Patent ID: 7887666

Claim:
A method for manufacturing a singular ID product comprising the steps of: a) opening a die having a first half and a second half wherein the die first half includes a male punch and the die second half includes a female die complementary to the male punch; b) placing a sheet material having a first surface and a second surface between the die first half and the die second half; c) directing the male punch of the first die half against a surface of the sheet material and thereafter causing the die to form a die cut sheet material including a decorative portion and a scrap portion wherein the decorative portion becomes at least partially separated from the scrap portion of the sheet material to form voids in the scrap portion of the sheet material corresponding to the decorative portion; and d) directing the at least partially separated decorative portion of the sheet material back into the scrap material voids by moving the die first half away from the die second half to thereby form a die cut sheet material including an embedded decorative portion wherein the method includes the further steps of: i. applying a carrier including an adhesive layer and a mask layer to one of the first surface or the second surface of the sheet material either before directing step c or after directing step d; ii. removing the mask layer if the carrier is applied to the sheet material before directing step c and cutting the sheet material by directing the die first half including the male punch through the adhesive layer and the sheet material and into the female die of the die second half to cut the adhesive layer in registration with the decorative portion; applying a mask to the adhesive layer after directing step d to form a die cut sheet material having a mask covered surface and an exposed surface; and iii. separating the embedded decorative portion including the adhesive layer in registration with the decorative portion and the mask from the scrap portion to form a singular ID product having a decorative portion that includes two or more die cut decorative pieces that are separate from one another.