Printed sheet mailers and methods of making

Description

FIELD OF THE INVENTION
The invention relates to mailers and sheet products for use as parts of mailers and, in particular, to sets of uniquely encoded cards, tags, labels and other sheet elements used in mailers.
BACKGROUND OF THE INVENTION
A substantial market has developed in recent years for inexpensively manufactured, individually encoded, transaction cards for such uses as store credit cards, membership cards, I.D. cards, etc. The transaction cards typically bear the code in a bar format to permit automatic machine scanning of the card. Such cards typically are supplied in sets with one or more labels, tags, etc. being supplied with each card and bearing the same individual code number as the card for attachment to application forms, membership lists, etc.
Previously, it has taken many separate manufacturing steps to provide such sets. Perhaps the most efficient prior method has been printing in multiple steps, individual sheets of uniquely encoded, typically sequentially numbered, transaction cards, printing separate strips of release paper back adhesive labels with the same, unique codes as the cards, in the same sequence of codes as the codes appear on the cards of the sheets, and attaching the strip(s) with the appropriate code numbers to each sheet with the labels adjoining the like coded card(s).
In practice, this apparently simple, straightforward method requires several labor intensive steps. The appropriate labels for each sheet of cards must be identified and applied by hand to the sheet so that the labels properly adjoin the associated transaction cards. Because this correlation of the separate elements of each sheet is done by hand, considerable time and effort also must be spent in checking the final product to assure accuracy.
In addition, because the transaction card sheets and label strips must be printed separately, more time is needed to complete the task if the same printer is used to print the transaction card sheet and label strips. Alternatively, several printers must be available to simultaneously print the cards and the strips.
The present invention is directed to solving the twin problems of relatively high cost and errors associated with hand production of sets of plural related printed elements, all bearing some code unique to each set of elements, by eliminating hand collation and assembly of the separate elements into the sets as well as the material costs associated with such elements.
The present invention is also directed to solving the problem of the numerous printing steps which are currently required to produce related sets of card sheets and separate label strips, by reducing the number of required printing steps.
The present invention is also directed to solving problems associated with mailing other types or card or cardsized objects that, in some way, require the provision of multiple, variable data sets with each mailer.
SUMMARY OF THE INVENTION
In one aspect, the invention is a card mailer comprising: a generally rectangular envelope having a length and width and a front face with a window; and an integral card/insert sheet section of generally rectangular configuration having length about the length of the envelope or less and a width about the width of the envelope or less, the sheet section being received in the envelope without folding, the sheet section being printed in a first data field with a unique code in a machine readable format and in a second, separate data field with a name and mailing address of an individual assigned the unique code, the second data field being located on the sheet section aligned with and visible through the window of the envelope, the sheet section including a generally rectangular shaped scoring extending at least sufficiently through the sheet section to define a generally rectangular card portion removable from a remainder of the sheet section, the card portion including at least the first data field with the unique code, the card portion having a given material composition and the remainder of the sheet section adjoining the scoring having a material composition identical to the material composition of the card portion.
In another aspect, the invention is a method of making a transaction card mailer comprising the steps of printing a plurality of sets of variable data fields on at least a first of a pair of opposing major planar sides of a thin core, each set of printed variable data fields including at least a first data field printed with a unique code in a machine readable format, the unique code of each variable data field set printed on at least the first side of the core being different from the unique code of each other set of variable data fields printed on the first side of the core, and each set of variable data fields including a second data field printed with a name and mailing address uniquely associated with the unique code of the set of printed variable data fields, the name and address of the second data field of each set being different from the name and address of the second data field of each other set of data fields printed on the core; scoring the core to divide the core into a plurality of individual, generally rectangular sheet sections and to further define at least one element in each sheet section removable from the sheet section, each sheet section containing a separate one of the plurality of said printed variable data fields, and one removable element of each sheet section containing at least the first variable data field of the one set of variable data fields printed on the sheet section; and inserting at least one of the sheet sections with at least the one removable element of the one sheet section still in the one sheet section into a generally rectangular envelope without folding the sheet section, the envelope having a window and the printed name and mailing address of the inserted sheet section being visible through the window.

BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing summary, as well as the following detailed description of the presently preferred embodiments of the invention, will be better understood when read in conjunction with the appended drawings. It should be understood, however, that this invention is not limited to the precise arrangements illustrated. In the drawings:
FIG. 1 depicts diagrammatically a first major planar side of a first printed sheet product of the invention;
FIG. 2 depicts diagrammatically a second major planar side of the sheet product of FIG. 1;
FIG. 3 depicts diagrammatically a cross section through the sheet products of FIGS. 1 and 2 along the lines 3--3;
FIG. 4 depicts diagrammatically part of a first side of a second printed sheet product;
FIG. 5 depicts diagrammatically part of a second, opposing side of the sheet product of FIG. 4;
FIG. 6 depicts diagrammatically a cross section through the second sheet product of FIGS. 4 and 5 along the lines 6--6;
FIG. 7 depicts diagrammatically an intermediate step in making the sheet product of FIGS. 4-6;
FIG. 8 depicts diagrammatically a first major planar side of a third printed sheet product;
FIG. 9 depicts diagrammatically a cross section through the sheet product of FIG. 8 along the lines 9--9;
FIG. 10 depicts diagrammatically the insertion of a sheet section of the sheet product of FIG. 8 inserted into a standard size business envelope;
FIG. 11 depicts diagrammatically an alternate embodiment of a fourth embodiment sheet product;
FIG. 12 depicts diagrammatically a fifth embodiment printed sheet product;
FIG. 13 depicts diagrammatically a cross-section of the embodiment of FIGS. 12 taken along the line 13--13 in FIG. 12;
FIG. 14 depicts diagrammatically a line for fabricating the components of an assembling a transaction card mailer;
FIG. 15 depicts diagrammatically a portion of a sixth embodiment printed sheet product bearing a pair of irregular yet symmetrically shaped transaction cards;
FIG. 16 depicts diagrammatically a seventh embodiment printed sheet product;
FIG. 17 is a cross-section taken along lines 17--17 of FIG. 16;
FIG. 18 depicts diagrammatically an eighth embodiment printed sheet product;
FIG. 19 depicts diagrammatically a cross-sectional view taken along the lines 19--19 in FIG. 18; and
FIG. 20 depicts diagrammatically a tenth embodiment printed sheet product.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIGS. 1, 2 and 3 depict, in varying views, a first printed sheet product of the present invention indicated generally at 10. The product 10 includes a thin, flexible core 12 (see FIG. 3) which is, in this embodiment, the size of the product 10 depicted in FIGS. 1 and 2 and which has two major planar opposing sides 14 and 16. As will be seen, core sides 14 and 16 effectively form the imprinted sides of the product 10 as well. Side 14 is depicted in FIG. 1. Side 16 is depicted in FIG. 2.
Referring to FIG. 1, there is printed on the first major side 14 of the core 12, a plurality of sets of code fields. In the depicted product 10, eight code field sets of two code fields each are preferred but larger or smaller numbers of code field sets with equal or larger numbers of code are possible. A first code field of each of the eight code field sets is identified generally at 20a through 27a, respectively, while a second code field of each of the eight code field sets is indicated generally at 20b through 27b, respectively. Printed in each of the first code fields 20a through 27a and second code fields 20b through 27b are unique codes, examples of which are actually shown on FIG. 1. The code of each of the eight sets of code fields 20a and 20b, 21a and 21b, etc., is unique to the set and differs from the unique code of each of the remaining sets of fields printed on the first side 14 of the core 12. In the depicted example, each code has six decimal digits. The first five digits are sequential between 01000 and 01007. The sixth digit in each code is a check digit. The six digit codes are merely examples. More or fewer digits and even letters and other symbols can be incorporated into the codes, although it will be appreciated that letters and other symbols may not be usable in some code formats, for example, in some bar code formats. Also, although it is a preferred method of encoding, the unique codes need not be numerically sequential, merely uniquely identifiable.
The unique code of each set of code fields is printed in at least a machine readable format and, preferably, in both machine readable bar and machine and human readable numeral formats in the first code field 20a through 27a, respectively, of each of the eight sets of code fields. The same unique code of the set preferably is printed in at least numeral format in the second code field 20b through 27b of each set of code fields as indicated. The second code field 20b through 27b of each code field set is spaced from the first code field of the set, 20a through 27a, respectively, on the first side 14 of the core 12 and the sheet product 10.
Also printed on the first side 14 of the core 12 are a first plurality of static graphic fields, represented by various dot and dashed blocks, indicated collectively at 30 through 37, respectively. Such fields typically contain text and/or graphic designs. In the embodiment being depicted, each static graphic field has four separate components, numbered individually for a first of the fields 30 as 30a, 30b, 30c, 30d. The numbers and locations of the components of the static graphic fields are not significant per se to the invention. The static graphic fields 30-37 are usually identical to one another, but need not be so. Preferably, the number of static graphic fields 30-37 printed is at least equal the number of sets of code fields, in this case eight, whereby one of the static graphic fields 30-37 is associated with a separate one of the code field sets. One of the code fields of each of the sets of code fields is positioned substantially identically with respect to one of the static graphic fields 30-37. In this case, the first code field 20a-27a of each set of code fields is located in the same position with respect to each of the static graphic fields 30-37, slightly below and to the right of the various components of the static fields 30-37, for reasons which will be apparent.
One feature of one aspect of the invention is the printing of the code fields 20a-27a and 20b-27b in different directions on the same side of the sheet 10. One or more of the components of the static graphic fields 30-37 printed on the first side 14 of the core 12 typically contains text which is printed left to right across the sheet 10 when sheet 10 is viewed in the orientation it is presented in FIG. 1 with its shorter sides horizontal and located at the top and bottom of the sheet 10. As can be seen in FIG. 1, the bar and numeral format codes in the first code fields 20a-27a are printed in a first direction, namely the horizontal direction in each of those first code fields. The numeral format codes in each of the second plurality of code fields 20b-27b are printed in a direction transverse to the horizontal direction of the corresponding first code field 20a-27a of each set, preferably in a vertical direction, perpendicular to the horizontal direction in which the codes of the first plurality code fields 20a-27a are printed. While perpendicular directions are preferred for the first direction and the transverse direction in which the code sets are printed, the first and transverse directions need not be perpendicular. Nor do the first code fields all have to be printed in the same first direction, even though such an orientation is usually employed, nor do the second code fields have to be printed in the same transverse direction. As was indicated above, the first code field 20a-27a of each set of code fields is located in the same orientation and position, namely, partially below and partially to the right of a proximal one of the first plurality of static graphic fields 30-37, respectively. This conveniently permits the static graphic fields 30-37 and first code fields 20a-27a to be grouped together to produce an identical plurality of removable elements, as will be shortly described.
Referring to FIG. 2, the second side 16 of the core 12 preferably may be printed with a second plurality of static graphic fields, each field being indicated collectively at 40-47, respectively. Each of the second static graphic fields 40-47 in the depicted embodiment includes, for example, four separate components indicated by rectangular dot dashed lines and shading. These are numbered individually for the first field 40 as 40a, 40b, 40c and 40d for clarity. Again, the details of the second plurality of static graphic fields are immaterial to the invention. Typically, each of the second plurality of static graphic fields 40-47 is identical to one another and is preferably positioned identically opposite with respect to separate ones of the first code fields 20a-27a and the first plurality of static graphic fields 30-37 on the first side 14 of the core 12.
Preferably, after printing, there is applied to the first side 14 of the core 12, a first covering which is indicated generally at 54 in FIG. 3. Its edges can be seen in FIG. 3. The first covering 54 suggestedly covers at least a central portion of the first side 14, overlying all of the code fields 20a-27a and first static graphic fields 30-37. In this embodiment, the first covering 54 may extend to the long side edges of the core 12 covering the second printed code fields 20b-27b as well. Preferably, the covering 54 is at least sufficiently transparent to read the underlying printed fields 20a-27a, 20b-27b and 30-37. One of ordinary skill will appreciate that code fields can be "read" in various ways. The first covering must be sufficiently transparent in the visible light spectrum to permit human reading of the code field. However, the first covering may be transparent only in some other spectrum, for example, the infrared spectrum or ultraviolet spectrum. While not transparent to human visual examination, such a covering can be sufficiently transparent to known optical reader devices to permit reading of the machine readable representation of the unique code underlying the covering by such devices. A second covering 56 is preferably applied to the second side 16 of the core 12. Preferably, the second covering overlies only a central portion of the second side 16 containing at least a major portion of the second plurality of static graphic fields 40-47 printed on the second side. Preferably, the second covering is directly opposite at least the first plurality of code fields 20a-27a and at least most if not all of the first plurality of printed static fields 30-37. Again, the second covering 56 is at least sufficiently transparent to read the underlying printed static fields 40-47.
Also, preferably applied to the second side 16 of the core 12 are two stripes 60 and 64 of pressure sensitive adhesive. Preferably, the stripes 60 and 64 are applied directly opposite the second code fields 20b-23b and 24b-27b, respectively. In the embodiment of the invention depicted in FIGS. 1 through 3, strips of release paper 62 and 66 directly overlie the stripes of pressure sensitive adhesive 60 and 64, respectively.
The sheet product 10 is scored through the core 12 and, where present, the first covering 54, second covering 56 and adhesive layer 60, 64. This scoring is indicated by diagrammatically by unnumbered, bold dotted lines in FIGS. 1 and 2. The scoring defines a plurality of sets of elements which are removable from the sheet product 10. In particular, eight sets of removable elements, a number of sets equal to the numbers of sets of code fields, first plurality of static graphic fields and second plurality of static graphic fields printed on the core 12, are provided in product 10 by the scoring. Preferably, a first removable element of each of the eight sets of removable elements is a generally rectangular, transaction element and is indicated at 70a-77a. Each of the elements 70a-77a includes on one side, which is the second side 16 of the core 12 and product 10, a substantially identical portion of one of the second plurality of static graphic fields 40-47 which was printed on that side. Each element 70a-77a also includes on an opposing side, which is the first side 14 of the core 12 any product 10, a separate, substantially identical portion of one of the first plurality of static graphic fields 30-37 and an at least one of the first and second plurality of code fields, preferably, the first plurality of code fields 20a-27a. The elements 70a-77a can be used as a credit card (with or without magnetic stripe as will be discussed), identification card, membership card, etc. If desired, a closed perimeter opening can also be scored through the sheet product within each removable element 70a-77a, to permit the element 70a-77a to be mounted on a key chain or other key holder like a key or to receive a key chain or ring or the like and be used as a key fob supporting one or more keys on such chain or ring or the like.
The second removable element of each set is denoted at 70b-77b and consists of a portion of the product 10 having on one side, which was the first side 14 of the core 12 and product 10, one of the second set of code fields 20b-27b, respectively. Each removable element 70b-77b includes on its remaining side, which was the second side 16 of the core 12 and product 10, a portion of one of the two stripes 60 and 64 of pressure sensitive adhesive. Elements 70b-77b can be used as labels or tabs on an application or membership form, etc., of the person receiving the corresponding card element 70a-77a of the set.
The scoring has been indicated diagrammatically for several reasons. First, the exact type of scoring used, e.g., long, continuous cuts with short breaks, closely spaced perforations, etc. is a matter of choice. Furthermore, the product 10 without the scoring and without the release paper strips 62 and 66, is an intermediate sheet product which can be used to make a somewhat different sheet product indicated generally at 110 in FIGS. 4 through 6.
Product 110 in FIGS. 4 through 6 is so similar to the sheet product 10 of FIGS. 1 through 3 that only a top portion of product 110 is shown in FIGS. 4 and 5 to highlight the differences between the two embodiments 10 and 110. The sheet product 110 is formed from an intermediate sheet product also used to form the sheet product 10 of FIGS. 1 through 3. That intermediate product includes the core 10, the pluralities of code fields 20a-27a and 20b-27b and the first plurality of static graphic fields 30-37 printed on the first side 14 of the core 12 (FIG. 4) and the second plurality of static graphic fields 40-47, respectively, printed on the second side 16 of the core 12. Stripes 60 and 64 of pressure sensitive adhesive are also provided along the second side 16 of the core 12 adjoining the longer side edges of the core 12 and directly opposite the second code fields 20b-23b and 24b-27b, respectively, only fields 20b and 24b being indicated in FIG. 4. This intermediate sheet product is therefore identical to the sheet product 10 of FIGS. 1-3 except that it lacks the strips of release paper 62 and 66 and the scoring. The side edge portions of the first covering 54, overlying the second code fields 20b-27b can also be eliminated as a cost savings. This intermediate product is indicated in FIG. 7 at 100.
In converting this intermediate product 100 into the sheet product 110 of FIGS. 4-6, the first and second longitudinal edge portions 67 and 68 of the core 12, bearing the adhesive stripes 60 and 64, respectively, of the sheet product 100 are turned, as is indicated diagrammatically in FIG. 7, onto an adjoining portion of the core 12 and sheet product 100 forming a double thickness of the core 12 along the longitudinal edges of the resulting sheet product 110 part of which is indicated in FIG. 6. The sheet product 110 formed in this manner is thereafter scored, the scoring again being indicated by the unnumbered, bold dotted lines in FIGS. 4 and 5. The scoring defines plural sets of plural elements removable from the sheet product 110 and removably adhered to one another by the intervening adhesive stripe 60 or 64. In the depicted embodiment 110 continuous cuts have been made along the longer, folded side edges of the intermediate product 100 to define the outer side portions of the removable elements
FIGS. 8 and 9 depict a third printed sheet product of the present invention indicated generally at 210. The sheet product 210 again includes a thin, flexible core 212 like core 12 of products 10 and 100/110 (see FIG. 3) which, again, is the size of the product 210 depicted in FIG. 8 and which has a pair of major planar opposing sides 214 and 216 seen in FIG. 9, a first major planar side 214 of which is depicted in FIG. 8. There is printed on the first major planar side 214 of the core 212 a plurality of sets of variable data fields. In the depicted product 210 three variable data field sets of three variable data fields each are printed but as few as two and more than three separate variable data fields could be printed for each set. Again, a first variable data field of each of the three variable data field sets is a code field identified generally at 20a, 21a and 22a, respectively. Another data field of each of the three data field sets is a second code field indicated at 20c, 21c and 22c. Each of these data fields 20a through 22a and 20c through 22c is printed with a unique code, preferably in both bar code and numeric formats. As with the previous sheet products, the unique code of each variable data field set is unique to the set and different from the unique code of each other set of variable data fields printed on the first side 214 of the core 212.
In addition, each set of variable data fields includes another data field indicated at 20d, 21d and 22d, respectively, printed with a name and mailing address uniquely associated with the unique code of the set of printed variable data fields. The name and address of each of the data fields 20d, 21d and 22d is unique to the set 20, 21 or 22 and is different from the name and address of each of the other data fields 20d, 21d and 22d also printed on the first side of the core.
As is depicted in the figure, each of the various individual variable data fields 20a, 20b, 20c, 21a, 21b, 21c, 22a, 22b and 22c is spaced from one another for purposes which, if not already apparent from the previous discussion, will become apparent from the following discussion.
The first side 214 of the core 212 may also be printed with a first plurality of static graphic fields, represented by the various dashed and double-dotted blocks indicated collectively at 30 through 32, respectively. Such static graphic fields typically contain text and/or graphic designs which are repeated. In the embodiment being depicted, each static graphic field has five separate components numbered individually for the first of the static graphic fields as 30a through 30e, respectively. In this embodiment, each of the unique codes in the code-type variable data fields 20a through 22a and 20c through 22c is printed in the same orientation but could be printed in directions transverse to one another, if desired. As was the case with the previously discussed embodiments, the second major planar side 216 of the core 212 of the sheet product 210 can be printed with static graphic fields backing any of the fields printed on the first side of the core depicted in FIG. 8.
Preferably, a first covering is applied over a portion of the first side 214 after printing the static graphic fields and the variable data fields on the first side 214 of the core 212 of the depicted sheet product 210. The first covering of sheet product 210 is indicated generally at 254, the lead line of which extends to an edge of the first covering in FIG. 8. In this particular sheet product 210, the first covering 254 preferably covers only the right half of the sheet product overlying each of the variable data code fields 20a through 22a and 20c through 22c. The first covering 254 avoids the printed variable data address field 20d through 22d. Again, the first covering 254 is preferably at least sufficiently transparent to humans and/or machines to read the underlying printed variable data code field 20a through 22a and 20c through 22c. As was the case with sheet product 10 of FIGS. 1 through 3, a second covering 256 is preferably applied to the second major planar side 216 of the core 212 of the sheet product 210 directly opposite the first covering 254 and the variable data code fields 20a through 22a and 20b through 22b. The second covering 256 again can be transparent, if desired, to permit the reading of any variable data or static graphic fields which may be printed on the second major planar side of the core of the sheet product 210.
The sheet product 210 is preferably scored through its core and, where present, its first covering 254, second covering 256 and any other covering, such as an adhesive layer (not depicted). The scoring is indicated diagrammatically by bold, dotted lines in FIG. 8. Sheet product 210 differs from the previously described sheet product in that the scoring preferably includes two horizontal score lines, which are indicated at 201 and 203, respectively, which define the sheet product 210 into three sheet sections indicated at 202, 204 and 206, respectively. Each of the sheet sections 202, 204 and 206 contains a separate one of the plurality of sets of printed variable data fields (20, 21 and 22, respectively). Thus, sheet section 202 includes the three variable data fields 20a, 20c and 20d constituting the first variable set of data fields of sheet product 210. Sheet section 204 contains the second set of variable data fields 21a, 21c and 22d while the third sheet section 206 contains the third set of variable data fields 22a, 22c and 22d. In addition, scoring preferably defines at least one and preferably sets of two or more elements which are removable from each sheet section 202, 204 and 206. In particular, three sets of removable elements, equal to the number of sets of printed variable data fields, are provided in the sheet product 210 by the scoring. Preferably, the first removable element of each of the three sets of removable elements is a generally rectangular, card-sized transaction element and is indicated at 70a, 71a and 72a, respectively. Again, each of the elements 70a, 72a can include on a second side of the core of the product 210 a substantially identical portion of identical static graphic fields which may be printed on that side of the core and product. Again, each element 70a-72a also includes substantially identical portions of the first plurality of static graphic fields 30, 31 and 32 which are printed on the first side 214 of the core 212 forming the first side of sheet product 210. Each of the indicated first removable elements 70a, 71a and 72a is generally rectangular and about two inches by about three inches in size, approximating the size of a business card or credit card and may be used as a credit card, identification card, membership card, etc.
The second removable element of each sheet section 202, 204 and 206 defined by the scoring is identified at 70c, 71c and 72c, respectively. Like the first removable element, each second removable element 70c, 71c and 72c may include identical portions of static graphic or variable data fields printed on a second side of the core of sheet product 210 (not depicted). Removable elements 70c, 71c and 72c are preferably generally rectangular and smaller than removable elements 70a, 71a and 72a, respectively, preferably less than two inches along one side, such as either vertical side in FIG. 8, and less than three inches along another side, namely either horizontal side adjoining either vertical side in FIG. 8, to define a slightly smaller, removable element. Preferably the scoring defines a closed perimeter 70d, 71d and 72d opening through the sheet product 210 within each of the removable elements 70c, 71c and 72c, respectively. The closed perimeter openings 70d, 71d and 72d, extend transversely through the plane of the sheet product 210 and of each of the elements 70c, 71c and 72c and permit the element 70c, 71c and/or 72c to be used as a key tag lying flat and parallel planar with keys on a key chain or ring or in a key case. Alternatively, each element 70d, 71d and 72d, coated with suitably strong coverings 254 and 256 could be sufficiently strong, rigid and durable enough to act as a key fob supporting a key chain, key ring or like key fastener. Preferably, each of the removable elements 70c, 71c and 72c is approximately two and one-half by one inches in size for more convenient interleaving with conventionally sized keys.
Each of sheet sections 202, 204 and 206 is also preferably sized to fit into a standard-size envelope without folding. For example, each of the sheet sections can be formed by one-third of an eight and one-half by eleven inch single sheet product to be easily inserted into standard No. 9 or No. 10 size envelopes. Other standard envelope sizes may be used. For example, each section 202, 204 and 206 need only be less than four and one-half inches in height and ten and five-sixteenths inches in width to be capable of being inserted without folding in a standard No. 11 size business envelope. FIG. 10 depicts diagrammatically the insertion of sheet section 202 into a standard business size (No. 10) envelope indicated at 290. Preferably, the variable data address field 20d is positioned on the sheet section 202 to align with a window 292 through the front wall of the envelope. In this way, each sheet section 202, 204 and 206 is self-addressed.
While FIG. 8 depicts the division of a sheet product 210 into three individual sheet sections, each sized to essentially fully fit a standard size business envelope (e.g. No. 9 or No. 10) without folding of the section or significant movement of the section within the envelope, one of ordinary skill will appreciate that other sheet product and sheet section sizes can be conveniently employed. For example, a standard eight and one-half by eleven inch sheet product according to the present invention can be provided and scored to define into six sheet sections of equal size, namely about three inches in height by about four inches in width. One such sheet section 302 is indicated diagrammatically in FIG. 11. A first variable data code field 20a includes bar and numeral or other machine readable representations of a unique code and forms part of a removable element 70c of the sheet section. A second, variable data address field 20d is printed below. Removable element 70c may be provided with a closed perimeter opening indicated in phantom at 70d permitting use of the element 70c as a key tag or fob. The sheet section 302 can be inserted without folding into a comparably sized envelope or tipped onto a carrier 301 about four inches high and eight to nine inches wide, which can itself be received in a standard No. 9 or 10 size envelope without folding.
Advantages of the invention in the form of the sheet product 210 and like sheet products including sheet sections with a variable data address field is that both the address field and the unique code field(s) can be printed at the same time in a single pass of the core of the sheet product through a single printer. This insures accuracy and integrity between the variable data address field and unique code field(s) of each sheet section.
The core 12 of each sheet products 10, 100/110 and 210 can be any thin sheet or web material having two major planar opposing sides, which can be printed upon. Preferably, the core is a flexible material which can be used with conventional, high speed, offset printing machines. Acceptable materials include metal foils, cellulose based products, fabrics, cloths and preferably plastics including, for example, ABS, acetates, butyrates, phenolics, polycarbonates, polyesters, polyethylenes, polypropylenes, polystyrenes, polyurethanes and polyvinyl chlorides as monomers, copolymers and/or laminates. For example, the following specific trademarked products may be useful: Polyart I and II of Arjobex Synthetic Papers; various grades of GP700 from Bexford Limited (Engl.); Kapton, Tedlar and Telar of DuPont; Fascal, Fasprint and Crack n' Peel Plus of Fasson; Lasercal, Compucal II and Datacal Coating of Flexcon; Kimdura of Kimberly Clark; various grades of Pentaprint PR of Klockner Pentaplast; various grades of LLM-LV and Data Graphic II LLM of Lamart; Teslin of PPG Industries; the following products of Stanpat: APL-100, -110, -120, -150, -200, UM-546, UC-546, PPC-410, -450 and -460; and the following products of Transilwrap: Proprint, Transilprint, Transilmatte, T.X.P., Eve, Trans-Alley, Transglaze, Trans-AR, Trans V.L. and T Print; and others. These brand name products are treated or constructed in some fashion to make them particularly suited for use in one or more types of printing processes. Details regarding these products and companies and others are available to those of ordinary skill in the art through various sources including but not limited to published references such as AUTOMATED ID NEWS 1993-1994 REFERENCE GUIDE AND DIRECTORY, published and distributed by Advanstar Communications, Cleveland, Ohio.
Each of the first and second coverings 54 and 56 can be any material which is suitably and sufficiently transparent and which can be applied to the core material selected in any suitable fashion for the material(s) selected without adversely affecting the core or the printing thereon. The coverings might be, for example, sheets or webs of any of a variety of transparent Transcote FG and Copolymer plastic films of Transilwrap, Inc. of Chicago, Ill., which are transparent in at least the visible and infrared light spectrums or any of a variety of similarly transparent Durafilm plastic films of Graphic Laminating, Inc. of Cleveland, Ohio. The plastic films are preferably adhered to the core with an adhesive appropriate for use with the materials selected for the core and transparent covering. Typically, polymer based adhesives are used with the exemplary plastic films identified above.
In addition, such laminate films can be obtained from various commercial sources incorporating one or more magnetic (magnetizable) stripes, of the type found on most common credit cards. Alternatively, a separate magnetic stripe can be applied to the transparent covering in a conventional manner for such materials, such as by hot stamping. In such case(s), the removable elements 70a-77a (FIGS. 1 and 2), 170a-177a (FIGS. 4 and 5) and 70a-72a (FIG. 8) may be vertically oriented on each sheet 10, 100/110 and 210 (90' from the indicated orientation in the figures) to run the magnetic stripe(s) continuously along columns of such elements.
For the particular removable elements being made in the preferred embodiments disclosed in this application, namely, transaction size elements such as cards, key tags and fobs and labels, the above-identified coverings are preferred, as they provide a layer of polyester having good strength, wear and soil resistant properties which can be used on the outer side of the products 10, 100, 110. The pressure sensitive adhesive used may be any conventional, commercially available, pressure sensitive contact adhesive suitable for use with the particular materials selected for the sheet product. For the embodiments being described, double coated, permanent adhesive transfer tapes, such as those available from Enterprise Tape Company of Dalton, Ill., for example, are suitable.
The preferred methods of manufacturing the preferred sheet products 10, 100 and 110 are quite similar and straightforward. Preferably, the static graphic fields are printed first on each selected side of the core material selected. Any known, conventional type of printer and printing process may be used including, for example, flexographic, offset lithographic, silkscreen, letter press, thermal transfer, thermal direct, ink jet, color laser, formed character impact, hot stamp, electrostatic, ion deposition, magnetographic, dot matrix, cycolor, photographic silver halide, sublimation, diffusion, pad, gravure, spray painting, dyeing, electrolytic plating, electroless plating, sputter deposition, in-mold decorating, flocking, embossing, vacuum evaporation metallizing, engraving, hot transfer, electrophotographic printing or electro ink printing process. Preferably, a high speed printing process such as flexographic or offset lithography is used to print on continuous webs of thin flexible planar material for efficiency and cost. A printing method and machine capable of simultaneously printing the first and second sets of static graphic fields on the first and second sides of the web in one pass through the printer is preferred for efficiency, but single side printing in separate passes may be preferred for quality.
Next, the core bearing the printed static graphic fields preferably is passed through a variable data field printer, preferably a programmable printer capable of printing variable data fields in at least bar and character format on at least one side of the core, which becomes the first side of the sheet products, in a single pass of the core through that printer. "Character" encompasses at least alphanumerics and conventional punctuation symbols. Commercially available printers having this capability include thermal transfer, thermal direct, ink jet, color laser, formed character impact, electrostatic, ion deposition, magnetographic, dot matrix, photographic and sublimation and are available from almost an innumerable list of suppliers. Again, printers printing on continuous webs are preferred for efficiency but printers printing on individual sheets (cut lengths of web) are preferred for quality. Currently, thermal transfer and laser printers are preferred in the industry for variable format printing, particularly of characters and bar codes. Generally speaking, existing thermal transfer printers provide high quality, sharp characters and bars while laser printers provide characters and bars which are not as sharp but more consistent in thickness. Improvements continue to be made to both ink jet and ion deposition printers as well. Ink jet and/or ion deposition printers may be preferred for speed. It will be appreciated that four lines 70a, 71a and/or 71c, 72c could be continued entirely within the parameter of each section 402, 404, 406, etc. by providing additional scoring lines, for example, on 170a, 171a (and/or 171c, 172c) so that a generally rectangular shaped scoring 70a/170a, 71a/171a, etc. is provided in each sheet section 402, 404, 406, etc., cutting sufficiently through such sheet section to define at least one removable card element 70, 71, etc. in each sheet section. However, at least currently available machines, generally speaking, do not provide the quality provided by currently available thermal transfer and laser printers. Currently, laser printing is preferred for the particular embodiments 10, 100 and 110 being described. For example, laser printers are made and/or distributed in the United States by such well-known corporations as Hewlett-Packard, IBM, Kodak, NCR, Panasonic, Pentax, Ricoh, Siemans, Toshiba and Xerox. In addition, literally dozens of other, smaller manufacturers offer programmed or programmable printers which can be used or can be configured to be used to perform the steps indicated above. Again, the material selected for the core 12 should be compatible with the preferred printing method and equipment or the printing methods and equipment selected to be compatible with a preferred material. For example, for laser printing, a microvoided polysilicate plastic sheet material, having at least about sixty percent porosity is preferred.
The programmable code field printer selected preferably is configured to print each of the variable data fields. With respect to sheet products 10, 100/100 the first plurality of code fields 20a-27a are printed in a first direction and the second plurality of code fields 20b-27b in a direction transverse to the first direction of the first code field of the set on the one side of the sheet or web constituting the first side 14 of the core 12. As is indicated in FIGS. 1, 2 and 4, 5, the bars and numerals of the first plurality of code fields 20a-27a are printed in a portrait mode running horizontally across the sheet 10, while the second plurality of code fields 20b-27b are printed in a landscape mode running vertically along the side edges of the sheet 10. This is accomplished in straightforward fashion by simply programming the computer to identify the characters to be printed at predetermined locations on the web in defined angular orientations to the web. In this way, all of the code fields are printed on the web in a single pass of the web through the printer. Preferably, the first and second coverings 54 and 56 are then applied to the opposing sides 14 and 16 of the web in a conventional manner for the covering material selected. The stripes of pressure sensitive adhesive 60 and 64 are also applied, with or without release paper 62 and 66, respectively, for the embodiment 10, 100 or 110 selected.
Separate printing of static graphic and variable data fields is presently preferred for speed, cost and quality. However, the capabilities of programmable printers continues to improve in all three categories. In some instances, it is already possible to simultaneously print certain types of static graphic and variable data fields at the same time using the same programmable printer in a single pass of the core through the printer. Duplex printers are now becoming available which permit the printing of variable data fields on both sides of a core in a single pass through such printers. Sheet products printed by such devices are intended to be encompassed by the present invention. The present invention is also intended to cover all instances where static graphic fields may be printed before, after or simultaneously with the variable data fields on one or both sides of a continuous or cut length core.
Next, if the first embodiment sheet product 10 is produced, the printed, covered web is preferably fed through a cutter which scores the sheet products 10 through the core 12, covering 54 and 56 and stripes 60 and 64, where present, to define the sets of removable elements 70a-77a and 70b-77b and cuts a continuous web into the individual sheet product lengths if a continuous web is used. If the second embodiment sheet product 110 is being made, the side edge portions 67, 68 bearing the pressure sensitive adhesive strips 60 and 64 may be folded by conventional stock folding equipment upon an immediately adjoining central portion of the web. The longitudinal edge folded web product is thereafter preferably fed through a cutter which scores each of the individual sheet products 110 to define the plurality of sets of removable elements 170a-177a and 170b-177b and cuts the continuous web into the individual sheet product lengths 110 if a continuous web is used.
Sheet product 210 and similar sheet products are made in a similar fashion. In particular, the plurality of sets of variable data fields 20a-22a, 20c-22c and 20d-22d are printed on the first side 214 of a pair of opposing major planar sides 214, 216 of the thin core 212. Each set of printed variable data fields, collectively 20, 21 and 22, includes at least a first data field 20a or 20c, 21a or 21c and 22a or 22c, printed with a unique code preferably in at least a bar or other machine readable format. The unique code of each set of variable data fields 20, 21, 22, printed on the first side 214 of core 212 is different from the unique code of each other set of the variable data fields 20, 21, 22 printed on the first side 214 of core 212 and each set of variable data fields further includes a second data field 20d, 21d, 22d printed with a name and mailing address uniquely associated with the unique code of the set of printed data fields 20, 21 and 22. The name and address of the second data field 20d, 21d, 22d of each of the sets of printed variable data fields 20, 21 and 22 are different from the name and address of the second data field of each other set of the data fields 20, 21, 22 printed on the first side 214 of the core 212. All of the variable data fields 20, 21 and 22 preferably are printed in one pass of the first side 214 of the core 212 through a suitable printer. A first cover 254 is applied to the first side 214 of core 212 overlying at least one and preferably both variable data fields 20a-22a and 20c-22c, while preferably avoiding each of the name and address variable data fields 20d, 21d and 22d, to save manufacturing costs. Again, the preferred plastic film coverings identified are adhered or otherwise laminated in suitable, known ways for the materials involved to the first side 214 of the core 212 and are sufficiently transparent in the visible light and infrared spectrum to permit observers and suitable optical equipment, such as conventional infrared laser-equipped bar code readers, to read and decipher the bar format code underlying the first covering 254. Again, a second, similar, if not identical, covering 256 is applied to the second major planar side 216 of the core 212; opposite the first covering 254. The sheets 210 are thereafter scored completely, or nearly completely, through the core 212 and coverings 254, 256 to divide the sheet product 210 into the plurality of sheet sections 202, 204 and 206 and to define at least one, and in the case of sheet product 210, two elements 70a and 70d, 71a and 71d and 72a and 72d, in each sheet section 202, 204 and 206, respectively, removable from the sheet section. Simultaneously, closed perimeter openings 70d, 71d and 72d are similarly scored through the sheet product 210 within one of the two removable elements of each of the sheet sections 202, 204 and 206 to permit those elements 70c, 71c, 72c to be used as key tags or fobs. Each sheet section 202, 204 and 206 of the sheet product 210 can thereafter be inserted into a separate envelope 290 with the address field 20d-22d, respectively, aligned with the window 292 through the envelope 290.
It will be recognized by those skilled in the art that changes could be made to the above-described embodiments. For example, in addition to printing unique code fields for each associated set of elements, other fields can be reserved for printing other data uniquely associated with the code or with the person or entities ultimately assigned the codes, for example, names, addresses, phone numbers, dates, vital statistics, etc. Many if not most programmable printers are capable of reading such data from a conventional data storage device, such as a tape drive, disk drive, etc. and printing the information in fields which are predefined with respect to the core 12 and, preferably, with respect to one or more of the removable elements which are ultimately defined on the core.
Also, although one transaction sized laminated card and one adhesive back tab or label have been identified in the disclosed embodiments as constituting each set of removable elements, additional and/or alternate elements can be provided. For example, multiple transaction sized cards, multiple labels, and other elements including, for example, an element having a hole or opening cut therethrough for attachment to a key ring, hook or the like, can be provided.
One of ordinary skill will appreciate the order in which steps are taken may be immaterial. For example, while printing a static graphic field initially on a continuous web is preferred for rapid, inexpensive printing, static fields can be printed directly on cut sheets. Typically, it will also be immaterial whether the code fields are printed before, after or during the printing of the static graphic fields. Further, the order in which coverings are applied is generally not critical, and coverings could be applied to one side of a core after printing upon that side is completed and before printing is performed on the other side of the core.
Next, one of ordinary skill should be aware that it is now also possible to first laminate a tough, protective transparent film of vinyl or polyester to a relatively inexpensive core of PVC or other inexpensive backing or stock material and print variable data (and/or static graphic) fields directly onto the vinyl or polyester laminate layer. Smudge resistant, scratch resistant, high resin thermal transfer films now available from such manufacturers as Sony and Ricoh are sufficiently adhesive and tough that they do not require a protective film covering. The invention is intended to cover such sheet products as well. In such instances, the core will actually be a laminate.
FIGS. 12 and 13 depict a fifth printed sheet product of the present invention indicated generally at 410. The sheet product 410 includes a thin, flexible core 412 similar but not identical to cores 12 and 212, but which still has a pair of major planar opposing sides 414 and 416 seen in FIG. 12. The first major planar side 414 is depicted in FIG. 11. There is preferably printed on the first major planar side 414 of the core 412 a plurality of sets of variable data fields. In the depicted sheet product 410, one full set of and two partial adjoining sets of data fields are shown. Again, each data field set includes at least two or more separate variable data fields, three data fields 21a, 21c and 21d of the full data set being depicted while adjoining data fields 20a, 20d of one set and 22c of another set are shown. Again, the individual variable data fields are spaced from one another in each set and between sets. Either or both sides 414, 416 of core 412 may also be printed with a first plurality of static graphic fields, again indicated collectively and by example only at 30d and 31a-31e. Again, the second major planar side 416 can be printed as indicated earlier for any of the previous embodiments.
Referring now to FIG. 13, it will be seen that the core 412 differs from the previous cores 12 and 212 in that it is formed of two separate sheets of material 412a and 412b which generally adjoin one another longitudinal edge to longitudinal edge--side by side. The sheets 412a, 412b are preferably held together by at least a first covering 454, which preferably overlaps at least portions of each of the sheets 412a, 412b and further overlaps at least over the unique, at least machine readable code variable data fields 21c, 22c on the one sheet 412b and yet does not extend over the name and address variable data field 21d on the remaining sheet 412a. First covering 454 is preferably at least sufficiently transparent to machines and preferably humans to read the underlying printed variable data code fields. Again, as was the case with the previous embodiments, a second covering 456 is preferably applied to the second major planar side 416 of the core 412 directly opposite the first covering 454 and a numeric variable data field code on the first side of the core 412. Preferably, each covering 454 and 456 includes a solid film layer 454a, 456a which is adhered to the core 412 by an adhesive layer 454b, 456b. Preferably, adhesive layers 454b, 456b can be activated in some way, for example by heat, ultraviolet or visible light, to permanently bond the separate sheets 412a, 412b and coverings 454, 456 together so as to provide a protective outer covering on either side of removable portions of the sheet product 410.
The sheet product 410 is again preferably scored through its core 412 and, where present, first covering 454, second covering 456 and any adhesive layers adhering those coverings to the core. Horizontal score lines 401 and 403 in FIG. 12 define opposing upper and lower edges of one of the plurality of sheet sections 404, which sections are scored or otherwise separated from the longer sheet product 410. Each sheet section 404 taken from the sheet product 410 contains a separate one of the plurality of sets of printed data fields. In addition, the scoring preferably defines at least one element which is removable from the sheet section 404. In particular, first element 71a is removable from the sheet section 404 and is defined physically by scoring which is represented in FIG. 12 by the bold broken lines indicated by the lead line of reference numeral 71a. Scoring is indicated in FIG. 13 by solid vertical lines 71a, which define cut sides of the removable element 71a. A second removable element 71c is defined in FIG. 12 by scoring and is also indicated by the lead line from that reference numeral. Again, a closed perimeter opening 71d may be scored within the one removable element 71c, as was the case with the third embodiment 210. It will be appreciated that although broken lines 401, 403, 71a, 71c and 71d are used to represent scoring, the score lines 401, 403 and preferably the score lines defining elements 71a, 71c and 71d are continuous cuts.
If desired, another covering 458 can be applied to one side of one of the existing coverings 454, 456, as indicated in FIG. 13 in phantom. Preferably the covering 458 is releasably bonded to one of the coverings 456 with a pressure sensitive adhesive 458a, which will adhere to but release from the opposing covering 456 without delaminating that covering 456 from the core 412 or from the other covering 454. The preferred purpose of providing such an additional covering 458 is to permit the remainder of the sheet section 404 to be scored entirely through the core 412 and immediately facing layers 454 and 456. Conventional scoring equipment can be dimensioned sufficiently accuracy to permit full scoring through the core 412 and coverings 454, 456 while leaving the remaining covering 458 substantially if not essentially unscored. Less desirably, covering 458 can be deleted and small continuous strips of material left between elements 71a and/or 71c and the remainder of section 404 to retain elements 71a, 71c in place in the section 404.
FIG. 14 depicts diagrammatically the components of a line for making the component of an assembling a transaction card mailer. For the embodiment sheet product 410, the FIGS. 12 and 13, two separate continuous webs of core material 412a, 412b are fed from separate supply rolls through a pair of aligning nips 460, 462 which hold the two sheets 412a, 412b in adjoining side by side position until the sheets can be bonded together downstream in the laminating process. The sheets 412a, 412b may be preprinted with static data fields or printed while being passed through the line, for example, by a continuous web printer indicated diagrammatically and in phantom by opposing print rolls 464, 466. The statically printed sheets are then preferably passed through a variable data field printer 468 which prints all variable data fields on a first side 414 in a single pass of the sheets 412a, 412b through the printer 468. If desired, a second printer, indicated diagrammatically and in phantom at 470, can be provided opposing the first printer 468 to print on the remaining side 416 of the resulting sheet product 410. After printing, first and second coverings 454 and 456 are preferably applied to opposing sides of the core 412 at least partially overlapping both of the sheets 412a and 412b. Opposing rolls 460, 462 or other suitable means are preferably configured to activate the adhesive layer supplied with each covering 454, 456, for example by heating or by generating a visible or ultraviolet light while pressing the coverings 454, 456 to the core 412 and preferably to permanently bond and laminate the coverings 454, 456 to the core 412. If provided, the third covering 458 is preferably applied downstream from the rolls 460, 462 so as to not interfere with the activation of the adhesive on the coverings 454, 456. The continuous sheet product 410 is scored, for example by a pair of opposing roll cutters 470, 472, to define the plurality of individual, scored sheet sections 402, 404, 406, etc. which may thereafter be inserted individually into standard, rectangular, business size envelopes 290a, 290i through a conventional insertion machine, which is indicated diagrammatically at 476. One completed mailer 480 comprising envelope 290a and sheet section 402 is indicated. Paper sheet material 412a may be any paper stock compatible with the adhesive materials selected for use on the first and second coverings 454, 456, while sheet material 412b is preferably one of the aforementioned materials suitable for laser printing. The pressure sensitive, adhesive backed third covering 458 if used, might be a high density polyethylene or polypropylene 4 mils thick, low tack pressure sensitive adhesive, self-wound, packaging film available from any of a number of tape suppliers including Consolidated Graphic Materials of Somerset, N.J., Flexcon Co., Inc. of Spencer, Mass or Tape Rite of New Hyde Park, N.Y.
FIG. 15 depicts a sixth embodiment printed sheet product of the present invention particularly for mailers indicated generally at 510. The sheet product 510 includes a thin flexible core identical to core 412 in FIG. 13 having major planar opposing sides, a first side of which is seen in the figure. Preferably printed on the first major planar side 514 of the core shown in FIG. 15, are a plurality of sets of variable data fields, two full sets of variable data fields being shown. Again, each data field set includes at least two or more separate, variable data fields. Three variable data fields 21a, 21a' and 21d of the first full data set are depicted, while variable data fields 22a, 22a' and 22d of the other adjoining set are shown. Again, the individual variable data fields are spaced from one another in each set and between sets. Either or both sides of the core may be printed with a first plurality of static graphic fields which are indicated by example at 31d, 31d' and 31e. Again, the second major planar side can be printed with any desired static or variable data fields or left unprinted as indicated earlier for any of the previous embodiments Again, the laminate construction of sheet product 510 is identical to that shown in FIG. 13 for sheet product 410.
Sheet product 510 is also preferably scored through the core and, where present, first and second outer covering (e.g. coverings 454 and 456) and any adhesive layers adhering those coverings to the core. Horizontal score lines 501, 503, 505 in FIG. 15 define opposing upper and lower edges of a plurality of adjoining sheet sections 502, 504, etc. which are separated from the longer sheet product 510 for individual mailing. Each sheet section 502, 504 taken from the sheet product 510 contains a separate one of the plurality of sets of printed variable data fields. In addition, in this particular embodiment, the scoring additionally defines two irregularly yet identically shaped elements, indicated at 571, 571' which are removable from the sheet section 504. The scoring is indicated in FIG. 15 by both solid, horizontal and vertical lines 571a, 571b, respectively, and by intermediate solid line 571c. Each half of solid line 571c is a reversed mirror image of the other half of that line such that the two irregularly yet identically shaped elements 571, 571' are provided. Again, if desired, a closed perimeter opening 571d, 571d' can be provided within the boundaries of each of the elements 571, 571' to enable their attachment to a key holder, key chain or the like. Again, the scoring 571a-571d is preferably continuous down to an underlying covering like covering 458 shown in FIG. 13, to releasably retain each of the elements 571, 571' within each sheet section 502, 504 when the sheet sections 502, 504 are separated from one another for individual mailing. The removable card elements 571, 571' can collectively have a size of a standard transaction card, e.g. about 2.125.times.3.375 inches with the portions of each card bearing openings 571d, 571d' being wider than the width of the immediately adjoining portion of the adjoining removable card element. The narrow portion of each card should be sufficiently wide to enable the code thereon to be machine read, particularly through a swipe reader. That would be at least about one inch for one-dimensional printed bar code or one-half inch for encoded magnetic strip. Other dimensions may be or may become possible for different swipe readers. For printed bar codes, closed perimeter openings 571d, 571d' preferably should be positioned at least one inch from the longest straight outer edge of the card 571, 571' to avoid passing through the "read" area of the bar code reader. Again all printed variable data codes would be printed in one pass of the core through the printer.
FIGS. 16 and 17 depict a seventh embodiment printed sheet product of the present invention indicated generally at 610. As best seen in FIG. 17 the construction of sheet product 610 is substantially identical to that of the sheet product 410 of FIGS. 12 and 13. Again, a thin flexible core indicated generally at 412 is provided having a pair of major planar opposing sides 614 and 616. The first major planar side 614 is depicted in FIG. 16. Preferably printed on the first major planar side 614 is a plurality of sets of variable data fields, one set of printed variable data fields 21a and 21d being shown in FIG. 16. Again, the individual variable data fields are spaced from one another and from the variable data fields of adjoining sets. Either or both sides 614, 616 of the core 612 may be printed with static graphic fields, indicated by example only in phantom at 31e.
Referring to FIG. 17, core 612 is identical to core 412 of FIG. 13 in that it is again formed of the two separate sheets of material 412a and 412b, which generally adjoin each other longitudinal edge to longitudinal edge, side by side. The sheets 412a, 412b are again held together by at least a first covering 454, which overlaps at least adjoining portions of each of the sheets 412a, 412b and yet does not extend over at least one of the printed variable data fields 21a and 21d on the remaining sheet 412a, and a second covering 456 preferably applied to the second major planar side 416 of the core 412 directly opposite the first covering 454. In this particular embodiment, there is further a magnetic strip 652 preferably adhered by an adhesive layer 650 to the first covering 454. Magnetic strip 652 can be laid down in a continuous length from a roll, for example, at the same time outer coverings 454, 456 are being applied, as indicated in phantom in FIG. 14, or at a separate station between the adjoining nips 460, 462 and the adjoining nips 464, 466. Application of the magnetic strip 650 would be in any conventional manner for the material(s) used.
As further indicated in FIG. 17, the sheet product 610 is again preferably scored through its core 612, first and second coverings 454, 456 and any adhesive layers adhering those coverings to the core, and through the magnetic strip 652 to define a removable element 671. Preferably, the scoring is a continuous closed circuit cut 671a through those layers. Again, a third covering layer 458 with pressure sensitive adhesive layer 458a preferably is provided to retain the scored element 671 in the sheet product 610 and in the individual sheet sections 602, 604, etc. when they are separated from the sheet product 610 by horizontal score lines 601, 603, etc.
The outer surface of outer covering 454 is also suggestedly lightly buffed along the strip indicated at 660 between a pair of parallel broken lines to roughen the surface of the first protective layer sufficiently to take and retain ball point pen ink. In this way, a signature strip can be formed directly on the element 671 from the protective covering without the need of an additional laminate element. Strip 660 can be formed, for example, by the use of emory cloth adhered to the circumference of a driven wheel, such as a wheel 662 indicated in phantom in FIG. 14, which may be provided anywhere between the nips 460/462 and 470/472 as shown or in either of the rollers 460, 470. Preferably the abrasive wheel is adjustably supported so that the degree of scuffing can be controlled. Each sheet section 602, 604, 606, etc. can be processed after separation from the main sheet product 610 by machine reading of the machine readable code (21a) and thereafter applying the appropriate code and/or other information to the magnetic strip material 652, if such code/information is preassigned in the system being employed. Alternatively but less desirably, the magnetic strip 652 may be precoded and then the strip 652 and the machine readable code 21a read together in a post-assembly step to collate preassigned code on the magnetic strip with the machine readable code printed on the sheet section 604. It should be appreciated that the alphanumeric code in field 21a could be printed on removable card element 671 in addition to or in place of the magnetic strip and that plural removable cards rectangular or irregular but identically shaped like cards 571, 571' of FIG. 15, could be provided with pairs of parallel magnetic strips on the sheet product by rotating elements 571, 571' 90.degree. in FIG. 15.
FIGS. 18 and 19 depict an eighth embodiment printed sheet product of the present invention indicated generally at 710. Referring to both FIGS. 18 and 19, the sheet product 710 is formed by a one-piece flexible, printable core 712 having a pair of major planar opposing sides 714 and 716, seen together in FIG. 19. There is preferably printed on the first major planar side 714 of the core 712, a plurality of sets of variable data fields. In the depicted sheet product 710, three full sets of data fields are shown. Each data field set includes at least two separate variable data fields, data fields 21d, 21e of the first full set, 22d, 22e of the second full set and 24d, 24e of the third set being shown. Again, each of the variable data fields are spaced from one another in each set and between sets. Either or both sides 714, 716 of core 712 may be printed with a first plurality of static graphic fields, again indicated collectively and by example only at 31d, 31e. Again, the second major planar side 716 can be printed in any manner desired as indicated earlier for any of the previous embodiments. Core 712 preferably is of two piece construction but includes a flexible carrier sheet 712a to which is releasably adhered a flexible polymer magnetic strip 712b by adhesive layer 712c. Magnetic strip 712b can be obtained with a printable vinyl surface 712d. If desired, first and/or second coverings like coverings 454, 456 of FIG. 13, can be provided on either or both sides of the core 712 after printing but before scoring. Sheet product 710 is preferably completely scored through in continuous, spaced parallel lines 701, 703, 705, 707, 709, etc. to define separate sheet sections 702, 704, 708, etc. and only partially scored through in continuous closed circuit cuts 771a, 772a, 778a so as to define flexible magnetic card elements 771, 772, 778, etc. removable from each individual sheet section 702, 704, 708, etc.
In an alternate construction, the magnetic strip 712b can be permanently adhered to the "rear" side (i.e. side 716) of carrier 712a and the exposed surface of the carrier used for printing.
Regardless of whether first and/or second outer coverings 454, 456 are provided, there is suggestedly provided at least one outer covering 458, including a strong yet flexible carrier 458b, preferably supporting a pressure sensitive adhesive layer 458a releasably attached to the rear major side 716 of the core 712 "beneath" such magnetic layer 712c. The sheet product 710 preferably would be scored completely through the core 712 with a continuous, closed circuit cut, but not through the outer covering 458, to define a removable magnetic element within each sheet product and along parallel, horizontal lines 701, 703, 705 and 707 entirely through the core and the outer layer 458, if provided, to separate individual sheet sections 702, 704 and 708 from the sheet product 710. Again, each sheet section 702, 704 and 708 is preferably sized to approximately the internal dimensions of a window-type envelope (e.g. envelope 290 of FIG. 10) with which the mailer would be used (not separately depicted) so as to remain in view of the window. Uncoated or printable white vinyl coated flexible magnetic material can be obtained in roll form from any of the variety of manufacturers, including RJF International Corp., Koroseal Magnetics and/or Flexing Industries, Inc., all of Cincinnati, Ohio. Such flexible magnetic material strip can be ordered precoated with a pressure sensitive adhesive or ordered without adhesive and coated with a selected pressure sensitive or other adhesive to releasably or permanently retain it on the core carrier 712a.
FIG. 18 also depicts yet another variation of the invention in which only part of the variable data set associated with each sheet section is unique. Each particular sheet section may or may not include an alphanumeric code unique to the individual named on that sheet section. Rather, the sheet product is printed with consecutive data sets that include a unique name and address for each data set but a semi-variable data set such as an address and telephone number, which would be common to some individual sheet sections (e.g. 702, 704) but change for others (e.g. 708). Services are now available which can identify customers or potential customers which frequent particular locations of multi-location businesses or which are located most closely to particular locations of multi-location businesses. Such information would be provided to the sheet product preparer which would, with appropriate data processing support, print the core 712 with the appropriate data fields. If desired, the data can be clustered so as to print simultaneously all of the unique names and addresses associated with each individual business location address and phone number as indicated in FIG. 18 or could, for example, provide names and addresses for a particular zip code and print the appropriate business location address and phone number associated with each name in that zip code. The static data field would identify the common name of the business (i.e. "JOE'S PIZZA") in the static data field 31d, 32d, 34d while semi-variable data field 21e, 22e, 24e would change within runs of the sheet product (as indicated in FIG. 18) or from run to run. Thus, each removable element 771, 772, 778, etc. could be used as a refrigerator magnet and would bear the address and phone number of the nearest location of the business also identified on the magnet in the static data field.
FIG. 20 depicts diagrammatically a ninth sheet product of the present invention indicated generally at 810. A first major planar side 814 of the sheet product 810 is depicted in that figure. Preferably printed on the first major planar side 814 are a plurality of sets of variable data fields, two complete sets being shown in the figure. The first set includes a variable, machine readable code field 21a and a variable name and address field 21d. The second set includes a similar variable machine readable code field 22a and variable name and address field 22d. The variable code of each set is uniquely associated with the name and address of the other variable code field of the set. Applied to the first major planar surface 814, preferably by an adhesive layer 860 is a strip 862 containing a series of individual radio frequency transponders indicated in phantom at 864, 866, etc. Such transponders would have the characteristic of broadcasting in response to a predetermined radio frequency signal, a coded radio frequency reply, which can be received and decoded to identify the individual transponder 864, 866, etc. As a final step, the sheet product 810 would be scored into at least separate consecutive individual sheet sections 804, 806, etc., which could be individually mailed. Each transponder 864, 866, etc. will be removable from each sheet section 802, 804, but the sheet product 810 can be configured in a variety of ways depending upon the desired end form of the removable element containing the transponder. For example, the sheet product 810 can be scored at regularly spaced intervals, for example, along spaced apart lines 801, 803, 805, to define the individual, mailable sheet segments 802, 804, etc., the scoring cutting completely through the transponder strip 862. The strip 862 can be lightly adhered to a continuous, flexible printable sheet core by a pressure sensitive adhesive layer 860, which would remain with the core allowing individual removable elements 863, 865 with transponders 864, 866, etc. to be removed from the individual sheet portion 802, 804, etc. It may be desired to permit each removable element 863, 865, to carry a layer of pressure sensitive adhesive, in which case it may be desirable to adhere one side of a release strip bearing the pressure sensitive adhesive (not depicted) and the transponder strip 862 directly to the core. The release strip would remain on the core while the element 863, 865 is removed carrying away the pressure sensitive adhesive layer releasably attaching the element to the release strip. Also, if desired, protective coverings could be provided on either or both sides of the core. Also, each removable element 864, 866 can be separately scored within the edges of each sheet section 704, 706, etc. if it is desirable that the removable element be smaller in its maximum dimension than the minimum dimension of the sheet section.
At some point following the application of the transponder strip 862 and the printing of the machine readable variable data fields 21e, 22e, etc., each machine readable code 21e, 22e should be associated with each unique transponder 864, 866 in a database, for example, by simultaneously or sequentially reading a machine readable code 21a, activating its associated transponder 864 and decoding the transponders unique responsive coded reply signal. In an alternate version of the invention, each unique transponder 864, 866 can be pre-assigned uniquely in a database to a unique individual and the process of printing of the variable name and address databases 21d, 22d controlled by activating each transponder 864, 866, identify the unique code and then the individual preassociated with that transponder and printing either the name and address of that individual on the printable core of the sheet product either with or without a machine readable code. Transponder strip 862 should be sought from a manufacturer of such products such as, for example, Hughes Identification Devices of Tustin, Calif., or from other manufacturers of such transponders such as Cotag International of Wilmington, Del.; Abbhafo Incorp. of San Diego, Calif.; Balogh T.A.G. of Ann Arbor Mich.; Motorola of San Diego, Calif. and Texas Instruments of Attleboro Mass. It may be necessary to package individual transponders 864, 866, etc., into a strip 862, for example by laminating the transponders between outer coverings such as coverings 454, 456 of FIGS. 12-13 if the named manufacturers will not supply such transponders in continuous rolls. Also the sheet product 810 could include such outer protective layers 454, 456, if the outer material of the strip 862 is deemed to be insufficiently protective. It will further be appreciated that so-called "smart cards", which can also be polled directly or from a small distance, can be conveniently and inexpensively handled in the same way for mailing or distribution.
It will be recognized by those skilled in the art that other changes can be made to the above-described embodiment disclosed and suggested without departing from the broad, inventive concepts thereof. For example, each of the variable data field sets may include only two variable data fields printed on opposing sides of a core by a duplex printer. Each cut sheet section would therefore have only one variable data field on either of its two sides. More than one variable data field per set can be provided on either or both sides of the core. However, all variable data fields of the one set would be printed on one or both sides of the sheet section in a fashion similar in concept to the other previously described embodiments of the invention. While single ply cores are preferred for cost and simplicity in most uses, multiple plies might be used for various reasons. It will further be appreciated that sheets 412a and 412b might be partially overlapped to be directly joined together by an intermediate adhesive layer. It will further be appreciated that in most cases, it is only necessary that the unique code be identified with a unique name or unique name and address as, in some instances, it may be desirable to assign multiple unique codes to one person or entity. It should be understood, therefore, that this invention is not limited to the particular embodiments disclosed, but is intended to cover any modifications which are within the scope and spirit of the invention as defined by the appended claims.

Claims

1. A printed sheet product comprising: a core and a separate strip, the core being planar and having opposing major sides and being printed on one major side in a variable data field with a name and mailing address of a particular person assigned a unique code, the separate strip being permanently secured partially covering one major side of the core while extending completely along the one major side of the core, the separate strip being spaced on the core laterally away from the printed variable data field, the product including an at least generally U-shaped scoring which scoring cuts at least sufficiently through the product to define a card element removable from a remainder of the product, the removable card element including only a portion of the separate strip, and the printed variable data field being left on the remainder of the sheet product.
2. The sheet product of claim 1 wherein the removable card element has a given material composition and the remainder of the product immediately adjoining the scoring has a material composition identical to the material composition of the removable card element, at least one portion of the sheet product including the removable card element being of a laminate construction with a predetermined plurality of layers including the core and another portion of the sheet product including the printed variable data field with the name and mailing address of the particular person being of fewer layers than the predetermined number of layers.
3. The sheet product of claim 2 wherein a portion of the sheet product bearing the name and address of the printed variable data field consists of only a single sheet layer, which single sheet layer is the core.
4. The sheet product of claim 3 wherein the core in the removable card element has a composition different from a composition of the core bearing the name and address of the printed variable data field in an other portion of the sheet product.
5. The sheet product of claim 2 wherein the one portion of the sheet product further includes at least one outer covering applied over one side of the sheet product at least entirely overlapping the removable card element and avoiding any overlap of the name and address of the printed variable data field.
6. The sheet product of claim 5 wherein the outer covering is permanently secured with the core of the removable card element and forms an outer surface of the removable card element and wherein a portion of the outer covering forming the outer surface of the removable card element is roughened sufficiently to accept and retain ball point pen ink.
7. The sheet product of claim 1 wherein the removable card element includes a portion of the core having a composition different from a composition of the core bearing the name and address of the printed variable data field.
8. The sheet product of claim 1 wherein the core includes separate first and second sheets fixedly secured together generally edge to edge, side by side such that only the first of the first and second sheets defines a first end of the core and only the second of the first and second sheets defines a second, opposing end of the core, the first sheet being of a first material and bearing the name and address of the printed variable data field and the second sheet being of a second material different from the first material and being permanently secured with the separate strip.
9. The sheet product of claim 8 further comprising a first outer covering permanently secured with one major side of the core at least partially overlapping each of the first and second sheets so as to fixedly secure together the first and second sheets, the first outer covering at least partially overlapping the removable card element and being cut by the scoring defining the removable card element such that part of the first outer covering forms part of the removable card element.
10. The sheet product of claim 9 further comprising another outer covering releasably adhered to one side of the sheet product at least partially overlapping the removable card element and wherein the other outer covering at least substantially lacks any of the scoring defining the removable card element of the sheet product.
11. The sheet product of claim 10 wherein the scoring extends in a continuous cut entirely around a closed perimeter defining the removable card element and wherein the removable card element is releasably retained in the sheet section by the other outer covering.
12. The sheet product of claim 9 further comprising a second outer covering permanently secured with an opposing major side of the core at least partially overlapping the second sheet and the removable card element and only partially overlapping the first sheet, the second outer covering being cut by the scoring defining the removable card element such that part of the second outer covering also forms part of the removable card element.
13. The product of claim 1 wherein the separate strip is magnetic and the unique code is magnetically encoded on the portion of the separate strip secured with the removable card element.
14. The sheet product of claim 1 wherein the portion of the separate strip includes a radio frequency transducer encoded with the unique code.
15. The sheet product of claim 1 in combination with a generally rectangular envelope having a length and a width and a front face with a window, the product having a length and a width sufficient for the product to be received in the envelope without folding and substantially without movement and with the name and mailing address of the printed first data field being aligned with and visible through the window of the envelope.
16. The sheet product of claim 1 further being printed on the one major side with a plurality of variable data fields, each of the variable data fields of the plurality including a name and mailing address of a particular person in an at least human readable form, each variable data field of the plurality being different in content from each other variable data field of the first plurality printed on the core, each printed variable data field being spaced apart from each other variable data field of the plurality along the length of the core such that the core can be severed transversely across its length into sheet sections each bearing a portion of the separate strip and only one of the plurality of printed variable data fields, and each sheet section laterally adjoining one of the variable data fields being encoded with a unique code assigned to the individual identified in the adjoining variable data field.
17. A printed sheet product comprising:
a generally planar core having a pair of opposing major sides, a width and a length greater than the width; and
a separate, flexible strip permanently secured with the core extending entirely along the length of the core on one of the major sides of the core only partially covering the one major side; and
the core being printed with a plurality of variable data fields, each of the variable data fields of the plurality including a name and mailing address of a particular person in an at least human readable form, each variable data field of the plurality being different in content from each other variable data field of the plurality printed on the core, each variable data field being spaced apart from each other variable data field of the plurality along the length of the core such that the core can be severed transversely to its length into a plurality of sheet sections, each sheet section bearing a portion of the secured flexible strip and only one variable data field of the plurality, and each sheet section laterally adjoining one of the variable data fields being encoded with a unique code assigned to the person in the adjoining variable data field.
18. The printed sheet product of claim 17 wherein the strip is magnetic.
19. The printed sheet product of claim 17 wherein the strip includes a plurality of radio frequency transducers, each transducer laterally adjoining a separate one of the plurality of variable data fields.
20. A printed sheet product comprising:
a generally planar core having a pair of opposing major sides, a width and a length greater than the width;
a separate, flexible magnetic strip secured with the core extending entirely along the length of the core on one of the major sides of the core only partially covering the one major side of the core; and
the core being printed with a plurality of variable data fields, each of the variable data fields including a name and mailing address of a particular person in at least human readable form, each line of the printed name and address extending in a direction generally parallel to the width of the core and generally perpendicular to the flexible magnetic strip, each variable data field being spaced apart from each other variable data field of the plurality along the length of the core such that the core can be severed transversely across its length into sheet sections, each sheet section bearing a portion of the affixed flexible magnetic strip and only one of the plurality of variable data fields.
21. A printed sheet product comprising a generally planar core having a pair of opposing major sides, the sides having a length and a width greater than the length, the core being printed on one major side in at least two, spaced apart locations with a common, unique code;
a separate, transparent, flexible strip permanently secured with the core extending entirely along the length of the core on one of the major sides of the core only partially covering the one major side; and
scoring extending sufficiently through the transparent flexible strip and the core and around only a first of the two, spaced apart locations sufficiently to define a card element removable from the printed sheet product including only the first of the two spaced apart locations and a first one of the at least two printed codes.
22. The printed sheet product of claim 21 having a length less than eight inches.
23. The printed sheet product of claim 22 wherein a remaining one of the at least two printed code locations underlies the transparent flexible strip.
24. The printed sheet product of claim 23 further comprising scoring extending sufficiently through the transparent flexible strip and the core and around a second of the at least two spaced apart printed code locations sufficiently to define a second card element removable from the printed sheet product and bearing the second location with second printed code.
25. The printed sheet product of claim 21 further comprising a name and address of a person assigned the unique code printed on the sheet product, the name and address being located on a portion of the core left uncovered by the transparent flexible strip.
26. The printed sheet product of claim 25 wherein the card element has been removed from the printed sheet product.
27. The printed sheet product of claim 25 wherein the one major side of the core is machine printed with the name and address of a person assigned the unique code printed on the sheet product has been assigned.

Parent Case Info

This application is a continuation-in-part of U.S. patent application Ser. No. 08/191,975, filed Feb. 4, 1994, now U.S. Pat. No. 5,495,981, which is a continuation-in-part of U.S. patent application Ser. No. 07/628,236, filed Dec. 1, 1990, now abandoned.

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Entry
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Continuation in Parts (2)

	Number	Date	Country
Parent	191975	Feb 1994
Parent	628236	Dec 1990

Printed sheet mailers and methods of making

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