Inkjet Roll Punch-Out Cards Bottom-Side Perforation

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Solution Overview

Problem

Existing punch-out cards are typically toner-based and produced on sheets, limiting their width and requiring perforation from the card side, which results in adhesive residue on cutting devices when converted to rolls for inkjet printing.

Innovation Solution

An inkjet-based roll with punch-out cards featuring a carrier sheet with cut-outs, where a patch/tape with adhesive is applied to the bottom side to attach a polyester plastic card, and both are perforated from the bottom side, allowing the roll to be cut into wider sheets without using UV light to dry the adhesive.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If punch-out cards are produced on sheets for customer use, then the cards can be easily used, but the width is limited and cannot accommodate wider printing requirements

Engineering Contradiction:

Improvesheet widthVSAvoidproduction complexity

Core Design Contradiction:

Area of stationary objectVSEase of manufacture

Solution Approach 1:

The roll is segmented into multiple individual sheets through perforations, allowing each sheet to be separated and used independently while maintaining the ability to produce wider formats from a single roll structure

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention transitions from producing individual sheets to producing a continuous roll format, adding the dimension of continuous length while maintaining width capabilities, allowing wider sheets to be produced by cutting across the roll width

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Strength

If perforation is done from the card side with card adhered to carrier sheet by tape, then the cards can be attached securely, but the cutting device pierces the tape last leaving adhesive on the cutting device

Engineering Contradiction:

Improvecard attachment strengthVSAvoidadhesive residue on cutting device

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The perforation direction is inverted from the conventional card-side approach to the carrier sheet side. This reversal allows the cutting device to pierce the card and tape simultaneously without the tape being pierced last, eliminating adhesive residue on the cutting device while maintaining secure card attachment

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The adhesive property of the tape, which causes harm by leaving residue on the cutting device, is converted into a benefit by changing the perforation sequence. The tape is now pierced before the card, allowing the adhesive to be cut through cleanly without contaminating the cutting device

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Ease of manufacture

If rolls are made 11 inches wide for standard production, then the manufacturing process is standardized, but it limits the sheets that can be produced

Engineering Contradiction:

Improvemanufacturing standardizationVSAvoidsheet width capability

Core Design Contradiction:

Ease of manufactureVSArea of stationary object

Solution Approach 1:

The roll width is made dynamic rather than fixed at 11 inches. The system can accommodate variable widths by adjusting the carrier sheet and card dimensions, allowing the same manufacturing process to produce different sheet widths as needed

Inventive Principle:

Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables the production of wider sheets with punch-out cards that can be fed into an inkjet printer and cut without adhesive residue, expanding printing capabilities and efficiency.

Implementation Method 1

a patch/tape is applied to the bottom-side of the carrier sheet to cover the cut-out, and a card is attached to the patch through the cut-out

Methodology Applied

Scientific EffectAdhesive: Adhesive

Data Source

PatentUS20230330887A1Inkjet based roll with punch-out cards

Publication Date: 2023.10.19 WAUGH BILL

AI summary

Implementations of an inkjet based roll with punch-out cards comprising a carrier sheet having a top side and a bottom side, where the carrier sheet comprises a plurality of cut-outs, where for each cut-out, a patch/tape is applied to the bottom-side of the carrier sheet to cover the cut-out, and a card (e.g., a polyester plastic card) is attached to the patch through the cut-out from the top side of the carrier sheet. In some implementations, the card and the patch comprise perforations to create a punch-out card. In some implementations, the patch/tape is made from an opaque material having an adhesive on a first side on which the card is adhered. In some implementations, a method of using the inkjet based roll with punch-out cards comprises cutting a plurality of holes in a roll of a carrier sheet where the carrier sheet has a top side and a bottom side. In some implementations, the method further comprises applying to the bottom-side of the carrier sheet a patch/tape to cover the cut-out. In some implementations, the method further comprises attaching a card (e.g., a polyester plastic card) to the patch through the cut-out from the top side of the carrier sheet. In some implementations, the method further comprises perforating the patch and the card from the bottom-side of the carrier sheet. In the method, in some implementations, UV light is not used to dry the adhesive of the patch/tape.