FOLDABLE CARDS AND RELATED METHOD OF MANUFACTURE

Abstract: A foldable trading card including two adjacent cards hingedly connected to one another with a clear overlaminate layer. A method of manufacturing the foldable trading card comprising the steps of: providing a two-sided sheet construction of multiple first and second cards in paired configuration; cutting the sheet construction to bisect the paired cards; providing registration indicia on the sheet construction; depositing a laminate over the sheet construction so that bisected pairs are joined; and, cutting the sheet construction with overlaminate layer in register with the registration indicia to form an independent foldable trading cards having first and second cards of substantially identical size and shape.

Description: FOLDABLE CARDS AND RELATED METHOD OF MANUFACTURE BACKGROUND OF THE INVENTION The present invention relates to foldable cards including two independent sheets foldable over cftie upon the other and a method of manufacturing the same. Conventional trading cards are of a single card construction having a front side and a rear side. A trading card typically displays the image of a sports figure or celebrity on the front of the card, and career statistics or other data on the back of the card. Trading cards usually are made of paperboard or other paper-like material. Trading cards of the prior art present a variety of problems. First, given the paperboard construction, the cards do not endure repeated shuffling and handling, and are damaged easily. Second, given that there are only two surfaces upon which to view information or images, the amount of information on the trading card is limited. SUMMARY OF THE INVENTION The aforementioned problems are overcome by the present invention comprising a foldable card that effectively increases the surface upon which information may be displayed. The present invention also provides for a unique method of manufacturing such foldable cards. The application of the present invention is useful in the manufacture of trading cards, as well as greeting cards, pamphlets, brochures, and the like. The foldable card comprises paired individual sheets, or cards, hingedly attached to one another by a durable laminate adhered over the cards. The individual cards accordingly can be folded open and closed like a book about the hinge or spine. The foldable cards of the present invention are manufactured with a unique method to insure that the images or graphics on the cards are properly aligned and that each of the paired cards are identical in size and shape. First, a two sided sheet construction is provided. The sheet includes multiple, uncut first and second cards in a paired configuration. Second, the sheets are cut so that the first and second cards of each paired configuration are separated from one another. The cuts correspond to the spine or hinge of the completed foldable card. Registration holes are punched in the sheet construction during this spine cutting step to insure exact alignment of a future peripheral cut. Third, a lamination film is adhered to one side of the sheet construction to form a hinge between the paired cards. Finally, the sheet construction and lamination layer are peripherally cut. The previously punched registration holes are identified by the cutter to position the cutter to cut booklet style trading cards where each of the individual cards of the pairs are substantially identical in size and shape to the other. In an alternative method of manufacturing the foldable cards, multiple uncut first and second cards are provided in paired configuration on a carrier web. The cards are cut so that the first and second cards are separated along a spine. Notably, registration indicia are not required given the precision cutting of conventional web label processing. Next, a lamination layer is adhered to one side of the web to form a hinge between the card. Finally, the web and lamination layer are peripherally cut so that each of the individual cards of the pairs are substantially identical in size and shape to the other. These and other objects, advantages, and features of the invention will be more readily understood and appreciated by reference to the detailed description of the preferred embodiment and the drawings. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a sectional view of a foldable card of the present invention; Fig. 2 is an exploded view of the foldable card; Fig. 3 is a sectional view of the layered construction of the foldable card; Fig. 4 is a flowchart showing the process of manufacturing the foldable card; Fig. 5 is a flowchart showing a first alternative process of manufacturing the foldable card; Fig. 6 is a perspective view of the outside covers of the foldable cards in a sheet construction of the preferred manufacturing process; and Fig. 7 is a perspective view of the foldout covers of the foldable cards in a sheet construction of the preferred manufacturing process. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT A foldable card having two sheets hingedly connected by an overlaminate film according to a preferred embodiment of the present invention is illustrated in Figs. 1 and 2, and generally designated 10. The foldable card of the preferred embodiment is a sports trading card; however, the construction alternatively may be used with greeting cards, pamphlets brochures, direct mailers, and the like. In the preferred embodiment, two independent cards or sheets 12, 14 are disposed immediately adjacent one another. As depicted in Fig. 1, a laminate film 20 is adhered to the cards 12, 14 with adhesive 16. With the laminate providing a spine 22, card 14 may be folded over on card 12. Accordingly, the foldout images 2 and 8 are hidden from view and the folded card resembles a conventional trading card. Preferably, foldout images 2 and 8 cooperate to form a single unitary image; however, images 2 and 8 may be independent of one another as desired. A flowchart diagramming the preferred method for constructing the foldable trading cards of the present invention is depicted in Fig. 5. The method being: providing a two-sided sheet construction having a plurality uncut, paired individual cards 202; die cutting the sheet construction whereby each of the paired cards are separated from each other along a spine cut 204; providing indicia on the sheet construction in registration with the spine cuts 206; adhering an over-laminate layer over the separated card pairs to reconnect adjacent individual cards to one another 208; aligning a peripheral die cutter with the registration marks, and accordingly, die cutting the sheet construction to form foldable trading cards including first and second individual cards of substantially identical size and shape 210. There will now be described in greater detail the construction of the foldable trading cards of the preferred embodiment. With reference to Fig. 2, the foldable cards include cards 12, 14 having images or graphics thereon. Card 12 has foldout image 2 on one side, and a front cover image 6 on the opposite side thereof. Similarly, card 14 has foldout image 8 on one side, and rear cover image 4 on the opposite side thereof. Images 2 and 8 cooperate to form a unitary image. Alternatively, images 2 and 8 may form additional surface area to provide non-cooperative additional independent images or independent information fields. While the preferred embodiment uses only two paired cards, alternative embodiments may include three or more cards foldable on one another. In the preferred embodiment, the images on the cards 12 and 14 are preferably colored with unique tinting layers as described below, but may be conventionally colored or black and white. Preferably, image 6 on card 12 is a picture or image of a sports figure or other desirable image. Image 4 of card 14 is preferably information or statistics concerning image 6. In this configuration, the foldable trading card, resembles a conventional trading card when folded closed. The information and images may be printed, etched, engraved, holographed, or otherwise incorporated into the cards 12 and 14. With further reference to Figs. 1 and 2, clear laminate 20 is adhered over the images 2 and 8 of the cards with adhesive 16. The overlaminate 20 may also include engravings or other surface indicia which enhance the images 2 and 8. The two cards 12 and 14 bound by overlaminate 20, may then be folded over upon one another, as depicted in Fig. 1 along spine 22. The overlaminate is a clear plastic polymer, for example, a polyester terephthalate (PET), or other material that is transparent, resilient, and tear resistant so that after repeated folding, it does not wear out. With reference to Fig. 3, the layered construction of the individual cards 12, 14 will now be described. The laminate 20 is adhered with adhesive 16 onto a raw film 24 which is effectively the top surface of the cards 12 and 14. The raw film 24 is preferably transparent or highly translucent PET of a thickness of 2 mils (2/1000ths of an inch); however, depending on the application, this raw film layer 24 may be of any thickness and made of any transparent material. Printed on the raw film 24 is an ink layer 26 which defines the images on the cards. This ink layer may be of any number of offset inks, depending on the desired colors of the images. Alternatively, the ink layer may include any suitable type of ink, including ultraviolet curable flexographic inks and the like. In the preferred embodiment, screen etch 28 is displaced on the ink layer to enhance the images. Screen etch 28 is adhered to a chrome polyester layer 32, preferably of 0.5 mil thickness; however, depending on the application, the chrome layer may be of any thickness. Alternatively, the chrome layer 32 may be deposited on the screen etch 28 or ink layer 26 using vacuum metalizing techniques, as will appreciated by those skilled in the art. The chrome layer 32 effectively enhances the reflective properties of the images as depicted in the ink layer 26. In the preferred embodiment, the chrome layer may also be replaced by any highly reflective material, for example, chrome ink, silver ink, and the like. The chrome layer 32 is adhered to base stock 36 with an adhesive 34, which is preferably an emulsion adhesive, but may be any type of adhesive suitable for the desired application, such as ultraviolet curable adhesive, heat set adhesive, and the like. The base stock is preferably 18 point paper board stock but may be of any thickness depending on the application. The base stock be made from paper, plastic or other suitable material. On the back of board stock 36, an ink layer 38 is deposited. This ink layer comprises the images 4 and 6 as depicted in Fig. 2. With reference to Fig. 4, there will now be described a preferred method for manufacturing the foldable card of the present invention. Figs. 6 and 7 supplement the flowchart of Fig. 4. The method begins with step 202 by providing a two-sided sheet construction, as depicted in Fig. 6, having a plurality of paired, but uncut individual cards 12, 14. Each of the cards 12,14 have corresponding images 4, 6 printed thereon, on the front side of the sheet construction 120. On the rear side of the sheet construction 122, as depicted in Fig. 7, images 2, 8 cooperate to form a unitary image on each of the cards 12, 14 respectively. As illustrated in the flow chart of Fig. 4, the next step is to die cut 204 the spines of the sheet construction to bisect the paired individual cards 12, 14 from one another to form a plurality of adjacent transverse strips 114. Fig. 6 illustrates the spine die cut lines 110 which separating adjacent paired cards 12, 14. Next, in step 206, indicia in registration with spine cut are provided on the sheet construction to insure exact registration of the peripheral cutting step 210, as described below, in relation to the spine cut step 204. Accordingly, with this registration, the sizes and shapes of the paired cards 12 and 14 are substantially identical. This registration indicia is preferably pin holes located in at least two places on the sheet construction. Alternatively, the registration indicia may be scannable images on the sheet construction that can be detected by conventional die cutter aligning machines, or other like registration indicia. As shown in step 208 of Fig. 4, a laminate is adhered to the sheet construction so that the adjacent transverse strips are reattached to one another. Finally, the sheet construction is peripherally die cut to form independent foldable trading cards 210. The peripheral die cut is aligned with the registration indicia, so that each of the individual paired cards in the foldable trading card are substantially identical in size and shape to each other. As depicted in Fig. 6, the sheet construction 118 and attached overlaminate 20 are butt cut with the die cutter through the entire sheet 118, adhesive 16, and laminate 20, at cut lines 112 and 114 to form independent foldable trading cards comprised of paired individual cards 12 and 14. While the preferred method of manufacturing the foldable trading cards described above uses a butt cutting method to separate the finished foldable cards from the sheets, the finished cards may also be removed from the sheets using conventional skeleton die cutting. Accordingly, a waste matrix would be created and would require removal from the finished foldable cards. Alternative Embodiment A first alternative embodiment of the foldable card will now be described. With reference to Fig. 3, a foldable trading card may also have a simplified layered construction including only overlaminate 20, ink layer 26, base stock 36 and second ink layer 38. The ink layer 26 is deposited directly on base stock 36, and the overlaminate 20 is deposited directly over the ink layer with adhesive 16. As depicted, second ink layer 38 would similarly be deposited directly on the base stock 36. Any permutation of the layered construction, including the addition of other layers of different materials will also be appreciated by those skilled in the art. An alternative method of manufacturing foldable cards is illustrated in the flow chart of Fig. 5. This method of manufacturing produces foldable trading cards provided from a web of multiple paired first and second individual cards. The first step in producing foldable trading cards from a web includes providing a web of multiple first and second cards in paired configuration on the web 302. Next, the web is cut for example, with a conventional bladed rotary cutter so that each of the paired first and second cards are bisected 304. A laminate is then applied over the entire web so that the previously bisected first and second cards are rejoined to one another on the web by way of the adhered laminate overlying both of the cards 306. Finally, the web is cut with, for example, a rotary cutter, a second time into the completed foldable cards 308. Each of the foldable cards include the first and second individual cards in paired configuration. Because of the precise cutting capabilities provided by conventional web cutting techniques, the resultant individual first and second cards are substantially identical in size and shape without the need to use registration indicia to precisely cut the cards as in the preferred embodiment. As with the preferred embodiment, the web of foldable cards may be dissected into individual cards using a butt cutting technique, or a conventional skeleton cutting technique which would consequently produce a waste matrix. The above description is that of a preferred embodiment of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. Any references to claim elements in the singular, for example, using the articles "a," "an," "the," or "said," is not to be construed as limiting the element to the singular.

Claims: CLAIMS The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows: - 1 - A foldable card comprising: a first card having a first image; a second card having a second image; and a laminate covering said first and second cards whereby said first and second cards are hingedly connected and are capable of being folded between an open position and a closed position with respect to one another. - 2 - The foldable card of claim 1 wherein said first card includes a first portion of a unitary image and said second card includes a second portion of said unitary image, said first portion and said second portion cooperating to form a full unitary image when said cards are in said open position. - 3 - The foldable card of claim 1 wherein said laminate is a plastic polymer film. - 4 - The foldable card of claim 3 wherein at least one of said first and second cards include a reflective layer incorporated therein whereby the reflective characteristics of at least one of said first and second images is increased. - 5 - The foldable card of claim 4 wherein said first and second images are disposed on said laminate. - 6 - The foldable card of claim 4 wherein said first and second cards include a layered construction. - 7 - The foldable card of claim 6 wherein said layered construction includes a film layer having a first ink layer disposed thereon. - 8 - The foldable card of claim 7 wherein a screen etch layer is disposed adjacent said first ink layer. - 9 - The foldable card of claim 8 wherein said screen etched layer is adhered to said reflective layer. - 10 - The foldable card of claim 9 wherein said reflective layer is constructed of materials selected from the group consisting of chrome polyester, chrome ink, and silver ink. - 11 - The foldable card of claim 10 wherein said reflective layer is adhered to a first side of a base stock with an adhesive. - 12 - The foldable card of claim 11 wherein said adhesive is an emulsion adhesive. - 13 - The foldable card of claim 10 wherein said reflective layer is disposed on said film layer. - 14 - The foldable card of claim 12 further comprising a second ink layer disposed on a second side of said base stock opposite said first side. - 15 - A foldable card assembly comprising: a first card having a first graphic portion and a first straight edge; a second card having a second graphic portion and a second straight edge, said first and second cards abutting one another along said first and second straight edges, said first and second graphic portions abutting one another to cooperatively define a composite graphic; and a transparent overlaminate entirely overlying and secured to both of said first and second cards, said overlaminate being sufficiently flexible to permit said overlaminate to flexibly bend at said abutting first and second edges, whereby said first and second cards can be folded together and unfolded. - 16 - A method for constructing a foldable card comprising the steps of: providing a sheet construction including a plurality of first and second cards in paired configuration; cutting the sheet construction whereby each of the card pairs are bisected at a spine cut; laminating the sheet construction; and peripherally cutting the sheet construction to define a plurality of foldable cards wherein the first and second cards are substantially identical in size and shape. - 17 - The method of claim 16 further comprising the step of providing indicia on the sheet construction and registration with the spine cut wherein the sheet construction is peripherally cut in alignment with the registration indicia. - 18 - The method of claim 17 wherein said peripheral cutting step includes butt cutting the sheet construction. - 19 - The method of claim 17 wherein said peripheral cutting step includes skeleton cutting the sheet construction whereby a waste matrix is created. - 20 - A process for manufacturing foldable cards comprising the steps of: providing a web of multiple paired first and second cards; cutting the web whereby each of the paired first and second cards are bisected at a spine cut; laminating the web; and cutting the web a second time whereby a plurality of foldable cards are defined, each foldable card including at least one of the card pairs with the first and second card substantially identical in size and shape. - 21 - The process of claim 20 wherein said laminating step reconnects said first and second cards at the spine cut to create a hinge. - 22 - The process of claim 21 wherein said second cutting step is in registration with said first cutting step. - 23 - The process of claim 22 wherein said second cutting step includes butt cutting the web to define the foldable cards. - 24 - The process of claim 22 wherein said second cutting step includes skeleton cutting the web to define the plurality of foldable cards, whereby a waste matrix is produced. - 25 - A process for manufacturing a foldable card comprising the steps of: providing a sheet having multiple images; cutting for a first time the sheet construction to form a plurality of transverse strips; depositing a laminate layer over the sheet construction whereby the transverse strips are hingedly connected to one another; detecting registration indicia on the sheet construction; and cutting the sheet construction a second time in proper alignment with the registration indicia a second time to form foldable cards including individual independent cards of substantially identical size and shape. - 26 - The method of claim 25 wherein said second cutting step includes butt cutting the sheet construction to form the independent foldable cards. - 27 - The method of claim 25 wherein said second cutting step includes skeleton cutting the sheet construction to form the independent foldable cards whereby a waste matrix is produced.

Inventors: KLIFF STEVEN L, MCKILLIP BARRON G, KLIFF, STEVEN, L., MCKILLIP, BARRON, G.
Applicants: CHROMIUM GRAHICS
Application year: 2001
Main classification: B44C
IPC codes: B42D15