Integrated plasticized card in a paper carrier and method of manufacture

• US 6,814,375 B2
• Filed: 10/10/2001
• Issued: 11/09/2004
• Est. Priority Date: 10/10/2000
• Status: Expired due to Fees

• Current Assignee: Relizon Canada, Inc. (Data Communications Management (US) Corp.), Relizon Canada
• Original Assignee: Relizon Canada
• Inventors: MacDonald, Thomas, Ritchie, William Dale, Cox, Christopher Robert, Carrigan, Thomas
• Primary Examiner(s): CARTER, MONICA SMITH
• Application Number:
  US09/973,044
• Publication Number:
  US 20020041093A1
• Time in Patent Office: 1,126 Days
• Field of Search: 283/61, 283/62, 283/74, 283/75, 283/81, 283/82, 283/94, 283/98, 283/101, 283/105, 283/106, 283/107, 428/40.1, 428/41.7, 428/42.1, 428/42.2, 428/42.3, 428/43
• US Class Current: 283/61
• CPC Class Codes: B42D 25/00 Information-bearing cards or sheet-like structures characterised by identification or security features; Manufacture thereof printing processes to produce identification or security features B41M3/14
• CPC Class Codes: B42D 25/20 characterised by a particular use or purpose
• CPC Class Codes: B42D 25/369 Magnetised or magnetisable materials
• CPC Class Codes: B42D 25/475 Cutting cards
• CPC Class Codes: B42D 5/027 Sheets or cards attached to a carrier strip or web shipping forms B42D15/006
• CPC Class Codes: Y10T 428/14 Layer or component removable to expose adhesive
• CPC Class Codes: Y10T 428/1486 Ornamental, decorative, pattern, or indicia
• CPC Class Codes: Y10T 428/15 Sheet, web, or layer weakened to permit separation through thickness

Abstract

A carrier sheet with an integrated card and preferably, but not exclusively, a magnetic strip card is described. The sheet contains printed information which is in part card information printed at a predetermined location on a front face of a carrier sheet in a card region thereof and oriented to be disposed on an outer surface of the front and a rear card panel of the card to be formed. The siliconized liner patch, containing a pressure-sensitive adhesive, is laminated on the back surface of the carrier sheet and disposed to extend over the card region. A face patch of clear poly material containing a magnetic strip is immovably secured over the card region on the front face of the paper carrier sheet. A die cut delineates card contour panels and a straight fold line separates the panel whereby they may be folded together when detached from the carrier sheet with the pressure-sensitive adhesive of the liner being transferred to the rear surface of the panels so that the panels can be folded together with their rear surface stuck together. The method of manufacture and a method of use is also described herein.

Claims

1. A carrier sheet with an integrated card, said carrier sheet having printed information thereon, said printed information containing card information printed at a predetermined location on a front face of said carrier sheet in a card region of said sheet and oriented to be disposed on an outer surface of at least one of a front and a rear card panel of a card to be formed, a siliconized liner patch containing a pressure-sensitive adhesive surface is laminated on a back surface of said carrier sheet and disposed to extend over said card region, a face patch of clear poly material is immovably secured over said card region on said front face of said carrier sheet, a magnetic strip patch is immovably secured over said card region on an outer surface of a magnetic strip panel, a die cut delineates said front and rear card panels disposed adjacent one another and said magnetic strip panel adjacent said front panel, said die cut extending through said face patch and said carrier sheet;

said die cut card panels being retained in said carrier sheet by said pressure sensitive adhesive of said siliconized liner patch, and straight fold lines in said face patch between said front and rear card panels and between said magnetic strip panel and said front card panels, said card being formable by peeling off said panels from said carrier sheet with said pressure-sensitive adhesive releasing from said siliconized liner patch whereby said adhesive now lies on a back face of said card panels, and folding said panels along said straight fold lines to firstly mate said back face of said front and rear card panels and then said back face of said magnetic strip panel on said rear card panel.

2. A carrier sheet as claimed in claim 1, wherein said magnetic strip is disposed spaced and parallel to an edge of said rear panel.

3. A carrier sheet as claimed in claim 1, wherein said carrier sheet is a paper printed form having opposed detachable perforated carrier strips for feeding same in a high speed printer and patch applying and a butterfly die cutting machine.

4. A carrier sheet as claimed in claim 1, wherein said magnetic strip is compatible for use in an encoder/reader machine to be encoded or read or both read and encoded.

5. A carrier sheet as claimed in claim 1, wherein said carrier sheet is a paper sheet detachable panel of a plurality of fan-folded sheet panels.

6. A carrier sheet as claimed in claim 1, wherein said magnetic strip contains personalized information, said magnetic strip being an encoded magnetic strip.

7. A method of forming a carrier sheet having an integrated detachable card, said method comprising the steps of:

i. Printing a carrier sheet with information containing card information printed at a predetermined location on a front face of said carrier sheet in a card region of said carrier sheet and oriented to be disposed on an outer surface of at least one off a front and rear card panel of a card to be formed,

ii. applying a siliconized liner patch containing a pressure-sensitive adhesive surface on a back surface of said carrier sheet and attached by said adhesive to extend over said card region,

iii. securing a face patch of clear poly material and a magnetic strip patch over said card region on said front face of said carrier sheet,

iv. die cutting said front card panel, said rear card panel and a magnetic strip panel in said card region, said die cut extending through said face patch, said magnetic strip patch and said carrier sheet whereby said die cut panels adjacent one another are solely retained in said carrier sheet by said pressure sensitive adhesive on said siliconized liner patch on said back surface of said sheet, and

v. forming a straight fold line in said face patch between said front and rear card panels and front card panel and magnetic strip panel to permit said adjacent card panels to be folded together on their back faces along said fold line when said adjacent die cut card panels are peeled off said siliconized liner patch with the pressure-sensitive adhesive on their back surface.

8. A method of forming a carrier sheen as claimed in claim 7, wherein said step (iii) includes orienting said magnetic strip across said magnetic strip panel and heat sealing said face patch on said card region.

9. A method of forming a carrier sheet as claimed in claims 7 and 8, wherein there is further provided before step (i) inputting personalized data in a computer programmable unit whereby said step (i) comprises printing personalized information.

10. A method of forming a carrier sheet as claimed in claim 7, wherein there is further provided the step of encoding said magnetic strip with personalized information and verifying said personalized information.