact relationship with respect to the top and bottom panel lengths of the folded sheet stock. Following completion of this final fold, the outsert will have an overall thickness of forty plies.  
         [0038]    [0038]FIG. 4A is a perspective view of a universal, nonjamming, multi-ply outsert  50  having multiple folds, which is manufactured from an integral sheet of stock. FIGS.  4 B- 1  through  4 B- 7  illustrate the method of forming the outsert  50  depicted in FIG. 4A. Referring to FIGS. 4A and 4B, the method starts with web stock that is fed to an in-line cutter, where the stock is cut into separate individual sheets (or, alternatively, starting with individual sheet stock which is automatically stacked and fed). The size of the individual sheet stock is variable. For example, it has been demonstrated that starting with a commercial grade sheet stock having an overall length (L) of approximately 18 inches, and an overall width (W) of approximately 12 inches, an outsert can be manufactured having a total of eight folds, a sixty-four total ply thickness, and an overall size of approximately 2.25 inches wide, approximately 1.5 inches high, and approximately 0.25 inches thick (depending on the thickness of the individual sheet stock used).  
         [0039]    To manufacture the outsert depicted in FIG. 4A, starting at FIG. 4B- 1 , and with the individual sheet stock  51  traveling in a predetermined first direction, an initial fold  52  is made across the entire length of the sheet stock and is at a right angle from the point of origin (see FIG. 4B- 2 ). This initial fold may be an even fold or an uneven fold (i.e., may be folded over to less than all of the adjoining section of sheet stock). This initial fold results in the sheet stock having a top section (W 1 ) and an adjoining bottom section (W 2 ).  
         [0040]    If the initial fold is an even fold, the resulting width will be ½ of the initial width (i.e., W 1 =W 2 =½ W). Following completion of this initial fold, the sheet stock will have an overall thickness of two plies.  
         [0041]    At FIGS.  4 B- 3 A through  4 B- 3 C, a second fold  53 , which consists of a number of substantially parallel folds (consisting of a series of tandem folds comprising a three-fold accordion fold  54 ( a ),  54 ( b ) and  54 ( c )), is made across the entire length of the sheet stock and is at a right angle from the point of origin. This second fold may be an even fold or an uneven fold (i.e., may be folded over to less than all of the adjoining section of sheet stock).  
         [0042]    If the second fold is an even fold, the resulting width will be ¼ of the initial width (i.e., W 1 =W 2 =W 3 =W 4 =¼ W). This second fold is a three-fold tandem accordion fold, and assuming the second fold has four equal panels, each panel will consist of the three-fold tandem accordion fold that is equal to ¼ the original width (i.e., W=¼ W). This second fold results in the sheet stock having a tandem series of substantially equally-sized adjoining panels, with accordion folds (running length-wise) being positioned between adjacent panels. Following completion of this fold, the sheet stock will have an overall thickness of eight plies.  
         [0043]    At FIG. 4B- 4 , and following the re-orientation of the individual sheet stock  51  to a different predetermined second direction (i.e., re-oriented substantially 90 degrees from the first direction), a third fold  55  is then made across the entire width of the sheet stock at a designated location and is at a right angle from the point of origin. This third fold is an uneven fold (i.e., a short fold); this third fold will result in the sheet stock having a top panel length (L 1 ) having open edges and an adjoining bottom panel length (L 2 ) having no open edges (but having one end with open edges). The third fold will create a top panel having open edges that is equal to ⅜ of the initial length (L 1 =⅜ L) and an adjoining bottom panel (L 2 =⅝ L). Following completion of this third fold, the outsert will have an overall thickness of sixteen plies. Also, after completion of this third fold, the resulting folded sheet stock will have two ends of orientation, one end longer than the other end.  
         [0044]    At FIG. 4B- 5 , a fourth fold  56  is made across the entire width of the sheet stock at a designated location and is at a right angle from the point of origin at a location on the short panel lengths. This fourth fold is an uneven fold (i.e., a short fold) and is located at the shorter top panel end having open-edges of the folded sheet stock. This fourth fold will result in the sheet stock having a top panel length (L 1 ) having no open peripheral edges and an adjoining bottom panel length (L 2 ) having no open peripheral edges. The fourth fold will create a top panel that is equal to ⅖ of the initial length (L 1 =⅖ L) and an adjoining bottom panel that is equal to ⅗ of the initial length (L 2 =⅗ L). Following completion of this fourth fold, the outsert will have an overall thickness of twenty-four plies (and sixteen plies at the other portion of the outsert). Also, after completion of this fourth fold, the resulting folded sheet stock will have two ends of orientation, each end having no open edges.  
         [0045]    At FIG. 4B- 6 , a fifth fold  57  is made across the entire width of the sheet stock at a right angle from the point of origin, the fifth fold being located at the section of folded sheet stock that is adjacent to the open-edge end portion of the folded sheet stock on the panel having the longer panel length. This fifth fold is equal to approximately ⅓ of the total panel length and will result in the outsert now having a resulting top panel length (L 1 ) and a resulting adjoining bottom panel length (L 2 ) (i.e., L 1 =⅓ L and L 2 =⅔ L). Each of the resulting adjoining bottom and top panels will now have closed ends (i.e., no open edges). Following completion of this fifth fold, the sheet stock will have an overall thickness of forty plies for the resulting bottom panel length, and twenty-four plies for the resulting top panel length.  
         [0046]    At FIG. 4B- 6 , following the fifth fold, at a designated location on the resulting top panel length, a single glue spot  58  (or glue spots) is made thereon, with a suitable adhesive. If desired, the gluing step may be omitted.  
         [0047]    At FIG. 4B- 7 , a sixth fold  59  is made to complete the outsert. The sixth fold is made across the entire width of the sheet stock at a right angle from the point of origin. This sixth fold is equal to approximately ½ of the total panel length and will result in the sheet stock now having a resulting top panel length (L 1 ) and a resulting adjoining bottom panel length (L 2 ) (i.e., L 1 =½ L and L 2 =½ L). This sixth fold is made and folded over the second end of the resulting panel length and is made in a manner whereby the adhesive will maintain the outsert in a more or less fixed and compact relationship with respect to the top and bottom panel lengths of the folded sheet stock. Following completion of this final fold, the outsert will have an overall thickness of sixty-four plies.  
         [0048]    [0048]FIG. 5 is a perspective view of an outsert  60  applied to the outside of a container  62  for a pharmaceutical product.  
         [0049]    [0049]FIG. 6A is a perspective view of a universal, nonjamming, multi-ply, multi-fold, reduced-size outsert  130  having increased copyspace, which is manufactured from an integral sheet of stock. FIGS.  6 B- 1  through  6 B- 10  illustrate the method of forming the outsert  130  depicted in FIG. 6A. Referring to FIGS. 6A and 6B, the method starts with web stock that is directly fed to an in-line cutter, where the stock is cut into separate individual sheets (or, alternatively, starting with individual sheet stock which is automatically stacked and fed). The size and weight of the individual sheet stock are variable. For example, it has been demonstrated that starting with a commercial grade sheet stock having an overall length (L) of approximately 11 inches, and an overall width (W) of approximately 6.625 inches, an outsert can be manufactured having nine folds, a total thickness of sixty plies, and an overall size of approximately 1.125 inches long, approximately 1.125 inches wide, and approximately 0.188 inches thick (depending on the thickness of the sheet stock utilized).  
         [0050]    To manufacture the outsert depicted in FIG. 6A, starting at FIG. 6B- 1 , and with the individual sheet stock  131  traveling in a predetermined first direction, an initial accordion fold is made across the entire length of the sheet stock and is at a right angle from the point of origin (see FIG. 6B- 2 ). This initial fold consists of a number of substantially parallel folds (consisting of a series of tandem folds  132 ,  133 ,  134 ,  135  and  136 , comprising a five-fold accordion fold), and is made across the entire length of the sheet stock and is at a right angle from the point of origin (see FIGS.  6 B- 2  through  6 B- 6 ).  
         [0051]    This initial fold is a five-fold tandem accordion fold and results in the sheet stock having a tandem series of substantially equally-sized adjoining panels, with accordion folds (running length-wise) being positioned between adjacent panels. The initial fold may be an even fold or an uneven fold (i.e., may be folded over to less than all of the adjoining section of sheet stock). Assuming the initial fold has equal panels (e.g., the initial fold is an even fold), each panel will consist of the five-fold tandem accordion fold that is equal to ⅙ the original width (i.e., W 1 =⅙ W) and the resulting width of each panel will be ⅙ of the initial width (i.e., W 1 =W 2 =W 3 =W 4 =W 5 =W 6 =⅙ W). Following completion of this initial fold, the sheet stock will have an overall thickness of six plies.  
         [0052]    At FIG. 6B- 7 , and following the re-orientation of the individual sheet stock  131  to a different predetermined second direction (i.e., re-oriented substantially 90 degrees from the first direction), a sixth fold  137  is then made across the entire width of the sheet stock at a designated location and is at a right angle from the point of origin. This sixth fold may be an even fold or an uneven fold (i.e., may be folded over to less than all of the adjoining section of the sheet stock). This sixth fold will result in the sheet stock having a top panel length (L 1 ) and an adjoining bottom panel length (L 2 ).  
         [0053]    If the sixth fold is an even fold, the resulting panel length will be ½ of the initial length (i.e., L 1 =L 2 =½ L). Following completion of this sixth fold, the sheet stock will have an overall maximum thickness of twelve plies. Also, after completion of this sixth fold, the resulting folded sheet stock will have two ends of orientation, one end being a folded closed-end, and the other end being an open-edge end, not having any fold.  
         [0054]    At FIG. 6B- 8 , a seventh fold  138  is made across the entire width of the sheet stock at a right angle from the point of origin, the seventh fold being located at the open-edge end of the folded sheet stock. This seventh fold is equal to approximately ⅖ of the total panel length and will result in the sheet stock now having a resulting top panel length (L 1 ) and a resulting adjoining bottom panel length (L 2 ) (i.e., L 1 =⅖ L and L 2 =⅗ L). Following completion of this seventh fold, the sheet stock will have an overall maximum thickness of twenty-four plies (e.g., resulting in twelve ply thickness at one end of the outsert and resulting in twenty-four ply thickness at the opposite end of the outsert).  
         [0055]    At FIG. 6B- 9 , an eighth fold  139  is made across the entire width of the sheet stock at a right angle from the point of origin. This eighth fold is equal to approximately ⅓ of the total panel length and will result in the sheet stock now having a resulting top panel length (L 1 ) and a resulting adjoining bottom panel length (L 2 ) (i.e., L 1 =⅓ L and L 2 =⅔ L). Following completion of this eighth fold, the sheet stock will have an overall maximum thickness of forty-eight plies (e.g., resulting in twelve ply thickness at one end of the outsert and resulting in forty-eight ply thickness at the opposite end of the outsert).  
         [0056]    At FIG. 6B- 10 , following the eighth fold, at a designated location on the outsert, a single glue spot  140  (or glue spots) is made thereon, with a suitable adhesive. If desired, the gluing step may be omitted.  
         [0057]    At FIG. 6B- 10 , a ninth fold  141  is made to complete the outsert. The ninth fold is made across the entire width of the sheet stock at a right angle from the point of origin. This ninth fold is equal to approximately ½ of the total panel length and will result in the sheet stock now having a resulting top panel length (L 1 ) and a resulting adjoining bottom panel length (L 2 ) (i.e., L 1 =½ L and L 2 =½ L). This ninth fold is made in a manner whereby the adhesive will maintain the outsert in a more or less fixed and compact relationship with respect to the top and bottom panel lengths of the folded sheet stock. Following completion of this final fold, the outsert will have an overall thickness of sixty plies.  
         [0058]    The method of forming the outsert  130  depicted in FIG. 6A may be modified slightly to form an outsert having a slightly different structure. In particular, the method of forming the outsert  130  may be modified in the following respects: 1) the modified method utilizes a sheet of stock having an overall length (L) of approximately 18 inches and an overall width (W) of approximately 10 inches; 2) in the modified method, an accordion fold having eight tandem folds (to produce nine equal-length panels) is initially made (instead of an accordion fold with five tandem folds as shown in FIG. 6B- 6 ); 3) in the modified method, the accordion fold is made in the direction parallel to the width of the sheet stock (instead of parallel to the length of the sheet stock as shown in FIGS.  6 B- 1  through  6 B- 6 ); and 4) two spots of glue may be used (instead of the single spot  140  shown in FIG. 6B- 10 ). This modified method will form an outsert having twelve folds, a total thickness of ninety plies, and an overall size of approximately 2 inches long, approximately 1 inch wide, and approximately 0.25 inches thick (depending on the thickness of the sheet stock used).  
         [0059]    [0059]FIG. 7A is a perspective view of a universal, nonjamming, multi-ply, multi-fold, reduced-size outsert  170  having increased copyspace, which is manufactured from an integral sheet of stock. FIGS.  7 B- 1  through  7 B- 10  illustrate the method of forming the outsert  170  depicted in FIG. 7A. Referring to FIGS. 7A and 7B, the method starts with web stock that is fed to an in-line cutter, where the stock is cut into separate individual sheets (or, alternatively, starting with individual sheet stock which is automatically stacked and fed). The size and weight of the individual sheet stock are variable. For example, it has been demonstrated that starting with a commercial grade sheet stock having an overall length (L) of approximately 10 inches, and an overall width (W) of approximately 7.5 inches, an outsert can be manufactured having a total of nine folds, a total thickness of forty-eight plies, and an overall size of approximately 1.375 inches long, approximately 1.375 inches wide, and approximately 0.188 inches thick (depending on the thickness of the individual sheet stock utilized).  
         [0060]    To manufacture the outsert depicted in FIG. 7A, starting at FIG. 7B- 1 , and with the individual sheet stock  171  traveling in a predetermined first direction, an initial accordion fold is made across the entire length of the sheet stock and is at a right angle from the point of origin (see FIG. 7B- 2 )). This initial fold consists of a number of substantially parallel folds (consisting of a series of tandem folds  172 ,  173 ,  174 ,  175  and  176 , comprising a five-fold accordion fold), and is made across the entire length of the sheet stock and is at a right angle from the point of origin (see FIGS.  7 B- 2  through  7 B- 6 ).  
         [0061]    This initial fold is a five-fold tandem accordion fold and results in the sheet stock having a tandem series of substantially equally-sized adjoining panels, with accordion folds (running length-wise) being positioned between adjacent panels. The initial fold may be an even fold or an uneven fold (i.e., may be folded over to less than all of the adjoining section of sheet stock). Assuming the initial fold has equal panels (e.g., the initial fold is an even fold), each panel will consist of the five-fold tandem accordion fold that is equal to ⅙ the original width (i.e., W 1 =⅙ W) and the resulting width of each panel will be ⅙ of the initial width (i.e., W 1 =W 2 =W 3 =W 4 =W 5 =W 6 =⅙ W). Following completion of this initial fold, the sheet stock will have an overall thickness of six plies.  
         [0062]    At FIG. 7B- 7 , and following the re-orientation of the individual sheet stock  171  to a different predetermined second direction (i.e., re-oriented substantially 90 degrees from the first direction), a sixth fold  177  is then made across the entire width of the sheet stock at a designated location and is at a right angle from the point of origin. This sixth fold may be an even fold or an uneven fold (i.e., may be folded over to less than all of the adjoining section of the sheet stock). This sixth fold will result in the sheet stock having a top panel length (L 1 ) and an adjoining bottom panel length (L 2 ).  
         [0063]    If the sixth fold is an even fold, the resulting panel length will be ½ of the initial length (i.e., L 1 =L 2 =½ L). Following completion of this sixth fold, the sheet stock will have an overall maximum thickness of twelve plies. Also, after completion of this sixth fold, the resulting folded sheet stock will have two ends of orientation, one end being a folded closed end, and the other end being an open-edge end, not having any fold.  
         [0064]    At FIG. 7B- 8 , a seventh fold  178  is made across the entire width of the sheet stock at a right angle from the point of origin, the seventh fold being located at the open-edge end of the folded sheet stock. This seventh fold is equal to approximately ⅕ of the total panel length and will result in the sheet stock now having a resulting top panel length (L 1 ) and a resulting adjoining bottom panel length (L 2 ) (i.e., L 1 =⅕ L and L 2 =⅘ L). Following completion of this seventh fold, the sheet stock will have an overall maximum thickness of twenty-four plies (e.g., resulting in twelve ply thickness at one end of the outsert and resulting in twenty-four ply thickness at the opposite end of the outsert).  
         [0065]    At FIG. 7B- 9 , an eighth fold  179  is made across the entire width of the sheet stock at a right angle from the point of origin. This eighth fold is equal to approximately ⅓ of the total panel length and will result in the sheet stock now having a resulting top panel length (L 1 ) and a resulting adjoining bottom panel length (L 2 ) (i.e., L 1 =⅓ L and L 2 =⅔ L). Following completion of this eighth fold, the sheet stock will have an overall maximum thickness of thirty-six plies (e.g., resulting in twelve ply thickness at one end of the outsert and resulting in thirty-six ply thickness at the opposite end of the outsert).  
         [0066]    At FIG. 7B- 10 , following the eighth fold, at a designated location on the outsert, a single glue spot  180  (or glue spots) is made thereon, with a suitable adhesive. If desired, the gluing step may be omitted.  
         [0067]    At FIG. 7B- 10 , a ninth fold  181  is made to complete the outsert. The ninth fold is made across the entire width of the sheet stock at a right angle from the point of origin. This ninth fold is equal to approximately ½ of the total panel length and will result in the sheet stock now having a resulting top panel length (L 1 ) and a resulting adjoining bottom panel length (L 2 ) (i.e., L 1 =½ L and L 2 =½ L). This ninth fold is made in a manner whereby the adhesive will maintain the outsert in a more or less fixed and compact relationship with respect to the top and bottom panels lengths of the folded sheet stock. Following completion of this final fold, the outsert will have an overall thickness of forty-eight plies.  
         [0068]    The method of forming the outsert  170  depicted in FIG. 7A may be modified slightly to form an outsert having a slightly different structure. In particular, the method of forming the outsert  170  may be modified in the following respects: 1) the modified method utilizes a sheet of stock having an overall length (L) of approximately 24 inches and an overall width (W) of approximately 10 inches; 2) in the modified method, an accordion fold having seven tandem folds (to produce eight equal-length panels) is initially made (instead of an accordion fold with five tandem folds as shown in FIG. 7B- 6 ); 3) in the modified method, the accordion fold is made in the direction parallel to the width of the sheet stock (instead of parallel to the length of the sheet stock as shown in FIGS.  7 B- 1  through  7 B- 6 ); and 4) two spots of glue may be used (instead of the single spot  180  shown in FIG. 7B- 10 ). This modified method will form an outsert having eleven folds, a total thickness of sixty-four plies, and an overall size of approximately 1.25 inches long, approximately 3 inches wide, and approximately 0.188 inches thick (depending on the thickness of the sheet stock used).  
         [0069]    [0069]FIG. 8 is a perspective view of an outsert  210  applied to the top of a container  212  for a pharmaceutical product.  
         [0070]    Each of the outserts described above may optionally be imperceptibly scored at various positions intrinsic to the outsert (indicating that the outsert is folded in a particular direction along the score line), to assist in the folding of the outsert, and, accordingly, each score line is part and parcel of each outsert.  
         [0071]    The methods of folding described above in connection with FIGS.  2 B- 4 B and  6 B- 7 B eliminate all unfolded exterior edges which lie in a direction parallel to the final fold direction, resulting in outserts having a more compact three-dimensional physical envelope. Inasmuch as the outserts depicted in FIGS.  2 A- 4 A and  6 A- 7 A are manufactured from a single sheet of stock, the outserts do not require any trimming step to be performed to achieve a certain size. The final size of the outserts is achieved by selecting a particular respective size of initial sheet stock to be utilized.  
         [0072]    Although specific dimensions have been disclosed herein for the sheet stock from which outserts are formed and for the final outserts themselves, those particular dimensions are not considered important to the invention, and outserts having different dimensions may be formed from sheet stock having different dimensions.  
         [0073]    Numerous additional modifications and alternative embodiments of the invention will be apparent to those skilled in the art in view of the foregoing description. This description is to be construed as illustrative only, and is for the purpose of teaching those skilled in the art the best mode of carrying out the invention. The details of the structure and method may be varied substantially without departing from the spirit of the invention, and the exclusive use of all modifications which come within the scope of the appended claims is reserved.
A method of producing a folded item having printed information thereon to provide information to the user of a product is disclosed. The method comprises (a) forming a first article having a first end, a second end, a length along a first direction, and a width along a second direction perpendicular to the first direction, the first article having a plurality of first elongate sheet portions and a plurality of second elongate sheet portions, each of the first elongate sheet portions having a first end and a second end, and each of the second elongate sheet portions having a first end and a second end, each of the first ends of the first elongate sheet portions being joined to a respective one of the first ends of the second elongate sheet portions at a respective fold coinciding with the first end of the first article so that the first end of the first article has no exterior unfolded sheet edges, each of the respective folds being parallel to the second direction; (b) folding the first article by making a first transverse fold in the first article to form a second article, the first transverse fold being parallel to the second direction and being made so that the second end of the first article is disposed between the first end of the first article and the first transverse fold; (c) depositing an adhesive on a portion of the second article; and (d) folding the second article by making a second transverse fold in the second article to form the folded item, the second transverse fold being parallel to the second direction so that the folded item has no exterior unfolded sheet edges which lie in a direction parallel to the second direction, the thickness of the sheet being such that when the folds in the first and second directions are made, the folds will cause the folded item to have a thickness of 0.25 inches or greater.