Abstract A method of producing an aperture record card from a substantially continuous web of cardstock of predetermined thickness, each of the record cards having a shouldered aperture arranged to receive a film chip over the aperture. The method comprises the combination of the steps of supplying a substantially continuous web of the cardstock and conveying the web along a predetermined path. The web is embossed as it is moved along the path, for example about a rotating embossing drum, to raise a portion thereof above the surface of the surrounding web, with the center portion higher than the peripheral portion of the web. The web is then ground to form a rectangular ground area on the raised surface of the web and a layer of a fluid-impermeable material, such as molten thermoplastic, is applied to the ground area of the web to seal and protect the surface of the web. The ground area is deembossed and an aperture is formed through the web in the ground area.
The invention according to claim 1 including the step of cutting said web into a plurality of record cards each containing a shouldered aperture therein.
Claim 2
Dependent Claim
26 words
The invention according to claim 1 wherein said web is conveyed around a rotating drum having a plurality of embossing dies on the outer surface thereof.
Claim 3
Dependent Claim
37 words
The invention according to claim 3 including the step of applying a vacuum to the web to hold it in close contact with the outer surface of the drum and to emboss it over the dies thereon.
Claim 4
Dependent Claim
55 words
The invention according to claim 1 including the step of raising a first portion of the web above the surface of the surrounding web a distance just less than the thickness of the web and a second portion of the web surrounding said first portion a distance substantially less than the thickness of the web.
Claim 5
Dependent Claim
38 words
The invention according to claim 5 including the step of removing a portion of said first and second embossed portions of said web to form a substantially rectangular ground area spaced above the surface of the surrounding web.
Claim 6
Dependent Claim
21 words
The invention according to claim 1 including the step of applying said material to said ground area with a gravure roll.
Claim 7
Independent Claim
253 words
The method of producing an aperture record card from a substantially continuous web of fibrous cardstock, each of said record cards having a shouldered aperture arranged to receive a film chip over said aperture, said method comprising the steps of supplying said web to a rotating drum having a plurality of embossing dies on the outer periphery thereof extending above the surface of the drum, embossing said web on said dies to raise a first portion of the web above the surface of the surrounding web a distance at least as great as the thickness of said film chip and a second portion of the web surrounding and contiguous with said first portion a distance substantially less than the thickness of said film chip, grinding the outer surface of the first and second raised portions of said web to a depth less than the thickness of the web to form a substantially rectangular ground area on said raised portion of said cardstock, printing a substantially uniform layer of fluid-impervious material with a gravure roll on the ground area of said cardstock, said layer having a thickness such that it does not extend above the face of the record card removing said coated ground cardstock from said drum, de-embossing said coated ground area downstream from said drum, perforating an aperture substantially in the center of said de-embossed coated ground area, and cutting said web into a plurality of individual record cards each containing an aperture substantially in the center of a coated ground area.