Abstract:
Sealed cards and methods for producing the same are described. An example method includes exposing a first side portion of a first layer of a sealed card assembly. The first layer covering instructions on an inner portion of a second layer of the sealed card assembly. The method also includes coupling the first side portion to an object to enable the instructions to be covered by the first layer until removal thereof.

Description:
RELATED APPLICATION 
       [0001]    This patent arises from a continuation of U.S. application Ser. No. 12/203,638, filed Sep. 3, 2008, which is hereby incorporated herein by reference in its entirety. 
     
    
     FIELD OF THE DISCLOSURE 
       [0002]    The present disclosure relates generally to forms and, more particularly, to sealed cards and methods of producing the same. 
       BACKGROUND 
       [0003]    In the manufacture of hidden or sealed cards or forms (e.g., forms that are attachable to other forms or products but concealed from view by a label or other material), the cards or forms to be sealed are typically manufactured separately and then wrapped in a material such as a plastic that has a transfer tape applied to one side (e.g., the back of the card or form) for coupling the wrapped card or form to another product. These constructions require several manufacturing steps and result in bulky cards or forms that are difficult to handle using automation machines, are easily detached from the receiving products, and difficult to open. 
         [0004]    In addition, a plurality of similar cards or forms may be produced with variable indicia printed thereon such as names of intended recipients or tickets numbered in a sequence. After the printing of such variable indicia, a secondary manufacturing process is typically used to verify that the variable indicia had been properly printed. One known method of verifying variable indicia includes manual verification, which requires a human operator to detect an error and implement corrective measures. In such systems, it is common for an error to go undetected. Furthermore, corrective measures typically require a work stoppage and/or the loss of a potentially large volume of material. 
         [0005]    Another known method incorporates automatic verification through a secondary process. The variable indicia is read from each form and compared to information stored in a database. If an error is detected, variable printers are reset to correct the error. In such systems, volumes of material are lost until the printers are reset and/or a third manufacturing process may need to be implemented to reorder the reprinted forms. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  is a schematic view of an example apparatus for practicing an example method described herein for producing an example sealed card. 
           [0007]      FIG. 2  is a schematic view of a portion of an example web of a plurality of example sealed card intermediates with one example sealed card removed. 
           [0008]      FIG. 3  is a front view of an example sealed card intermediate. 
           [0009]      FIG. 4  is a back view of an example sealed card intermediate. 
           [0010]      FIG. 5  is a cross-sectional view of an example sealed card intermediate. 
           [0011]      FIG. 6  is a cross-sectional view of an example sealed card. 
           [0012]      FIG. 7  is a flow chart depicting an example process to produce an example web of example sealed card intermediates. 
       
    
    
     DETAILED DESCRIPTION 
       [0013]    Certain examples are shown in the above-identified figures and described in detail below. In describing these examples, like or identical reference numbers may be used to identify common or similar elements. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale or in schematic for clarity and/or conciseness. 
         [0014]    Sealed cards are important for a variety of purposes, such as maintaining the secrecy of sensitive or confidential information and/or protecting a sealed card and the information contained thereon from environmental elements. Sealed cards may also provide non-sensitive information such as marketing information when, for example, the sealed cards are included with various products. In addition, verifying the information contained on a sealed card during the manufacturing process increases the integrity of the product and may reduce manufacturing time, costs, and manufacturing waste. 
         [0015]    In general, the example apparatus, methods and articles of manufacture described herein provide for an example sealed card that protects proprietary or otherwise sensitive or confidential information from viewing by unauthorized persons or machines. In addition, the examples provided here protect the example sealed cards from environmental elements including, for example, harsh weather, rough handling, harsh operating conditions, etc. 
         [0016]    The example sealed cards described herein also provide a relatively large surface area for the inclusion of more information, including for example, marketing information, than traditional constructions. Furthermore, the example sealed cards described herein have slimmer profiles than many known cards or forms to enable the example sealed cards to be included in a wider variety of products than traditional sealed cards. 
         [0017]    In addition, an example method for producing the example sealed cards described herein verifies the printing of the example sealed cards substantially simultaneously with the printing. In such examples, any erroneously printed material can be fixed immediately. 
         [0018]    More specifically, an example sealed card described herein includes a first layer having a first side and a second side and a perimeter of weakness formed in the first layer forming an inner area and an outer area. The example sealed card also includes a first indicia on the second side in the inner area and a second indicia to correspond to the first indicia in the outer area. Furthermore, the example sealed card includes a release liner releasably coupled to the second side, wherein the release liner covers the first indicia. 
         [0019]    One or more example sealed cards may be printed in sequence to form a web of sealed cards. An example web includes a first layer having a first side and a second side and a first perimeter of weakness formed in the first layer forming a first inner area and a first outer area. The example web also includes a first primary indicia on the second side in the first inner area and a first secondary indicia to correspond to the first primary indicia in the first outer area. In addition, the example web has a second perimeter of weakness formed in the first layer forming a second inner area and a second outer area, a second primary indicia on the second side in the second inner area and a second secondary indicia to correspond to the second primary indicia in the second outer area. Furthermore, the example web includes a release liner releasably coupled to the second side. 
         [0020]    An example method of producing an example web of sealed cards includes feeding a first layer having a first side and a second side into a printer, printing at least one of the first side or the second side and cutting a first perimeter of weakness into the first layer to form a first inner area and a first outer area. In addition, the example method includes printing a first primary indicia on the second side and in the first inner area, and printing a first secondary indicia corresponding to the first primary indicia in the first outer area. Furthermore, the example method includes verifying a correspondence between the first primary indicia and the first secondary indicia. The example also includes cutting a second perimeter of weakness into the first layer to form a second inner area and a second outer area, printing a second primary indicia on the second side and in the second inner area, printing a second secondary indicia corresponding to the second primary indicia in the second outer area, and verifying a correspondence between the second primary indicia and the second secondary indicia. Finally, the example method includes releasably coupling a release liner to the second side. 
         [0021]    Now turning to the figures,  FIG. 1  illustrates an example apparatus  100  for practicing one of the example methods described herein for producing an example web  200  ( FIGS. 1 and 2 ) containing one or more example sealed card intermediates  202  ( FIGS. 2-5 ), each of which includes an example sealed card  204  ( FIGS. 2 and 6 ). The example sealed card intermediate is an intermediary form or construction that includes or supports the example sealed cards. In some examples, the example sealed card intermediate is the structure in which the example sealed card is provided to a user prior to use of the example sealed cards. In addition, the example sealed cards described herein may be any type of cards, constructions or form including for example, credit card type forms, postcards, reply cards, paper forms, labels, photos, tickets, tags, stickers, etc. 
         [0022]    The example apparatus  100  includes a first unwinder  102  that unwinds a top ply  206 . The top ply  206  includes a release liner layer  208 , which may be, for example, a roll of paper, a plastic material (e.g., polypropylene), other synthetic substrates (e.g., Polyart®) or any other suitable substrate, including a combination of materials, which is coupled to a backing liner  210  via a layer of adhesive  212  ( FIG. 5 ). In this example, the layer of adhesive  212  is a removable layer that may be a continuous layer or a pattern of adhesive. In addition, the adhesive  212  may be a pressure sensitive adhesive or any other suitable adhesive. The release liner  208  and the adhesive  212  form part of a top layer  214  of the sealed card  204 . As noted above, the release liner layer  208  may be any suitable material including, for example, polypropylene or any other suitable thermoplastic polymer. In one example, the top ply  206  includes polypropylene with about a 2.6 mil caliper and about a 50 # liner. More specifically, the top ply  206  may be, for example, RR Donnelley code 1305, which corresponds to 2.6 mil polypropylene 50 # LF spec # 2650 PPX MR1. 
         [0023]    The top ply  206  runs through one or more first print stations  104  that add a first printed indicia layer  216  on a side of the release liner  208 . The top ply  206  is further treated as detailed below. 
         [0024]    A second unwinder  106  unwinds a bottom ply  218  that forms part of a base layer  220  of the example sealed card  204 . The bottom ply  218  may be, for example, a roll of paper, a plastic material (e.g., polypropylene), other synthetic substrates (e.g., Polyart®) or any other suitable substrate including a combination of materials. In one example, the bottom ply  218  may be a synthetic paper that is a multi-layered, biaxially oriented film that is durable, uniform, opaque, chemical-resistant, UV-resistant, waterproof and provides a high quality print surface. The bottom ply  220  may have a basis weight of, for example, about 135.10 lbs/ream; a caliper of, for example, about 9.8 mils; a yield of, for example, about 3.52 msi/lb; a tear strength of, for example, about 158.0 MD/64.0 CD grams; a tensile strength of, for example, about 61.5 MD/195.8 CD lbs/in; an opacity of, for example, about 99%; and a gloss of, for example, about 19 gloss units. More specifically, the bottom ply 218 may be, for example, Fasson 10 mil FPG 250 YUPO spec # 76785. 
         [0025]    The bottom ply  218  is sent through one or more second print stations  108 , which may be the same as or in addition to the first print stations  104 . The second print stations  108  add a second printed indicia layer  222  to the bottom ply  218 . Optionally, the bottom ply  214  may be sent through a turn bar  110  that inverts the bottom ply  218 . Thereafter, the bottom ply  218  may be fed through a third set of printer stations  112  that may be the same as or in addition to the first print stations  104  and/or second print stations  108 . The third print stations  112  add a third printed indicia layer  224  to the bottom ply  218 . 
         [0026]    The first, second and/or third print stations  104 ,  108 , and/or  112  may include inkjet printer(s), thermal printer(s), and/or any other suitable printer(s). The printed indicia layers  216 ,  222  and  224  may include any suitable type of information including, for example, marketing information, variable print, personalized message(s), instruction(s), direction(s), coupon(s) and/or any other information including letter(s), number(s), image(s), shape(s), etc. 
         [0027]    In some examples, as described in greater detail below, one or more of the printed indicia layers  216 ,  222 , and  224  may include first and second primary indicia and/or first and second secondary indicia that is used to verify proper printing of the printed indicia layers  216 ,  222  and  224 . Furthermore, the printing of any of the indicia layers  216 ,  222  and  224  or the first and second primary indicia and first and second secondary indicia may occur at any point during the example methods described herein and/or via an imaging process separate from the described manufacturing process, which may be, for example, a separate off-line process or a direct in-line process. A separate off-line process may allow greater flexibility and/or reduce costs by allowing a client to image the sealed cards. In such examples, the printed indicia layers  216 ,  222 , and  224  may only include first and second primary indicia and/or first and second secondary indicia, and the client adds all other marketing information, variable print, etc. 
         [0028]    The example apparatus  100  also includes a first stripper  114  that separates the release liner  208  and adhesive layer  212  of the top ply  206  from the backing liner  210 . The release liner  208  and the adhesive layer  212  are then coupled (e.g., pressed, laminated, or otherwise coupled) via a press  116 . Prior to pressing the release liner  208  and adhesive layer  212  of the top part  214  with the base ply  218  of the bottom part  220 , a release coating such as, for example, a release coating  226  may be applied between the top part  214  and the bottom part  220  ( FIG. 5 ). After the press  116 , the top part  214  and bottom part  220  form the web  200  of sealed card intermediates  202 . 
         [0029]    The release coating  226  may be, for example, silicone. More specifically, the release coating  226  may be, for example, a UV silicone release coating that is cured by a free-radical mechanism. In one specific example, the release coating  226  is a Craigcoat 1021A UV release coating. In some examples, the release coating  226  may be applied via an anilox roll such as, for example, an anilox roll with about 550 line (i.e., a 550 line screen or number of cells per linear inch measured along the engraving angle) and about 3.5 BCM volume (i.e., about 3.5 billion cubic microns per square inch, which is the ink carrying capacity of a cell as determined by the depth, diameter and profile of the cell multiplied by the number of cells in a given square inch of roll surface). However, the weight of the release coating  226  may vary. 
         [0030]    Varying amounts of a release material such as, for example, silicone, are used depending on the nature of the substrate of the release liner  208  and/or the base ply  218 . In addition, with some constructions, for example paper substrates, the release coating  226  may be applied, for example, by a direct thermal or a thermal transfer process. This combination of materials in this construction allows the sealed card intermediate  202  to maintain its form and endure a rewind process for storage and/or shipping, as detailed below. In other words, the sealed card intermediates  202  can be rolled about a core, for example, without creating an unwieldy bulky and/or misshapen roll and/or without the sealed card  204  displacing or otherwise decoupling from the bottom portion  22  and outer area  234 . In addition, the sealed card intermediate  202  can be used in a dispensing device by an end-user with these same benefits. 
         [0031]    The web  200  of sealed card intermediates  202  passes through a cutter  118  that die-cuts, kiss-cuts, perforates and/or otherwise adds one or more line(s) or perimeter(s) of weakness to the web  200 . For example, a first line of weakness  228  may be formed through the top part  214  and the bottom part  220  at intervals to form and separate the sealed card intermediates  202 . In the illustrated example, the first line of weakness  228  is a straight line. However, any other shape (e.g., diagonal lines) may be used in addition to or as an alternative to a straight line. In addition, prior to adding the line(s) of weakness  228 , a black line, notch or other indicator may be added to the top portion  214  and/or the bottom portion  220  to indicate the beginning of the next (e.g., adjacent) sealed card intermediate  202 . The indicator may be used to indicate both variable printing and/or the line(s) of weakness  228 . The indicator may be added by one or more of the printing stations  104 ,  108  or  112  or by another component such as, for example, a preliminary cutter (not shown). 
         [0032]    In addition, the cutter  118  may add a second line of weakness  230  through the bottom part  220 . In the illustrated example, the second line of weakness  230  has a generally rectangular shape, though any other shape may be used additionally or alternatively. In the illustrated example, the second line of weakness  230  separates the bottom part  220  into an inner area  232  and the outer area  234 . This is repeated on each sealed card intermediate  202  such that additional lines or perimeters of weakness are formed in the bottom part  220  down the web  200  forming a second inner area, a second outer area, a third inner area, a third outer area, and so forth. 
         [0033]    The cutter  118  also adds a third line of weakness  236  through the top part  214  of the sealed card intermediate  202 . The third line of weakness  236  separates the release liner  208  into a release label portion  238  and a waste matrix  240 . In the illustrated example, the third line of weakness  236  forms an area larger than the area of the second line of weakness  230 . Consequently, the release label portion  238  is larger than the inner portion  232 , which enables the release label portion  238  to conceal the inner portion  232  as detailed below. 
         [0034]    After the cutter  118 , a second stripper  120  separates the waste matrix  240  from the release label portion  238  and the rest of the sealed card intermediate  202 . The waste matrix  240  may be wound around a first rewinder  122  for later disposal or alternative uses. The sealed card intermediates  202  are sent to a packager  124  that winds, folds, or otherwise prepares the web  200  for shipping and/or storage.  FIG. 2  illustrates the web  200  with the waste matrix  240  coupled thereto, while  FIG. 3  shows an isolated sealed card intermediate  202  with the waste matrix  240  removed. The sealed card intermediates  202  may be sent stacked, folded, wound in a roll, or otherwise packages and shipped to a purchaser for later use such as, for example, inclusion on to a receiving product (e.g., a car battery, a piece of furniture, an envelope, a business form, an electronic device, an appliance, etc.). Alternatively, the matrix  240  may be removed by the end-user or left adhered to the bottom portion  220 . 
         [0035]    To use the sealed cards  204 , the sealed cards  204  are removed from the sealed card intermediates  202  as shown in  FIGS. 2 and 6  (leaving an opening  242  in the bottom portion  220 ). That is, the release label portion  238  and the inner area  232  are separated from the outer area  234  (along with the intermediary and/or auxiliary layers shown in  FIG. 6 ). The example sealed card  204  may then be coupled to a receiving product (not shown) such as, for example, by coupling the exposed portions of the adhesive layer  212  to the product with the inner portion  232  disposed between the product and the release label portion  238 . The second and/or third printed indicia layers  222  and  226  may include any type of information including, for example, warranty and/or repair information. The first printed indicia layer  216  may also include any type of information such as, for example, information relating to the information included in the second and/or third printed indicia layers  222  and  226 . In addition, the release label portion  238  fully covers or substantially covers all of the inner portion  232 , which protects the inner portion  232  and the information contained therein from exposure to unauthorized persons or machines, environmental conditions such as, for example, the high operating temperatures and presence of oil and grease in an automobile engine. 
         [0036]    To access the information included in the second and/or third printed indicia layers  222  and  226 , the release label portion  238  is pulled away to reveal the inner portion  232 . The inner portion  232  may be removed from the product and placed in another place or area such as, for example, in a filing cabinet, wallet, drawer, etc. In addition, the inner portion  232  may be returned to the position under the release label portion  238  for storage thereunder. 
         [0037]    The example sealed card  204  may be used with many other industries as well as in many other environments. For example, the example sealed cards  204  may be used to provide warranty and/or instructional information for a product; to provide membership cards with sensitive or confidential information such as, for example, health insurance numbers, Social Security Numbers or other identification information; to provide discount cards on directories, magazines, catalogs, books and/or direct mailings; to provide spare parts information, numbers and/or ordering information; to provide important numbers such as health care provider information or directories; to protect invoice and/or shipping information on parcels; etc. The example sealed cards may be customized for any industry and personalized for various clients, consumers, prospective consumers, etc. 
         [0038]    In some of the foregoing examples (e.g., the uses of the example sealed card  204  with product serial numbers or personalized information) or in other examples (e.g., use of the example sealed card  204  with game pieces, lotteries, raffles, etc.), it is important that the variable information (e.g., Social Security Number, winning ticket number, etc.) printed on each sealed card  204  of the web  200  contain the exact correct information to avoid situations in which one person receives someone else&#39;s Social Security information or duplicative winning tickets are produced, or any other undesired situation. To avoid such undesired situations, the variable information on each sealed card  204  is verified as one or more of the printed indicia layers  216 ,  222 , and  224  are printed. 
         [0039]    One example verification method and system includes the printing of a primary indicia  250  on a first side  252  of the bottom portion  220  in the inner area  232 . A secondary indicia  254  corresponding to the primary indicia  250  is printed in the outer area  234  on the first side  252  and/or a second side  256  of the bottom portion  220 . The release liner label  238  is releasably coupled to the first side  252 , as noted above, and covers the primary indicia. Prior to coupling the release liner label  238 , i.e., the top portion  214 , the correspondence between the primary indicia  250  and the secondary indicia  254  is verified by reading the primary indicia  250  and the secondary indicia  254  with any suitable reading means and comparing the read information to determine if the primary indicia  250  and the secondary indicia  254  correspond (e.g., match, relate, etc.). 
         [0040]    In some examples, the primary indicia  250  and the secondary indicia  254  are identical and in other examples they are different, though they correspond in some manner. For example, in some examples, both the primary indicia  250  and the secondary indicia  254  are identical bar codes. In other examples, the primary indicia  250  is human readable text while the secondary indicia  254  is a bar code detailing the same or similar information. In some examples, the release liner label portion  238  covers the secondary indicia  254  in addition to or as an alternative to covering the primary indicia  250 . In addition, either or both of the primary indicia  250  and the secondary indicia  254  may include a bar code (as noted above), a number, an image, variable print, or any other text, character(s), notch(es), or code(s). 
         [0041]    In some examples, the correspondence between the primary indicia  250  and the secondary indicia  254  is verified substantially simultaneously with the printing of the primary indicia  250  and/or the secondary indicia  254 . If it is determined that there is no correspondence between the primary indicia  250  and the secondary indicia  254 , one or more of the primary indicia  250  and the secondary indicia  254  is voided by, for example, reversing the direction of the web  200  through the printer and/or moving a print head (not shown) forward along the web  200  to print over the defective sealed card intermediate  202 . In such a situation, the next sealed card intermediate  202  may be used to reprint the erroneously printed sealed card  204  so that the defect is corrected substantially simultaneously without the loss (or a significant loss) of production time, costs and materials. 
         [0042]    Furthermore, after the primary indicia  250  and the secondary indicia  254  are printed and the correspondence therebetween is verified, the web  200  advances to print the next sealed card intermediate  202 . The next card is printed with a second primary indicia and a second secondary indicia in a manner similar to that described above with respect to the primary indicia  250  and the secondary indicia  254 . The following sealed card intermediate  202  is printed with a third primary indicia and a third secondary indicia once the correspondence between the second primary indicia and second secondary indicia is verified and so forth. 
         [0043]      FIG. 7  is a flow chart of an example process  700  for creating a web of sealed cards such as, for example, the web  200  of the sealed cards  204  discussed above. Although the example systems or processes are described with reference to the flow chart illustrated in  FIG. 7 , persons of ordinary skill in the art will readily appreciate that many other methods of creating a web of sealed cards may alternatively be used. For example, the order of execution of the blocks may be changed, and/or some of the blocks described may be changed, eliminated or combined. 
         [0044]    In the example process  700  described in  FIG. 7 , a first layer, e.g., the top ply  206  of  FIG. 1 , is fed into a printing press, e.g., the first printer station  104 , (block  702 ) and a first and/or second side of the first layer is printed (block  704 ). A second layer, e.g., the bottom ply  218  of  FIG. 1  is fed into a printing press, e.g., the second printer station  108  and/or the third printer station  112  of  FIG. 1  (block  706 ) where a first and/or second side of the second layer is printed (block  708 ). The printed indicia printed by the second and/or third printing press is primary and/or secondary indicia, e.g., the primary indicia  250  and the secondary indicia  254  of  FIGS. 3-6  in what will be an inner and an outer area of the second layer, e.g., the inner area  232  and outer area  234  of the bottom part  220  of  FIGS. 3 and 4  (block  708 ). 
         [0045]    The primary indicia and secondary indicia are compared to verify if they correspond (block  710 ). If the primary indicia and the secondary indicia do not correspond (e.g., match) the sealed card with the defect is voided (block  712 ) by, for example, reversing the direction of advancement through the printers or moving the printers and printing X&#39;s, the word “VOID” or some other indication on the sealed card or by otherwise destroying the sealed card. When a sealed card has been voided (block  712 ), control returns to block  706  in which the second layer is advanced into the printing press. 
         [0046]    Where the primary indicia and the secondary indicia correspond, it is determined if an additional sealed card is to be included in the web (block  714 ). If so, control returns to block  702  in which the first layer is fed into the printing press. If the order is complete, i.e., no further sealed cards are to be included in the web, the first and second layers are pressed together by, for example, the press  116  of  FIG. 1  (block  716 ). This may occur after a backing liner is removed from the first layer in those examples in which a first layer includes a backing liner (e.g., as detailed above with respect to  FIG. 1 ). In some examples, portions of the first and second layers are coupled (block  716 ) as other portions of the first and second layers are printed and otherwise treated as noted above and below (blocks  702 - 714 ,  718 - 724 ). 
         [0047]    Lines of weakness, e.g., the line(s) or perimeter(s) of weakness  230  and  228  are added by, for example, the cutter  118  of  FIG. 1 , to the second layer, e.g., the bottom portion  220 , to separate individual sealed card intermediates and to form an inner and outer region of the second layer, i.e., the inner and outer regions  232  and  234 , respectively of the bottom portion  220  of  FIGS. 2-6  (block  718 ). Similarly, lines of weakness, e.g., the line of weakness  236  is added to the first layer by, e.g., the cutter  118  of  FIG. 1 , to form a release label, e.g., the release label portion  238 , which produces a waste matrix, e.g., the waste matrix  240  (block  720 ). 
         [0048]    The waste matrix may be removed, e.g., by the splitter  120  of  FIG. 1  (block  722 ) and the remaining sealed card intermediates on the web are packaged for shipping and/or storage (block  724 ) by, for example, separating the sealed card intermediates and stacking them, folding the web, and/or rolling the web, as discussed above. 
         [0049]    The example apparatus and methods described herein may be used to produce a plurality of sealed cards that include variable indicia including, for example, a numbered sequence of cards or tickets. In the examples described herein, the variable printing on the sealed cards can be verified to ensure that defective cards are voided, that no numbers are missing from a sequence, that duplicative numbers are not included, etc. 
         [0050]    In addition, the example sealed cards  204  described herein include the relatively large release label portion  238  that provides a relatively large area for the inclusion of additional information such as, for example, marketing information, than prior forms that are wrapped in other packaging. In addition, the release label portion is much thinner than prior bulky packaging and allows the example sealed cards to lie relatively flat on a surface of the product to which the sealed cards are applied or adhered. 
         [0051]    Although certain example methods, apparatus, and articles of manufacture have been described herein, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all methods, apparatus and articles of manufacture fairly falling within the scope of the appended claims either literally or under the doctrine of equivalents.