RELATED APPLICATIONS  
       [0001]    This application claims priority from the U.S. Provisional application Ser. No. 60/859,466 filed Nov. 15, 2006. 
     
    
     FIELD OF THE INVENTION  
       [0002]    The invention herein relates to a composite sheet of individual media cards supported on a liner and easily separable therefrom after printing. 
       BACKGROUND OF THE INVENTION  
       [0003]    With the current availability of high quality desktop printers and sophisticated word processing and desktop publishing software, it is both desirable and possible to print quality graphic products without requiring print shop or other professional printing services. One obstacle to producing high quality graphics products on desktop printers is the print media itself, particularly when printing small individual media products, such as business cards. 
         [0004]    Quality card stock is readily available to accept black and white and/or color printing. However, the desktop printers only accept card stock in relatively large sizes, e.g. standard 8½″×11½″ paper, A4 size paper, and to a lesser extent, envelopes. Even though the printers will accept and pass media stock of envelope size or smaller, it is not possible to feed a standard 2″×3½″ business card media stock, or to achieve registration of printing and graphics on such a media card if the printer can be coaxed into accepting it for printing. 
         [0005]    To solve the foregoing products, individual media cards, such as business cards, have been formed as part of a composite sheet. The composite sheet is generally a laminate or plurality of layers, consisting of card stock and a backer, sometimes also referred to as a liner. The card stock is separated into individual media and supported on the liner during printing. After printing, individual media cards are separated from the others, and often from the liner as well. To this end, the liner may have a releasable adhesive holding the individual media cards to it. 
         [0006]    Further technical problems reside in how to separate individual media cards held on a liner. One method is to form a complete cut about the entire periphery of the media, which provides a sharp clean edge for the individual media, but in using this method the media must be sufficiently adhered to the liner so that it doesn&#39;t separate from the liner during the curved feed path found in most desktop printers. On the other hand, the media must not be adhered too well to the liner, so that the media may be removed from the liner. 
         [0007]    Another method of separating the individual media is to form perforated separation lines about the perimeter thereof. Thus, the card stock is not fully separated until after printing, which resolves many of the technical problems in providing individual media cards completely cut apart and adhered to a liner. However, the perforated cuts leave a less than desirable edge. 
         [0008]    Therefore, to date, there have been no fully satisfactory composite sheets for printing individual media, and improvement in the art should be well-received. 
       SUMMARY OF THE INVENTION  
       [0009]    It is a principal object of the invention herein to provide an improved composite sheet of individual media cards. 
         [0010]    It is another object of the invention herein to provide an improved composite sheet of individual media cards sized for use as business cards. 
         [0011]    It is another object of the invention herein to maintain the integrity of a composite sheet of individual media cards during and after printing, yet provide for easy separation of the individual media card after printing. 
         [0012]    It is also an object of the invention herein to reduce separation and curl that may be imparted to the individual media by printing in desktop printers. 
         [0013]    In carrying out the foregoing objects of the invention, there is provided a composite sheet of plural individual rectangular media cards for printing by inkjet and laser printers. The composite sheet is made of a rectangular card stock sheet having a length and a width, the length establishing a length-wise direction for passing the composite sheet through a printer. The card stock sheet has a front surface for printing and a back surface. A liner sheet is juxtaposed the back surface of the card stock sheet and has a layer of adhesive applied thereto for releasably adhering the card stock sheet to the liner sheet. A plurality of width-wise and a plurality of length-wise media card definition cuts extend through the card stock sheet, but not through the liner sheet, to define a plurality of individual rectangular media cards releasably adhered to the liner sheet. The width-wise and length-wise media card definition cuts form flanking edges of adjacent individual media cards and intersect to form corners of adjacent individual media cards, the corners being connectably supported by the liner sheet. A plurality of spaced-apart liner flex cuts are formed aligned with the length-wise media card definition cuts and extend through the liner sheet, each liner flex cut positioned between and spaced from corners of adjacent individual media cards wherein at least some of the flanking edges of adjacent individual media cards are unconnectedly supported by the liner sheet. 
         [0014]    According to further aspects of the invention, the card stock may be pulp, cotton or a liner paper and may be in the range of 8 mils to 11 mils thick, and may be 10 mils thick. The liner sheet may be pulp or other suitable paper and may be in the range of 4 mils thick, with a weight of 70 g/m 2  to 6½ mils thick with a weight of 140 g/m 2 . The adhesive is a low tach, repositionable adhesive. The adhesive may be coated directly onto the liner without coating the liner with other coating materials. 
         [0015]    According to further aspects, two columns of the media cards are formed on one composite sheet, defined by a central and two side length-wise media definition cuts, such that the composite sheet has card stock margins having liner releasably adhered thereto. The liner flex cuts may be provided on the central length-wise media definition cut, and the liner flex cuts may be provided on the side length-wise media definition cuts, and the liner flex cuts may be provided on all of the of the center and side length-wise media definition cuts. 
         [0016]    According to another aspect of the invention, the line flex cuts may have a length of one-half to two-thirds of the flanking edges of adjacent media cards extending between adjacent corners of adjacent media cards. 
         [0017]    Other and more specific objects and features of the invention herein will, in part, be recognized by those skilled in the art and will, in part, appear in the following Detailed Description and the Claims, taken together with the Drawings. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS  
         [0018]      FIG. 1  is a front plan view of a composite sheet of media cards according to the invention herein; 
           [0019]      FIG. 2  is a back view of the composite sheet of individual media cards of  FIG. 1 ; 
           [0020]      FIG. 3  is a sectional view of the composite sheet of  FIG. 1 , taken along the lines  3 - 3  of  FIG. 1 ; 
           [0021]      FIG. 4  is a sectional view of the composite sheet of media cards of  FIG. 1 , taken along the lines  4 - 4  of  FIG. 1 ; 
           [0022]      FIG. 5  is a sectional view of the composite sheet of media cards of  FIG. 1 , taken along the lines  5 - 5  of  FIG. 2 ; and 
           [0023]      FIG. 6  is a sectional view of the composite sheet of media cards of  FIG. 1 , taken along the lines  6 - 6  of  FIG. 2 . 
       
    
    
       [0024]    The same reference numerals refer to the same elements throughout the various figures. 
       DETAILED DESCRIPTION  
       [0025]    A composite sheet  10  of plural individual media cards  20 - 29  is illustrated in the various figures, and generally comprises a card stock sheet  30 , a liner sheet  32  and an adhesive layer  34  releasably securing the card stock sheet  30  and the plurality of individual media cards  20 - 29  to the liner sheet. 
         [0026]    The plurality of individual media cards are rectangular portions of the card stock sheet  30 , shown in a size suitable for printing as business cards, formed by dividing the card stock sheet  30  as more fully discussed below. 
         [0027]    The card stock sheet  30  is a pulp paper having a thickness of about 10 mils and a weight of about 220 g/m 2 . The card stock sheet may also be linen or cotton based paper, and may have a thickness range of from about 8 mils to about 11 mils. It is coated with a polymer on both sides, but may be coated on one side or uncoated. The card stock sheet  30  is suitable for use in constructing a composite sheet  10  that is accepted by most desktop inkjet and laser printers. The card stock sheet has a front surface  36  for printing text and graphic images thereon. The surface  36  may be coated to enhance the acceptance of inkjet inks and/or laser printer toner, to enhance brightness and to otherwise optimize printing, as is well known in the art. 
         [0028]    The liner sheet  32  is preferably a pulp paper having a thickness in the range of 4 mils and weight of 70 g/m 2  to 6½ mils and weight of 140 g/m 2 , i.e. substantially less dense than the card stock sheet  30 . The liner sheet is uncoated, although it may be coated, if desired, as is well known in the art. 
         [0029]    The card stock sheet  30  and more particularly a back surface  38  thereof is releasably adhered to the liner sheet  32  by an adhesive  34 . The adhesive is a low tack repositionable type and PROTECT 8748 low tack polymer adhesive is suitable for the adhesive layer of  34 . The adhesive may be applied to the liner  32  at a rate of 3-7 g/m 2 . The adhesive adheres well to the liner sheet such that the liner sheet is not releasable from the adhesive. If a coated liner sheet is utilized, care is taken to select the coating to cooperate with the adhesive such that the adhesive remains adhered to the liner sheet as the plurality of individual media cards  20 - 29  are removed therefrom. 
         [0030]    The card stock sheet  30  and the liner sheet  32  are co-extensive and share the same perimeter edges and dimensions. These include a leading edge  40 , a trailing edge  42 , and side edges  44  and  46 . The leading edge  40  and the trailing edge  42  are structurally the same, and are designated as “leading” and “trailing” because of their orientation in the various figures and either of the edges  40 ,  42  may be used as the first edge to enter a printer. However, the composite sheet  10  is intended for use in the portrait orientation for reasons more fully discussed below, and it is not recommended that the side edges  40 ,  46  be presented to a printer that has substantial curves or sharp turns in its paper path. The composite sheet  10  may be 8½″ in the width-wise direction, i.e. between the side edges  44 ,  46 , and may have a length of 11½″ between the leading and trailing edges  40 ,  42 . This dimension is chosen because it is relatively standard, and composite sheet  10  may be provided in other sizes acceptable by a printer and also sufficiently large to provide a plurality of individual rectangular media cards thereon. 
         [0031]    The plurality of individual rectangular media cards  20 - 29  are formed from the card stock sheet  30  by media card definition cuts. There are three length-wise media card definition cuts; namely, a central length-wise media card definition cut  50  and two side length-wise media definition cuts  52  and  54 . There are six width-wise media card definition cuts  56 - 61 . The width-wise media definition cuts  56 - 61  intersect and extend between the side length-wise media definition cuts  52  and  54 , and also intersect the central length-wise media definition cut  50 . With reference to  FIG. 1 , this is illustrated where width-wise media definition cut  57  intersects the side length-wise media definition cut  52  at  62 , intersects the central length-wise media definition cut  50  at  64 , and intersects the side length-wise media definition cut  54  at  66 . This divides the sheet  30  into ten individual rectangular media cards  20 - 29 , each having a dimension of 2″×3½″ such that they are suitable for printing as business cards, and leaves a peripheral margin with sides  70  and  72 , and ends  74  and  76 . 
         [0032]    With reference to  FIG. 4 , the width-wise media definition cut  58  is illustrated, and can be seen to extend entirely through the card stock sheet  30 , but not through the liner sheet  32 . In the embodiment shown, the media definition cut  58  extends into the adhesive  34 , which is desirable to accommodate any manufacturing tolerances in the depth of the cut to ensure that the cut extends through the card stock sheet  30 . The media definition cuts may or may not extend part way into the liner sheet  30 , and this is also in part a matter of manufacturing tolerances. However, it is contemplated that the cut does not extend through the liner sheet  30 , except as specifically intended and further discussed below. 
         [0033]    Therefore, in the central area of the composite sheet  10 , the adjacent individual rectangular media cards have juxtaposed or flanking edges separated by media card definition cuts, and the individual media cards also have juxtaposed flanking edges with the sides  70 ,  72  and ends  74 ,  76  of the peripheral margin also separated by media card definition cuts. Where the media definition cuts intersect, adjacent media cards also have adjacent corners. For example, media cards  20 ,  21 ,  25  and  26  have four adjacent corners at the intersection  64  of width-wise media definition cut  57  and length-wise media definition cut  50 , and media cards  24  and  29  have adjacent corners at the intersection  65  of width-wise media definition cut  61  and central length-wise media definition cut  50 . The media cards  20 ,  24 ,  25  and  29  deployed toward the corners of the composite sheet  10  are defined by intersecting media definition cuts, e.g. side length-wise media definition cut  52  and width-wise media definition cut  36 , intersect at  66  and are considered to have the equivalent of adjacent corners because of their proximity to the juxtaposed and flanking portions of the peripheral margin. 
         [0034]    With reference to  FIGS. 2 ,  5  and  6 , the composite sheet  30  is further provided with a plurality of spaced-apart liner flex cuts  80 . The liner flex cuts are formed aligned with the length-wise media card definition cuts  50 ,  52 ,  54  and are positioned between and spaced from the adjacent corners of adjacent individual media cards defined by the width-wise media definition cuts  56 - 61 . As noted above, the width-wise media definition cuts  50  and  56  have ends  74 ,  76  of the margin adjacent thereto, and these end margin portions are considered equivalent to corners of an adjacent media cards for the purposes of providing juxtaposed and flanking adjacent card stock. 
         [0035]    The liner flex cuts are particularly well illustrated in  FIG. 6 , where the media card  21  is separated from media cards  20  and  23  by width-wise media definition cuts  57  and  58  and is separated from media card  26  by the central media definition cut  50 , which appears along the edge  82  of media card  21 . The liner flex cut  80  extends through the liner sheet  32 , and is positioned between the width-wise media definition cuts  57  and  58 , and spaced from the corners of the media card  21 . The length L of the liner flex cut  80  is preferably about one-half to two-thirds of the height H of media card  21  and is deployed approximately mid-way between the corners of media card  21 . The liner flex cuts may also be of lesser length, and may be a line of perforations extending to near adjacent corners of adjacent media cards. 
         [0036]    This arrangement results in the adjacent corners of the media cards  21 - 29 , including those corners adjacent marginal edges, being connectedly supported on the liner sheet  32 . As the composite sheet  30  is passed through a printer, the connectedly supported corners tend not to separate from the liner sheet  32  such that they would cause paper jams, and the structure of the composite sheet at the corners remains of the individual media cards  20 - 29  from the liner sheet  32 , with the stiffness of the card stock providing “lift off” at the corners so that no picking is required to separate an individual media card from the liner sheet. 
         [0037]    By forming the liner flex cuts  80  along the length-wise media definition cuts  50 ,  52 ,  54 , the composite sheet  10  is stable and maintains its dimensions as it is handled by a printer, and the composite sheet  10  resists jams when passing through a printers. 
         [0038]    Accordingly, a composite sheet of individual rectangular media cards has been described which admirably achieves the objects of the invention herein. It will be appreciated that the foregoing detailed description is directed toward a particular preferred embodiment of the invention, and that various changes may be made by those skilled in the art without departing from the spirit and scope of the invention, which is limited only by the following claims.
A composite sheet of individual rectangular media cards for ink jet and laser printers includes a rectangular card stock sheet, and an adhesive releasably adhering the card stock sheet to a liner. Widthwise and lengthwise media card definition cuts extend through the card stock sheet but not the linear to define the media cards. Spaced-apart liner flex cuts are formed aligned with at least one lengthwise media definition cut and spaced from adjacent corners of adjacent media cards.