초록 ▼

A low density polyethylene film layer is extrusion coated on densified bleached kraft paper liner to form a film-coated liner sheet. A facestock sheet is adhered with a layer of hot melt adhesive to the film layer to form a laminate sheet web, which is rolled on a roll. The facestock sheet, the film

A low density polyethylene film layer is extrusion coated on densified bleached kraft paper liner to form a film-coated liner sheet. A facestock sheet is adhered with a layer of hot melt adhesive to the film layer to form a laminate sheet web, which is rolled on a roll. The facestock sheet, the film layer and the adhesive layer together define a laminate feedstock. The roll is transported to and loaded on a press with the liner side up. One (or both) edge(s) of the web is (are) crushed with a calendering die to form thin lead-in edge(s). The web is die cut on the bottom face, up through the laminate facestock, but not through the paper liner, to form the perimeters of a grid of blank business cards or other printable media, with a waste paper frame of the laminate facestock encircling the grid. The web is then die cut from the top through the paper liner and to but not through the laminate facestock, to form liner strips covering the back face of the laminate facestock. According to one preferred embodiment of the invention, alternate ones of the strips are then pulled off of the laminate facestock web. A final production step is to sheet the web to form the desired sheet width (or length) of the laminated sheet construction. The individual laminated business card sheets can be stacked into the infeed tray of an ink jet printer for example, and the sheets individually and automatically fed lead-in edge first into the printer and a printing operation performed on each of the printable media, to form a sheet of printed media. The remaining strips on the back of the laminate facestock cover the lateral cut lines in the laminate facestock and thereby hold the facestock together as it is fed into and passed through the printer. The user then individually peels the printed media off of the strips and out from the waste paper frame. Thereby printed business cards (or other printed media), each with its entire perimeter defined by clean die cuts, are formed. Instead of calendering both edges of the web and thus the sheet, one end can be calendered and a strip of the laminate facestock can be stripped off of the liner sheet from the other end. The remaining thin liner sheet strip at the other end forms a thin infeed edge for feeding into a horizontal feed, ink jet printer.

대표청구항 ▼

1. A method of forming sheets of printable media, comprising the steps of:(a) providing a roll of a web of dry laminate sheet construction comprising a liner sheet on a facestock sheet; (b) unwinding the web from the roll; (c) calendering an edge of the unwound web; (d) die cutting the facestock she

1. A method of forming sheets of printable media, comprising the steps of:(a) providing a roll of a web of dry laminate sheet construction comprising a liner sheet on a facestock sheet; (b) unwinding the web from the roll; (c) calendering an edge of the unwound web; (d) die cutting the facestock sheet of the unwound web without cutting the liner sheet to form outline perimeters of printable media; (e) die cutting the liner sheet of the unwound web without cutting the facestock sheet to form liner strips; (f) after step (e), removing at least some but not all of the liner strips from the web; and (g) after steps (c), (d), (e) and (f), sheeting the web into sheets. 2. The method of claim 1 further comprising removing an end strip of the facestock sheet to expose a top surface of a strip of the liner sheet.3. The method of claim 2 wherein the exposed liner sheet strip is opposite to the calendered edge.4. The method of claim 3 further comprising feeding the sheet with the exposed liner sheet strip first into a vertical feed printer.5. The method of claim 3 further comprising feeding the sheet with the calendered edge first into a horizontal feed printer.6. The method of claim 1 wherein step (c) is before steps (d) and (e).7. The method of claim 6 wherein step (d) is before step (e).8. The method of claim 1 wherein step (c) is after steps (d) and (e).9. The method of claim 1 wherein the removed liner strips of step (f) form a waste liner matrix from the web, and step (f) includes winding the waste liner matrix on a roll.10. The method of claim 1 further comprising after step (g), stacking the sheets in a stack and packaging the stack in a package.11. The method of claim 1 further comprising after step (b) and before step (g), printing indicia on the facestock sheet.12. The method of claim 11 wherein the indicia includes product code indicia and manufacturer indicia.13. The method of claim 11 wherein said printing step is before steps (c), (d) and (e).14. The method of claim 11 wherein said printing step is with the facestock sheet facing up and the liner sheet facing down, and after said printing step, turning the web so that the liner sheet is facing up.15. The method of claim 1 wherein steps (c), (d), (e) and (f) are with the web disposed with the liner sheet facing up and the facestock sheet facing down.16. The method of claim 1 wherein the liner strips have wavy side edges.17. The method of claim 1 wherein the printable media comprise printable business cards.18. A method of forming sheets of business cards, comprising:(a) providing a roll of a web of dry laminate sheet construction including a liner sheet on a facestock sheet construction, the facestock sheet construction including a cardstock sheet, an adhesive layer on a backside of the cardstock sheet, and a film layer on the adhesive layer, the liner sheet being extrusion coated on one side with the film layer; (b) unwinding a portion of the web from the roll; (c) die cutting the facestock sheet construction of the unwound web portion without through-cutting the liner sheet to form perimeters of blocks of printable business cards, each of the blocks including a plurality of rows and columns of the cards; and (d) sheeting the web into individual sheets, each sheet including one of the blocks of printable business cards surrounded by a facestock sheet construction waste frame, and the liner sheet being solid and covering back sides of all of the die cut lines formed by the die cutting. 19. The method of claim 18 further comprising after the unwinding calendering an edge of the unwound web.20. The method of claim 19 wherein the calendering is before the die cutting.21. The method of claim 18 further comprising after the sheeting, stacking the sheets in a stack and packaging the stack in a package.22. The method of claim 18 further comprising before the sheeting, printing indicia on the cardstock sheet.23. The method of claim 22 wherein the indicia includes product code indicia and manufacturer indicia.24. The method of claim 22 wherein the printing is before the die cutting.25. The method of claim 18 further comprising removing an end strip of the facestock sheet construction to expose a top surface of a strip of the liner sheet.26. The method of claim 25 wherein the exposed liner sheet strip is opposite to a calendered edge of the dry laminate sheet construction.27. The method of claim 26 further comprising feeding the sheet with the exposed liner sheet strip first into a vertical feed printer.28. The method of claim 26 further comprising feeding the sheet with the calendered edge first into a horizontal feed printer.29. The method of claim 18 wherein the sheeting includes the liner sheet of each of the individual sheets covering the entire backside of the facestock sheet construction.30. The method of claim 18 further comprising after the sheeting, passing the individual sheets through a printer or copier and printing desired indicia on the printable business cards to form printed business cards.31. The method of claim 30 further comprising after the printing, removing the printed business cards from the liner sheet and the frame.32. The method of claim 30 wherein the printer or copier is an ink jet printer.33. The method of claim 18 wherein the cards in adjacent rows adjacent each other, abut one another separated only by die cut lines therebetween.34. The method of claim 18 wherein the die cutting includes the cards in adjacent columns directly abut each other separated only by a die cut line therebetween.35. A method of forming sheets of printable media, comprising:(a) providing a roll of a web of dry laminate sheet construction comprising a liner sheet on a facestock sheet; (b) unwinding the web from the roll; (c) die cutting the facestock sheet of the unwound web without cutting the liner sheet to form outline perimeters of printable media; (d) die cutting the liner sheet of the unwound web without cuffing the facestock sheet to form liner strips; (e) removing at least some but not all of the liner strips from the web; and (f) sheeting the web into sheets. 36. The method of claim 35 wherein the printable media are printable business cards.