Envelope for producing laminated data cards having elevated stop elements
ite States atent 1 uhns [ 1 Apr..$,1975  
 1 ENVELOPE FOR PRODUCING LAMINATED DATA CARDS HAVING ELEVATED STOP ELEMENTS Roger J. Kuhns, Tower Rd. Lincoln, Mass. 01773 22 Filed: Oct. 12,1972  
  211 Appl. No.: 296,956  
 [76] Inventor:  
 Primary E.\&#39;aminerCharles E. Van Horn Assistant E.\&#39;aminerNeal Kalishman Attorney, Agent, or FirmRobert L. Nathans [57] ABSTRACT A plastic card envelope having a pair of outer sheets maintained in congruent relationship for receiving a data card between said outer sheets before lamination, an inner surface of one of said outer sheets having stop means thereon, elevated with respect to the inner surface, for properly positioning the inserted data card with respect to the edges of the plastic envelope. The use of the elevated stop means produces separation of portions of the inner adhesive bearing surfaces of the outer sheets after manufacture and before use, thereby to eliminate the need for a separation sheet which is otherwise utilized to prevent blocking or sticking together of the inner surfaces of the sheet before lamination. Two sets of elevated stop elements enable the use of a single envelope for selectively positioning different sized data sheets. Elevated stop elements in certain cases also function as optical fiducials to further aid in proper positioning of the inserted data card.  
 19 Claims, 8 Drawing Figures ENVELOPE FOR PRODUCING LAMINATED DATA CARDS HAVING ELEVATED STOP ELEMENTS BACKGROUND OF THE INVENTION In US. Pats. Nos. 3,679,512, 3,679,514 and 3,526,567 a pair of outer plastic sheets are coupled together by coupling means which also function as positioning means for properly positioning an inserted data card with respect to the outer edges of the sheets. A plastic separator sheet is inserted between the inner adhesive bearing surfaces of the outer sheets to prevent blocking or sticking of the inner surfaces to each other after manufacture and before use. It is desirable to eliminate the need for the separator sheet in the interest of economy.  
  It is believed that extensive use will be made of colored vinyl plastic materials for card envelopes. Further more, it is desirable to produce stop elements which also function as optical fiducials so that the stop elements would have a different coloration relative to the color of the vinyl outer sheet in order to further aid the operator in properly positioning the inserted data card rapidly and easily up against the stop elements.  
  It is also desirable to provide a plastic envelope for receiving two or more different sized data sheets and for accurately positioning either size correctly with respect to the edges of the outer sheets.  
  It is also desirable to provide a plastic envelope wherein the top outer sheet may be removed from the bottom outer sheet manually and a second outer sheet substituted for the first in order to provide for flexibility in the use of different types of outer sheets.  
 SUMMARY OF PREFERRED EMBODIMENTS OF THE INVENTION In accordance with one embodiment of the present invention, elevated stop means are employed to cause separation of the inner surfaces of the outer sheets to eliminate the aforesaid separator sheet (and the steps of insertion and removal) which is normally utilized to prevent blocking of the inner surfaces of the outer sheets. In accordance with a further aspect of the invention, elevated stop elements are produced by inducing stress into a colored (typically vinyl) plastic sheet, which causes an optical contrast to be produced be tween the elevated stop elements and the color base sheet in order to further aid the operator in positioning the inserted data card against the stop elements. In accordance with a further embodiment, two or more sets of stop means may be utilized to properly position two or more data sheets of different size with respect to the edges of the outer sheets. In another embodiment, the elevated stop means together with the lower sheet may be completely separated from the upper sheet to provide for flexibility in the use of various combinations of upper and lower sheets.  
  Other objects, features and advantages of the present invention will become apparent upon perusal of the detailed description taken in conjunction with the drawings in which: I  
  FIGS. 1 and 2 illustrate side and top views of one envelope utilizing the present invention;  
  FIG. 3 illustrates a method of forming a single elevated stop element;  
  FIGS. 4 and 5 illustrate top and side views of a second type of stop element;  
 FIG. 6 illustrates a third type of stop element;  
  FIG. 7 illustrates an envelope having two sets of stop elements which may be employed to selectively position two different sized data sheets with respect to the edges of the envelope; and  
  FIG. 8 illustrates the use of stop elements which provide for interchangeability of the upper outer sheet with respectto the lower outer sheet.  
 DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS In FIGS. 1 and 2, a lower outer plastic sheet I is illustrated having elevated stop elements 2, 3 and 4 formed therein. The upper outer sheet 5 is coupled to lower outer sheet 1 by means of coupling means 10 which could comprise a heat seal In FIG. 3, elevated stop element 2 formed within lower outer sheet 1, is formed by the use of male die 14 and female die 16. The elevated stop elements may be readily and economically produced through the use of the period found in an ordinary embossing machine. Preferably, the top of each stop element is elevated about 20 mils above the inneradhesive bearing surface of sheet 1. It should be observed that the elevated stop elements maintain a separation between the inner adhesive bearing surfaces of the outer sheets as illustrated in FIG. 1, thereby to eliminate the aforesaid separator sheet which is otherwise inserted between the outer sheets. The steps of insertion of the separator sheet and its ultimate removal have also been eliminated.  
  The operator separates outer sheets 1 and 5 and easily and rapidly inserts the data sheet up against the stop elements 2, 3 and 4, thereby to properly position the inserted data sheet with respect to the edges of the outer sheets to produce even borders.  
  Where a colored, vinyl base sheet is employed, the operation described in conjunction with FIG. 3 results in the induction of stresses within the plastic and with many plastic materials, produces a lightening of the color of the stop element so that the production of the stop elements in this manner further creates an optical contrast between the stop elements and the remainder of the base sheet. This in turn results in the production of optical fiducials to further aid in rapid and accurate operator positioning of the inner data bearing sheet up against the stop elements.  
  In FIG. 4, a slit 11 may be formed within outer sheet 1 and a die member similar to member 14 may press up against the portion of the cards situated just to the left of slit 11, thereby to produce an elevated portion 12 shown in FIG. 5 which functions as a stop element. In FIG. 6 orthogonal cuts produce a stop element 13&#39; which should further facilitate the generation of an elevated portion just to the left of the vertically oriented slit portion shown in FIG. 6.  
  In FIG. 7, two sets of stop elements may be formed as described hereinabove to perform similar function of the stop elements 2, 3 and 4. Upon the insertion of a relatively small data card, the operator positions the card up against stop elements l3, l5 and 17. Should a larger size card be inserted, she further separates the outer sheets to the point where the larger inserted card passes over the tops of elevated stop elements 13, 15 and 17 and is positioned against stop elements 2, 3 and 4. Thus, the same envelope may be employed for two or more different sized cards thereby to effect economy and flexibility of inventory.  
  It is sometimes desirable to provide for the use of a number of different combinations of upper andlower sheets. For example, a given production facility may employ the same lower base sheet but it may be desirable to employ different upper sheets, one for, say, each floor of a facility in order to control access. Such flexibility may be obtained by utilizing upper sheets 5, illustrated in FIG. 8, having cavities therein for receiving the elevated stop elements in the manner of a snap fastener. It should be apparent that any given top outer sheet 5 may be removed from the lower sheet and a second upper sheet may be snapped in place. The snap fastener aspect causes the outer sheets to remain congruent during lamination.  
  Another interesting aspect of the use of all of the above described stop elements is that they disappear after lamination in most cases, owing to the flow of the heated, pressurized (typically vinyl) plastic. For certain plastics this may not be true, such as MYLAR outer plastic sheets.  
  In summary, one or more sets of elevated stop elements function to provide separation of the inner surfaces of the outer sheets. In the case of certain materials, they also function as optical fiducials to further aid in the rapid positioning of the inner data bearing sheet with respect to the edges of the envelope, and further, two or more sets of stop elements may be utilized to position two or more different sized sheets with respect to the edges of the envelope. For many plastic materials, the elevated stop elements will disappear after lamination owing to the application of heat and pressure thereto for effecting lamination in a conventional manner.  
  It is believed feasible to employ one or two sets of heat seals in the configuration of FIG. 7 in order to provide for accurate positioning of different sized data sheets. The heat seals would be fairly weak, and thus if the operator desires to insert a larger sized sheet, she could effect separation of the outer sheets to the point where the heat seals in the position of elements l3, l5 and 17 in FIG. 7 would be ruptured so that the inserted data sheet could be positioned up against heat seals or elevated stop elements 2, 3 or 4. The positioning of two different sized data bearing cards could be practiced through the use of just two elongated heat seals where the lower heat seal may be ruptured upon separation. This is believed to be less desirable, however, since the illustrated stop elements properly position the data sheet in both X and Y directions. The invention may also be practiced by utilizing a single elongated elevated stop element parallel with the coupling means 10. The term stop means may include one or more stop elements which could be elevated dimples or bars, heat seals, raised portions shown in FIG. 5, globs of material placed upon the inner surface of sheet 1, areas of pressure sensitive adhesive, etc.  
  Lamination will generally involve the application of sufficient heat and/or pressure to cause the elevated stop means to flatten into the body of the first sheet. In the case of many plastics, such as vinyl, the optical coloration contrast will also be reduced&#39; or disappear owing to relieving of the stresses previously induced therein.  
  While the above described embodiments are preferred, other embodiments will fall within the scope of the following claims:  
 I claim:  
  l. A method of producing a laminated data card having a plurality of edges comprising the steps of:  
 a. providing an envelope including:  
 1. first and second outer sheets capable of being laminated to one another;  
 2. coupling means for coupling said first and second sheets together;  
 3. elevated stop means physically separated from said coupling means and elevated to a sufficient extent with respect to the inner surface of said first outer sheet for separating portions of the inner surfaces of said outer sheets;  
 b. inserting an inner data bearing sheet between said outer sheets and against said elevated stop means for accurately positioning an edge of said data bearing sheet with respect to said outer sheets; and  
 c. laminating substantial inner surface portions of said outer sheets together witli sufficient heat and- /or pressure to cause said elevated stop means to flatten into the body of said first sheet.  
 2. The method of claim 1 wherein said coupling means comprises at least one heat seal.  
  3. The method of claim 1 wherein said elevated stop means comprises a first and second set of stop elements separate from one another for selectively positioning a first data sheet of a smaller size or a second data sheet of a larger size with respect to the edges of said outer sheets.  
  4. The method of claim 2 wherein said elevated stop means comprises a first and second set of stop elements separate from one another for selectively positioning a first data sheet of a smaller size or a second data sheet of a larger size with respect to the edges of said outer sheets.  
  5. The method of claim 3 wherein each set of stop elements comprises at least two stop elements for positioning said data sheet in directions parallel to all edges of said envelope.  
  6. The method of claim 4 wherein each set of stop elements comprises at least two stop elements for positioning said data sheet in directions parallel to all edges of said envelope.  
  7. The method of claim 1 wherein said elevated stop means comprises at least one stressed portion of said first sheet and said first sheet is made of material which presents a different appearance to the eye when stressed relative to non-stressed portions of said sheets so that said stressed portions function as optical fiducials to aid in positioning the data sheet within said envelope in addition to functioning as stop elements.  
  8. The method of claim 4 wherein said elevated stop means comprises at least one stressed portion of said first sheet and said first sheet is made of a material which presents a different appearance to the eye when stressed relative to non-stressed portions of said sheets so that said stressed portions function as optical fiducials to aid in positioning the data sheet within said envelope in addition to functioning as stop elements.  
  9. The method of claim 3 wherein said elevated stop means comprises at least one stressed portion of said first sheet and said first sheet is made of a material which presents a different appearance to the eye when stressed relative to non-stressed portions of said sheets so that said stressed portions function as optical fiducials to aid in positioning the data sheet within said envelope in addition to functioning as stop elements.  
  10. The method of producing a laminated data card having a plurality of edges comprising the steps of:  
 a. providing an envelope including:  
 1. first and second outer sheets capable of being laminated to one another;  
 2. heat seal coupling means for maintaining the edges of said outer sheets in an aligned relationship with each other; and  
 3. elevated stop means, physically separated from said coupling means. formed upon the inner surface of said first sheet, which stop means is elevated with respect to said inner surface to a sufficient extent to cause separation of said outer sheets and for stopping and positioning an inserted data card with respect to the edges of said outer sheets;  
 b. inserting an inner data bearing sheet between said outer sheets and up against said elevated stop means; and  
 c. laminating substantial inner surface portions of said outer sheets together.  
 11. The method of claim wherein said coupling means comprises widely separated heat seal means.  
  12. The method of claim 11 wherein said heat seal means includes at least one elongated heat seal.  
  13. The method of claim 10 wherein said elevated stop means includes at least two stop elements for positioning said data sheet in both X and Y directions.  
  14. The method of claim 10 wherein said elevated stop means comprises a first and second set of stop elements separate from one another for selectively positioning a first data sheet of a smaller size or a second data sheet of a large size with respect to the edges of said outer sheets.  
  15. The method of claim 12 wherein said elevated stop means comprises a first and second set of stop elements separate from one another for selectively positioning a first data sheet of a smaller size or a second data sheet of a large size with respect to the edges of said outer sheets.  
  16. A method for producing a laminated data card having a plurality of edges comprising the steps of:  
 a. providing an envelope including:  
 1. first and second outer sheets capable of being laminated to one another;  
 2. a first set of stop means positioned with respect to the edges of said outer sheets for stopping an inserted data sheet of a first size and properly positioning said data sheet with respect to the edges of said outer sheets; and  
 3. a second set of stop means positioned with re spect to the edges of said outer sheets for stopping an inserted data sheet of a second size greater than the size of said first data sheet and for properly positioning said second data sheet with respect to the edges of said outer sheets;  
 b. inserting an inner data bearing sheet between said outer sheets and selectively against either said first set of stop means or said second set of stop means; and  
 c. laminating said outer sheets together.  
  17. The method of claim 15 wherein said first set of stop means is elevated with respect to the inner surface of one of said outer sheets.  
  18. The method of claim 16 wherein at least one of said sets of stop means includes heat seals which additionally function to couple said outer sheets together.  
  19. The method of claim 17 wherein said second set of stop means includes heat seals which additionally function to couple said outer sheets together.