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US 8,524,141 B2Granted
Method of making a card sheet
OwnerMartin Utz, Karl Lengfeller +6inventors
InventorsMartin Utz, Karl Lengfeller, Michael Wilkes, Sriram Venkatasanthanam, Ramin Heydarpour, Chia-Hsi Chu, Ronald Ugolick, Ali R. Mehrabi
Life of this patent
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Abstract
A card sheet including a top material having punched lines, the front side of the top material being printable. A carrier material of at least one polymer layer is directly applied as by extruding to the back side of the top material. The polymer has a stress-at-break in the range of 10 to 30 MPa and an elongation at break in the range of 10 to 120%. From the card sheet individual cards may be broken out to form high quality calling (business) cards, photograph cards, post cards or the like.
Claims77
A method of making card sheet, comprising:
- coating a polymer carrier layer directly onto a back side of a top sheet, wherein the top sheet includes a layer of paper, the layer of paper has a back side that is the back side of the top sheet, the resulting polymer carrier layer has a top side and an opposing back side, and the top side of the polymer carrier layer is coupled to the back side of the top sheet;
- applying a layer on the back side of the polymer carrier layer;
- and
- cutting at least one cut line entirely through the top sheet to form at least a portion of a perimeter of a card;
- wherein the polymer carrier layer has stress and elongation properties such that after the sheet has been passed through a printer or copier and desired indicia printed on the front side or on a coating on the top sheet, the sheet can be folded forward with a single folding action so that the polymer carrier layer snap breaks along one of the at least one cut line to form a separate or separable printed card.
2 more elements
A method of making a card sheet, comprising:
- extruding a polymer layer directly onto a back side of a top sheet, wherein the top sheet includes a layer of paper, the layer of paper has a back side that is the back side of the top sheet, the resulting polymer layer has a top side and an opposing back side, and the top side of the polymer layer is coupled to the back side of the top sheet;
- applying a layer on the back side of the polymer layer;
- and
- cutting cut lines entirely through the top sheet to form at least a portion of a perimeter of a card;
- wherein the polymer layer has stress and elongation properties such that after the card sheet has been passed through a printer or copier and desired indicia printed on the front side or on a coating on the top sheet, the card sheet can be folded forward with only a single folding action whereby the polymer layer snap breaks along one of the cut lines to form an edge of a separable printed card.
2 more elements
A method of making a snap-breakable card sheet, comprising:
- applying a coating of a polymer and vehicle mixture directly on a back side of a substrate, wherein the substrate includes a layer of paper, the layer of paper has a back side that is the back side of the substrate, and the polymer and vehicle mixture is applied to the back side of the substrate;
- drying the coating to at least in substantial part form a film layer on the back side of the substrate, the resulting film layer having a top side and an opposing back side, and the top side of the film layer is coupled to the back side of the substrate;
- applying a layer on the back side of the film layer;
- after applying the coating of the polymer and vehicle mixture, cutting cut lines through the substrate to form at least a portion of a perimeter of a card;
- and
- the film layer having physical properties such that after the cutting, the film layer breaks with only a single folding action along one of the cut lines to form an edge of the card.
3 more elements
A method of making a card sheet, comprising:
- applying a coating of a pre-polymer mixture directly on a back side of a substrate, wherein the substrate includes a layer of paper, the layer of paper has a back side that is the back side of the substrate, and the pre-polymer mixture is applied to the back side of the substrate;
- curing the coating to at least substantially form a film layer on the back side of the substrate, the resulting film layer having a top side and an opposing back side, and the top side of the film layer is coupled to the back side of the substrate;
- applying a layer on the back side of the film layer;
- cutting cut lines through the substrate and to the film layer to form at least a portion of a perimeter of a card;
- and
- the film layer having physical properties such that after the cutting, the film layer breaks with only a single folding action along one of the cut lines to form an edge of the card.
3 more elements
Dependencies are inferred from the claim text.