Integrated card and business form and method for making same

• US 20050181167A1
• Filed: 08/07/2003
• Published: 08/18/2005
• Est. Priority Date: 08/08/2002
• Status: Active Grant

• Current Assignee: David H. Behnen
• Original Assignee: David H. Behnen
• Inventors: Behnen, David H.
• Granted Patent: US 7,326,315 B2
• Time in Patent Office: Days
• US Class Current: 428/41.900
• CPC Class Codes: B42D 5/027 Sheets or cards attached to a carrier strip or web shipping forms B42D15/006
• CPC Class Codes: Y10T 156/1057 Subsequent to assembly of laminae
• CPC Class Codes: Y10T 156/1064 Partial cutting [e.g., grooving or incising]
• CPC Class Codes: Y10T 156/1082 Partial cutting bonded sandwich [e.g., grooving or incising]
• CPC Class Codes: Y10T 428/14 Layer or component removable to expose adhesive
• CPC Class Codes: Y10T 428/1481 Dissimilar adhesives
• CPC Class Codes: Y10T 428/149 Sectional layer removable
• CPC Class Codes: Y10T 428/1495 Adhesive is on removable layer
• CPC Class Codes: Y10T 428/24802 Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]

Abstract

A card and business form assembly (10) and method for making same. The assembly includes a printable carrier sheet (12) having a card (14) that is releasably attached to the sheet by a backer (16). The method for making this assembly includes introducing a tag web (60) into a printing press; printing indicia (30) on the tag web; applying a first layer of lamination (28) and a second layer of lamination (42) by adhesive means onto bottom surface of the tag stock (18); bonding all the materials including the first and second layers of lamination and the tag web using UV light; cooling the tag web; die cutting the cards; die cutting the backer; forming line feeding holes (109) adjacent to the side edges of the tag web; forming perforations to separate predetermined sections of the tag web; and feeding perforated tag web into a fan fold machine (106) for fan folding into the finished product.

Claims

1. An integrated card and business form assembly comprising:

a coated carrier sheet having a top surface and a bottom surface;

a backer extending over only a portion of said bottom surface; and

a card defined by a cut in said carrier sheet and attached to said carrier sheet by said backer.

2. The assembly as recited in claim 1, wherein said cut in said carrier sheet defines a border region that surrounds said card and is co-planar with said card.

3. The assembly as recited in claim 1, wherein said backer includes a layer of lamination that is adhered to said card and said bottom surface of said carrier sheet by a layer of adhesive, said layer of lamination extending over said card and extending over only the portion of said bottom surface, including said surrounding border region of said carrier sheet.

4. The assembly as recited in claim 1, wherein said bottom surface of said carrier sheet includes a first layer of lamination that is adhered to said bottom surface by a first layer of adhesive.

5. The assembly as recited in claim 4, wherein said first layer of adhesive is made of hold out adhesive that forms a permanent bond between said first layer of lamination and said bottom surface.

6. The assembly as recited in claim 4, wherein said bottom surface of said carrier sheet includes a second layer of lamination that is adhered to said first layer of lamination by a second layer of adhesive.

7. The assembly as recited in claim 6, wherein said second layer of adhesive is made of pressure sensitive adhesive that forms a fugitive bond between said first layer of lamination and said second layer of lamination.

8. The assembly as recited in claim 7, wherein said card is formed form a first cut that extends through said top surface, through said bottom surface, and through said first layer of lamination without extending through said second layer of lamination.

9. The assembly as recited in claim 7, wherein said backer is formed from a second cut that extends through said second layer of lamination and said first layer of lamination without extending through said bottom surface, said card being releasably attached to said carrier sheet by said backer.

10. A method for making an integrated card and business form assembly, said method comprising the following steps:

introducing a tag web having a top surface and a bottom surface into a printing press;

printing indicia on said tag web;

applying a first layer of lamination on the bottom surface of said tag web using a first adhesive means;

applying a second layer lamination over said first layer of lamination using a second adhesive means;

cooling said tag web;

cutting a card in said tag web; and

cutting a backer in said tag web.

11. The method as recited in claim 10, further comprising the step of providing a first adhesive means made of hold out adhesive, wherein said first adhesive means forms a permanent bond between said first layer of lamination and said bottom surface of said tag web.

12. The method as recited in claim 10, further comprising the step of applying said first adhesive means through the use of pattern coating.

13. The method as recited in claim 10, further comprising the step of providing a second adhesive means made of pressure sensitive adhesive, wherein said second adhesive means forms a fugitive bond between said first layer of lamination and said second layer of lamination.

14. The method as recited in claim 10, further comprising the step of cutting said card in said tag web, wherein said cutting step includes forming a cut that extends through said top surface, said bottom surface, and said first layer of lamination without extending through said second layer of lamination, said card being co-planar with said tag web.

15. The method as recited in claim 14, wherein said tag web includes a border region that surrounds said card, said card being co-planar with said border region.

16. The method as recited in claim 15, further comprising the step of cutting said backer in said tag web, wherein said cutting step includes forming a cut that extends through second layer of lamination and said first layer of lamination without extending through said bottom surface, said backer extending over said card and extending over only a portion of said bottom surface including said surrounding border region of said tag web, said card being releasably attached to said tag web by said backer.

17. The method as recited in claim 10, further comprising the step of bonding said first layer of lamination to said bottom surface using UV light.

18. The method as recited in claim 10, further comprising the step of bonding said second layer of lamination to said first layer of lamination using UV light.

19. The method as recited in claim 10, further comprising the step of forming perforations on predetermined sections of said tag web.

20. A method for making an integrated card and business form assembly, said method comprising the following steps:

introducing a tag web having a top surface and a bottom surface into a printing press;

printing indicia on said ton surface and said bottom surface of tag web;

applying a first layer of lamination on the bottom surface of said tag web using a first adhesive means, said first adhesive means being a hold out adhesive that is applied through the use of patter coating and that forms a permanent bond between said first layer of lamination and said bottom surface;

bonding said first layer of lamination to said bottom surface using UV light;

applying a second layer lamination over said first layer of lamination using a second adhesive means, said second adhesive means being a pressure sensitive adhesive that forms a fugitive bond between said first layer of lamination and said second layer of lamination;

bonding said first layer of lamination to said second layer of lamination using UV light;

cooling said tag web;

cutting a card in said tag Web, wherein said cutting step includes forming a cut that extends through said top surface, said bottom surface, and said first layer of lamination without extending through said second layer of lamination; and

cutting a backer in said tag web, wherein said cutting step includes forming a cut that extends through said second layer of lamination and said first layer of lamination, without extending through said bottom surface, said backer extending over only a portion of said bottom surface of said tag web, said card being releasably attached to said tag web by said backer;

forming a waste matrix including said first and second layers of lamination and second adhesive means;

forming feed holes along the side edges of said tag web;

forming perforations on predetermined sections of said tag web; and

fan folding said perforated tag web.