Patent Description:
Non-contact IC cards have been used as a cash card, an employment photo ID, a work pass, a membership card, a student ID, an alien registration certificate, and driving licenses. These cards are formed by laminating a pattern-printed front sheet and a pattern-printed back sheet on an inlay. Inlay is a film on which a circuit is printed. In the circuit, electronic information is recorded.

The inlay and continuous sheets that are to be the front sheet and back sheet are adjusted in their relative positions, and then are cut in individual card units.

The positional adjustment between the inlay and the continuous sheets is carried out by detecting respective marks on the inlay and the continuous sheets and adjusting the pattern on the continuous sheets with respect to the inlay. The mark is called registration mark. <CIT> discloses a laminating unit to manufacture a multi-layer composite in a laminating machine, comprising a laminating rotating roll, laminating a first web onto a second web, a driving means, rotating the roll; gripping means, maintaining the first web in contact with the roll; first detection means emitting first detection signals in accordance with detected longitudinal positions of the first web; second detection means emitting second detection signals in accordance with detected longitudinal positions of the second web; and control means, regulating a rotation speed of the driving means and of the roll as a function of the first and second signals, to convey, correct longitudinally positions of the first web, and laminate the first web in register onto the second web. <CIT> discloses a manufacturing method for an absorbent article, wherein a predetermined pattern can be precisely arranged in a predetermined part, and wherein a position of the pattern can be rapidly corrected. A first base material sheet is continuously fed by a feeding device so as to be carried; a second base material sheet is continuously fed so as to be carried, separately from the sheet; the sheets are stuck together in a sticking position so as to form a continuous laminate; and after that, the laminate is cut to a fixed length in a cutting position, so that the individual absorbent articles can be manufactured. The pattern is printed on the sheet at a shorter printing pitch than the cutting length of the absorbent article, and pitch reference marks are arranged at intervals equivalent to the printing pitch. An adjusting means for adjusting a carrying speed of the sheet is provided in front of the sticking position; a position of the mark of the sheet is adjusted by the adjusting means; the sheet is expanded/contracted, so that the printing pitch when both the sheets and are cut in the state of being stuck together can correspond to the cutting length of the absorbent article; and the carrying speed of the sheet is controlled so that the pattern can be positioned in a predetermined part of the absorbent article. <CIT> discloses a process of making an improved sheet/card laminate for packaging, signage, displays, transaction cards, ID cards and the like. The process comprises registering flat sheets to a film and then laminating the film or transferring coating(s) from the film to the individual, generally flat sheets via an adhesive. The film or coating(s) may include layered security, functional and/or decorative features.

<FIG> shows a printing machine <NUM> that prints patterns on the continuous sheet <NUM>. As shown in <FIG>, the single printing machine <NUM> is provided with number n (several) of printing plates <NUM> to <NUM> on the roll body <NUM> at roughly equal angle pitch. There is a technique that is able to easily manufacture the printing plates <NUM> to <NUM> so as to be the same form. With this technique, patterns printed by the plates are the same.

Due to the structure where the printing plates <NUM> to <NUM> are attached to the roll body <NUM>, it is inevitable that each plate is slightly misaligned when attached. Thus, pitches between the printed patterns are slightly unequal. Positional adjustment per every single pattern may not be good enough for a pattern adjustment control. In addition, it is difficult to manufacture cards at high-speed.

The present invention is to provide a method for manufacturing cards in which it is easy to adjust patterns while manufacturing cards at high-speed.

The card manufacturing method of the present invention includes:.

In the present invention, plural patterns, as one cycle, are repeatedly printed on the first continuous sheet <NUM>; and the feeding speed of the first continuous sheet <NUM> is controlled based on the detection result of the position of patterns at every one cycle. Thus, if the pitches between the printing plates are unequal in printing, it is possible to control so that the pattern is placed at a predetermined position with respect to the reference sheet <NUM> without bothered by the unequal pitches.

Also, the adjustment at every one cycle is efficient, and is easy to deal with high-speed manufacturing.

In the present invention, "pattern" includes letters, code, symbol, figure, painting, illustration, and registration mark. Typically, registration marks are used in the position detection of pattern.

In the case of a three-layer card in which an inlay is sandwiched between a front sheet and a back sheet (i.e., there is a second continuous sheet that is to be a back sheet), the present invention preferably includes a step of feeding a second continuous sheet <NUM> having a plurality of (a group of) different patterns repeatedly printed on the second continuous sheet <NUM>, the plurality of different patterns seen as one cycle as a whole;.

In this case, it is easy to control a pattern adjustment of the second continuous sheet <NUM>, and is possible to manufacture cards at high-speed.

Preferably, a cutting position at the time of producing the card is adjusted according to the position of each one of the plurality of patterns or each one of the plurality of different patterns.

In this case, it is possible to cut out a card depending on the pattern position.

Note that the registration mark may be cut and removed during the card production.

More specifically, the method of the present invention includes a step of discriminating (recognizing) a mark by the detection means, the mark being provided for each unit (corresponding to one card) on each of the first and second continuous sheets, wherein:
the first or second adjustment step is not performed if the number of the recognized marks is less than a predetermined number n equivalent to the one cycle and the first or second adjustment step is performed every time the number of the recognized marks reaches the predetermined number n.

In this case, the adjustment step is performed at every number n (one cycle of printing). Thus, it is efficient to adjust patterns.

Preferably, the adjustment step is performed by an actuator <NUM> driving a first dancer roll <NUM> that the first continuous sheet <NUM> winds around and a second dancer roll <NUM> that the second continuous sheets <NUM> winds around before the first and second continuous sheet <NUM>, <NUM> being laminated on the reference sheet <NUM>.

As in this case where the dancer roll is controlled by the actuator <NUM>, it is easy to control a feeding amount of the first continuous sheet <NUM> or that of the second continuous sheet <NUM>. In other words, control of the feeding speed of these sheets is easy.

Preferably, if a misalignment of the first or second continuous sheet <NUM>, <NUM> with respect to the reference sheet <NUM> exceeds a predetermined allowable range ±Δ and is within a first misalignment range ±Δ1 as a result of the detection, the first or second adjustment step is performed by displacing the first or second dancer roll <NUM>, <NUM> by a predetermined first certain amount T1 in a direction to reduce the misalignment.

A feed-back control is generally performed based on a variable amount corresponding to a misalignment amount. As the paperboard forming front and back sheets of a card is rigid and has a small amount of elongation to tensile force. Thus, if a feeding amount increases rapidly, conveyance may not work smoothly at nip rolls where the sheets are fed.

In the present invention, the first certain amount T1 is set in advance, so it is possible to control the feeding speed with smooth conveyance.

Here, the first certain amount T1 may be set in a range defined, for example, by Expression (<NUM>) below.

In the case where m number of dancer rolls are provided to each continuous sheet, the first certain amount T1 may be set by Expression (<NUM>) below.

Preferably, if the misalignment of the first or second continuous sheet <NUM>, <NUM> with respect to the reference sheet <NUM> is within the predetermined allowable range ±Δ as a result of the detection, the first or second dancer roll <NUM>, <NUM> is finely moved by the actuator <NUM> in a direction opposite to a previous moving direction in the first or second adjustment step.

When the dancer roll is finely moved as in this case, tension and bending of the first (or second) continuous sheet <NUM> (<NUM>) slightly changes while the feeding speed does almost not change. Thus, it is possible to bring the dancer roll to its home position with keeping the misalignment in the allowable range ±Δ.

Here, "dancer roll is finely moved" means "the movement amount of the dancer roll is at least within the allowable range ±Δ and is smaller than the first certain amount T1".

More preferably, if the misalignment of the first or second continuous sheet <NUM>, <NUM> with respect to the reference sheet <NUM> exceeds the first misalignment range ±Δ1 as a result of the detection, the first or second adjustment step is performed by displacing the first or second dancer roll <NUM>, <NUM> by a second certain amount T2 more than the first certain amount T1 in the direction to reduce the misalignment.

In the time of starting operation when the misalignment amount is large, it is possible to control feeding with smooth conveyance as mentioned above by moving the dancer roll by the second certain amount T2 larger than the first certain amount T1.

Any feature illustrated and/or depicted in conjunction with one of the aforementioned aspects or the following embodiments may be used in the same or similar form in one or more of the other aspects or other embodiments, and/or may be used in combination with, or in place of, any feature of the other aspects or embodiments.

The present invention will be understood more clearly from the following description of preferred embodiments taken in conjunction with the accompanying drawings. Note however that the embodiments and the drawings are merely illustrative and should not be taken to define the scope of the present invention. The scope of the present invention shall be defined only by the appended claims. In the accompanying drawings, like reference numerals denote like components throughout the plurality of figures.

An embodiment of the present invention will now be described with reference to the drawings.

Structure of a card is explained before an explanation of the embodiment.

As shown in these figures, the card <NUM> is formed by laminating layers: a front sheet <NUM>; a back sheet <NUM>; an inlay <NUM>; and fine paper <NUM>. These layers are adhered together by adhesive layers <NUM> made of, for example, polyurethane hot-melt adhesive.

The inlay <NUM> is provided with an IC chip and an antenna <NUM>. In the fine paper <NUM>, a through hole <NUM> is formed, in which the IC fits.

A name N of the card and a pattern G are printed on the front sheet <NUM> while another pattern (not shown) is printed on the back sheet <NUM>. These patterns are repeatedly printed by a printing machine <NUM> (<FIG>) wherein the number n of patterns is seen (counted) as one cycle. The pattern may be only letters and registration marks.

As shown in <FIG>, an individual card is produced from a laminated sheet <NUM>. The laminated sheet <NUM> is configured of a first continuous sheet that is to be the front sheet <NUM> of <FIG>, a second continuous sheet that is to be the back sheet <NUM>, the inlays <NUM>, and a continuous sheet of the fine paper <NUM>. The laminated sheet <NUM> of <FIG> is cut in lengthwise and crosswise to produce the card <NUM> of <FIG>.

The first and second sheets and the inlay <NUM> are provided with respective marks R0 to R2 of <FIG> used for positional adjustment. The mark is called Registration mark. In this embodiment, the registration marks R0 to R2 are positioned in the center of the respective sheets in the carrying direction for the sake of explanation. However, the marks may be positioned at a corner as shown in <FIG> and trimmed after lamination in the case of the front sheet <NUM> of <FIG>.

Summary of the card manufacturing method will be described below.

For the sake of drawing a figure, <FIG> shows the case where the first and second continuous sheet <NUM>, <NUM> each have a width equivalent to a width of a single card.

In <FIG>, a multi-row inlay 3A (the inlays <NUM> are continuous lengthwise and crosswise) and a continuous paper 3C of the fine paper <NUM> are slit into multiple single rows while conveyed. The slit single-row inlay 3B is cut into an individual card unit, and then each inlay <NUM> is attached to the continuous paper 3C of the fine paper to produce an intermediate sheet (a reference sheet) <NUM>.

On the front side and the back side of the intermediate sheet <NUM>, the first continuous sheet <NUM> and the second continuous sheet <NUM> are attached, respectively. As a result, the laminated sheet <NUM> is produced in which a to-be card <NUM> (<FIG>) is repeatedly shown. Thereafter, the laminated sheet <NUM> is cut into a unit of the individual card <NUM>.

Next, the outline of a manufacturing apparatus is explained together with an example of a manufacturing method.

As shown in <FIG>, the first and second continuous sheets <NUM> and <NUM>, the multi-row inlay 3A, the continuous paper 3C where the fine paper <NUM> (<FIG>) is continuous are unwound from a corresponding drum.

The multi-row inlay 3A of <FIG> is unwound from the drum, and slit into the multiple single-row inlays 3B by a slitter <NUM>. Thereafter, the slit single-row inlays 3B are apart from each other in the width direction by a guider <NUM>.

Then, the single-row inlays 3B are cut into a unit of the individual card by a first cutter 6A and a second cutter 6B. For example, the first and second cutters 6A and 6B contact respective first and second anvils 7A and 7B, and cut the corresponding single-row inlay 3B into a unit of the individual card. At upstream of the cutters and the anvils, first and second suction conveyers 8A and 8B are provided, which intermittently feed the single-row inlay 3B.

On a placement drum <NUM>, the rectangular inlays <NUM> (<FIG>) are intermittently conveyed at a fixed pitch.

On the other hand, the continuous paper 3C of the fine paper <NUM> (<FIG>) is unwound from the drum. The continuous paper 3C is provided with adhesive by an applicator <NUM>, and then is fed to the placement drum <NUM>. At the gap between the placement drum <NUM> and a nip roll <NUM>, the placement drum <NUM> produces the intermediate sheet (the reference sheet) <NUM> in which the inlays are intermittently placed on the continuous sheet <NUM>. The intermediate sheet <NUM> is fed to the gap between nip rolls <NUM> and <NUM> at downstream. Generally, one of the nip rolls <NUM>, <NUM> is driven by a drive roll.

As described below, the first and second continuous sheets <NUM> and <NUM> are continuously fed to the nip rolls <NUM> before bonding. The first and second continuous sheets <NUM> and <NUM> are unwound from the respective drums, and the applicator <NUM>, <NUM> apply adhesive on their back surfaces. The back surface is opposite side of a front surface, where prescribed patterns are repeatedly printed.

After the application of adhesive, the first and second continuous sheets <NUM> and <NUM> are respectively fed to first and second dancer rolls <NUM> and <NUM> at downstream, and are fed to the nip rolls <NUM> via these dancer rolls. The dancer rolls <NUM> and <NUM> each are reciprocated by an actuator <NUM> such as a servo motor to adjust a feeding speed of the continuous sheet <NUM> and <NUM> to the nip rolls <NUM>.

The continuous sheets <NUM>, <NUM> and the intermediate sheet <NUM> that are fed to the nip rolls <NUM>, <NUM> are bonded together at the nip rolls <NUM>, <NUM> to produce the laminated sheet <NUM>. The laminated sheet <NUM> is fed to a trim cutter <NUM>, and is separated into individual cards <NUM> and a lattice (frame) shape trim sheet 4T. The cards <NUM> are intermittently and continuously ejected onto a belt conveyor <NUM>, and conveyed.

Next, a control system of the present manufacturing method is described below.

As shown in <FIG>, a sensor S0 for detecting the registration mark R0 (<FIG>) on the inlay <NUM> is provided at upstream of the nip rolls <NUM>. Meanwhile, sensors S1 and S2 for detecting the respective registration marks R1 and R2 (<FIG>) on the first and second continuous sheets <NUM> and <NUM> are provided at downstream of the nip rolls <NUM>.

The first and second continuous sheets <NUM> and <NUM> are different in their patterns, but it is essentially the same for the structure in which both sheets are laminated on the intermediate sheet <NUM>; the lamination method; and the way of control. Thus, the case where the first continuous sheet <NUM> is laminated on the intermediate sheet <NUM> is representatively described below while the description of the case where the second continuous sheet <NUM> is laminated on the intermediate sheet <NUM> is omitted.

<FIG> shows a schematic diagram of the control system.

As shown in this diagram, a detection output from each sensor S0 to S2 is applied to a control device <NUM>. The control device <NUM> is configured of a computer.

The control device <NUM> includes: a calculation unit such as a mark recognition section <NUM> and a counter <NUM>; and a storage unit that stores a threshold for a misalignment discriminator <NUM> and drive amounts <NUM> for dancer rollers. To the control device <NUM>, an indicator <NUM> and an operation part <NUM> are connected.

As described below, a part of the control device <NUM> and each sensor S0 to S2 configure a detection means for detecting a position of a pattern through a position of the registration mark.

The mark recognition section <NUM> detects the registration marks R0 to R2 by receiving a signal from respective sensors S0 to S2. The counter <NUM> calculates what number of each registration mark R0 to R2. When the number of each registration mark reaches a predetermined quantity, the counter <NUM> has the misalignment discriminator <NUM> judge the degree of misalignment, as descried below.

The misalignment amount D is divided into three levels: the case where the amount exceeds a first misalignment range ±Δ1 as shown in <FIG>, the case where the amount exceeds an allowable range ±Δ while is within the first misalignment range ±Δ1 as shown in <FIG>, and the case where the amount is within the allowable range ±Δ as shown in <FIG>.

The misalignment amount D and the control thereof are explained with reference to <FIG>. In <FIG>, for the sake of explanatory convenience, the registration marks R0 to R2 are placed on the center of the corresponding sheet in the carrying direction. The rectangular defined by a two-dot chain line in <FIG> shows a card <NUM> that is cut out afterward.

As shown in <FIG> where the misalignment amount D is large (i.e., the case where the misalignment amount D exceeds a predetermined first misalignment range ±Δ1), the control device <NUM> reads out an amount T2 as a drive amount, and moves the dancer roll <NUM> (<NUM>) by the amount T2 (e.g., <NUM>) in a direction opposite to the misalignment direction. With this control, the large misalignment is greatly corrected. This control may continue until the operating condition becomes stable.

When the misalignment amount D is small as shown in <FIG> (i.e., the case where the misalignment amount D exceeds a predetermined allowable range ±Δ while is within the first misalignment range ±Δ1), the control device <NUM> of <FIG> reads out an amount T1 as a drive amount, and moves the dancer roll <NUM> (<NUM>) by the amount T1 (e.g., <NUM>) in a direction opposite to the misalignment direction. As a result, the misalignment is slightly corrected.

When the misalignment amount D is tiny as shown in <FIG> (i.e., the case where the misalignment amount is within the predetermined allowable range ±Δ), the control device <NUM> of <FIG> reads out an amount T as a drive amount, and moves the dancer roll <NUM> (<NUM>) by a minuscule amount in a direction opposite to the direction in which the dancer roll <NUM> (<NUM>) moved in the previous misalignment control. As a result, it may be possible to bring the dancer roll <NUM> (<NUM>) to its home position.

Next, a method for producing the card <NUM> from the sheets <NUM> to <NUM> of <FIG>.

As shown in <FIG>, the reference sheet <NUM> and the first continuous sheet <NUM> are fed to the nip rolls <NUM>. The reference sheet <NUM> is to be a basis for positional adjustment. On the continuous sheet <NUM>, predetermined patterns are repeatedly printed. The nip rolls <NUM> laminate the first continuous sheet <NUM> on the reference sheet <NUM> to produce the laminated sheet <NUM>.

In a step before the lamination, the control device <NUM> recognizes the registration mark R0 (<FIG>) printed on the single-row inlay 3B by receiving a signal from the sensor S0 to detect the presence of the registration mark. On the other hand, in a step after the lamination, the control device <NUM> recognizes the pattern (i.e., the registration mark) printed on the first continuous sheet <NUM> by receiving a signal from the sensor S1 to detect the presence of the registration mark.

The control device <NUM> judges if the number of the registration marks reaches a predetermined one cycle. When the number of recognized registration marks is less than a predetermined number n that corresponds to the one cycle, the adjustment step is not performed. The adjustment step is performed at every time when the number of recognized registration marks reaches the predetermined number n. That is, at every cycle, the control device <NUM> performs the first (second) adjustment step by controlling a feeding speed of the first continuous sheet <NUM> (the second continuous sheet <NUM>) of <FIG> based on the detection result, wherein the position of the registration mark R1 (R2) of the first continuous sheet <NUM> (the second continuous sheet <NUM>) is adjusted to a predetermined position with respect to the registration mark R0 of the reference sheet <NUM>.

When the misalignment of the first (or second) continuous sheet <NUM> (<NUM>) with respect to the reference sheet <NUM> (<FIG>) exceeds the first misalignment range ±Δ1 based on the detection result, the control device <NUM> of <FIG> performs the first (or second) adjustment step, wherein the control device <NUM> moves the dancer roll <NUM> (<NUM>) by the amount T2 larger than the predetermined first amount T1 in a direction that the amount of misalignment is reduced, thereby changing the feeding amount of the first (or second) continuous sheet <NUM> (<NUM>).

For example, in the case where the registration mark R1 (R2) of the first (or second) continuous sheet <NUM> (<NUM>) misaligns in large (larger than the first misalignment range ±Δ1) with respect to the registration mark R0 of the inlay <NUM> in downstream X1 of the carrying direction, the control device <NUM> moves the dancer roll <NUM> (<NUM>) by, for example, <NUM> (a fixed amount) in upstream opposite to the downstream X1.

That is, before laminating the first (or second) continuous sheet <NUM> (<NUM>), the dancer roll <NUM> (<NUM>) that the first (or second) continuous sheet <NUM> (<NUM>) winds around is driven by the actuator <NUM>, and the dancer roll is pulled in the direction that the misalignment amount D is reduced. As a result, the misalignment amount D becomes small. By repeating this control, the misalignment amount D will gradually be smaller than the first misalignment range ±Δ1 (<FIG>).

On the other hand, in the case where the misalignment amount D of the first (or second) continuous sheet <NUM> (<NUM>) with respect to the reference sheet <NUM> (<FIG>) exceeds a predetermined allowable range ±Δ while is within the first misalignment range ±Δ1, the control device <NUM> of <FIG> performs the first (or second) adjustment step, wherein the control device <NUM> moves the dancer roll <NUM> (<NUM>) by the predetermined first certain amount T1 in a direction that the amount of misalignment is reduced, there by changing a feeding amount of the first (or second) continuous sheet <NUM> (<NUM>).

For example, as shown in <FIG>, in the case where the registration mark R1 (R2) of the first continuous sheet <NUM> (or the second continuous sheet <NUM>) slightly misaligns with respect to the registration mark R0 of the inlay <NUM> in downstream X1 of the carrying direction, the control device <NUM> of <FIG> moves the dancer roll <NUM> (<NUM>) by, for example, <NUM> (a fixed amount) in upstream opposite to the downstream X1.

As a result, the slight misalignment becomes smaller by the same driving of the dancer roll as mentioned before. By repeating this control, the misalignment amount D will gradually be smaller than the allowable range ±Δ.

In another case, as shown in <FIG>, where the misalignment of the first (or second) continuous sheet <NUM> (<NUM>) with respect to the reference sheet <NUM> (<FIG>) is within the predetermined allowable range ±Δ based on the detection result, the actuator <NUM> moves the dancer roll <NUM>, <NUM> by a tiny amount T in a direction opposite to a direction in which the dancer roll of <FIG> previously moved in an adjustment step.

For example, as shown in <FIG>, the registration mark R1 (R2) of the first continuous sheet <NUM> (or the second continuous sheet <NUM>) is almost not misaligned with respect to the registration mark R0 of the inlay <NUM>, the control device <NUM> moves the dancer roll <NUM> (<NUM>) of <FIG> by, for example, a tiny amount T (a fixed amount) in a (downstream) direction X1 opposite to a (upstream) direction in which the dancer roll previously moved.

In this case, the misalignment amount D does almost mot change due to the looseness of the sheet. On the other hand, with this control repeated, the dancer roll <NUM> (<NUM>) becomes closer to its home position, and it is possible to prevent the dancer roll <NUM> (<NUM>) from being largely displaced with respect to its home position.

After the lamination, a position of the patterns is recognized based on the detection signal from the sensor S0, S1, or S2 of <FIG>; the rotation of a trim cutter <NUM> is controlled based on the position of the patterns; and a cut position for producing the card <NUM> is controlled.

In the inlay <NUM> and the sheet shown in <FIG>, the registration marks R0 to R2 may be trimmed and removed when the card <NUM> is cut out as shown in <FIG>.

There is a case where the registration mark R0 of the inlay <NUM> of <FIG> and the registration mark R1 (R2) of the first continuous sheet <NUM> (or the second continuous sheet <NUM>) are put on a card <NUM> at different positions with each other. In this case, the positional difference is input in the control device <NUM> before performing the aforementioned adjustment steps.

As shown in <FIG>, the sensor S0 and the sensors S1 and S2 are apart from each other in the carrying direction X. Thus, a detection of the registration mark for one specific card <NUM> is different in timing between the sensor S0 and the sensors S1, S2. Therefore, it needs to consider the timing difference for controlling the dancer roll.

The position adjustment of each sheet may be carried out by controlling its tension.

While preferred embodiments have been described above with reference to the drawings, obvious variations and modifications will readily occur to those skilled in the art upon reading the present specification.

For example, a card may be produced by bonding two sheets.

A card to be produced may be a contact-type card.

Thus, such variations and modifications shall fall within the scope of the present invention as defined by the appended claims.

Claim 1:
A card manufacturing method, comprising:
a step of feeding a reference sheet (<NUM>) serving as a reference for alignment;
a step of feeding a first continuous sheet (<NUM>) having a plurality of patterns (G) repeatedly printed on the first continuous sheet (<NUM>);
a step of detecting a position of each one of the repeatedly printed patterns (G) by detection means (<NUM>; S0, S1, S2);
a first adjustment step of adjusting such that the patterns (G) are at predetermined positions with respect to the reference sheet (<NUM>) by controlling a feeding speed of the first continuous sheet (<NUM>) according to a detection result on the positions of the patterns (G);
a step of producing a laminated sheet (<NUM>) by laminating the first continuous sheet (<NUM>) on the reference sheet (<NUM>); and
a step of producing a card (<NUM>) by cutting the laminated sheet (<NUM>) after adjusting a cutting position according to the positions of the patterns (G),
the first adjustment step being performed every time the number of the patterns (G) reaches a predeterminded number (n) greater than <NUM>.