Plastic display envelope for enabling subsequent lamination of large indicia bearing sheets and methods of making and using same

Claim 2

A warped heat and pressure laminatable display envelope comprising: (a) a core sheet having a front face and a rear face opposite said front face; (b) a heat activatable plastic backing sheet face laminated by heat and pressure to substantial rear face portions of said core sheet, said plastic backing sheet having physical characteristics which produce substantial bowing of said core sheet and said backing sheet after lamination by heat and pressure of said backing sheet to said core sheet; and (c) a heat activatable light transmissive plastic cover sheet having an approximate size at least as great as a file folder when folded, affixed to minor portions of the front face of said core sheet for enabling the subsequent lamination by heat and pressure of an indicia bearing insert sheet between said heat activatable light transmissive plastic cover sheet and said core sheet, said heat activatable light transmissive plastic cover sheet having physical characteristics which would produce substantial bowing of said cover sheet and said core sheet after being laminated together in the absence of said backing sheet, thereby enabling the subsequent production of a substantially flat laminated product from said warped heat and pressure laminatable envelope.

Claim 3

The warped plastic envelope of claim 1 wherein said backing sheet and said heat activatable light transmissive plastic cover sheet are congruent.

Claim 4

The warped plastic envelope of claim 1 wherein said core sheet has fiducial markings thereon composed of ink which disappears upon the application of said heat to said core sheet.

Claim 5

The warped plastic envelope of claim 1 having carbonless pressure sensitive paper therein.

Claim 6

The envelope of claim 1 further including at least one pouch forming flap attached to a bottom portion of said core sheet via a score line to facilitate upward folding of said flap to form a pouch or alternatively to enable manual separation of said flap from said core sheet.

Claim 7

The folder of claim 1 further including fiducial insert sheet positioning indentations formed in said core sheet and wherein said cover sheet is made of structured plastic having a polyester base layer and a heat activatable adhesive layer thereon, the polyester base layer having a minimum thickness or four mils, and the adhesive layer having a minimum thickness of six mils.

Claim 8

The heat and pressure laminatable envelope of claim 1, including at least one pressure sensitive data sheet positioned upon said core sheet, said pressure sensitive data sheet being constituted to produce visible characters thereon upon being impacted by a character forming member, for thwarting compromise of said visible characters.

Claim 9

The heat and pressure laminatable envelope of claim 7 wherein said pressure sensitive data sheet comprises carbonless paper.

Claim 10

The heat and pressure laminatable envelope of claim 8 wherein said core sheet has insert sheet positioning fiducial markings printed thereon with an ink which substantially disappears upon the application of heat thereto during heat lamination of said plastic cover sheet to said core sheet.

Claim 11

The plastic envelope of claim 1 wherein the thickness of said plastic backing sheet varies no more than plus or minus twenty-five percent of the thickness of said plastic cover sheet.

Claim 12

The warped plastic envelope of claim 10 wherein said backing sheet and said heat activatable light transmissive plastic cover sheet are congruent.

Claim 13

The plastic envelope of claim 10 wherein said plastic cover sheet and said plastic backing sheet each have a total thickness of 3-5 mils and are substantially less stiff than said core sheet.

Claim 14

The warped plastic envelope of claim 12 wherein said backing sheet and said heat activatable light transmissive plastic cover sheet are congruent.

Claim 15

The plastic envelope of 10 wherein said core sheet is made of paper having a substantially greater stiffness than said plastic backing sheet.

Claim 16

The plastic envelope of 10 wherein said core sheet is made of paper having a substantially greater stiffness than said plastic backing sheet.

Claim 17

The envelope of claim 10 further including at least one pouch forming flap attached to a bottom portion of said core sheet via a score line to facilitate upward folding of said flap to form a pouch or alternatively to enable manual separation of said flap from said core sheet.

Claim 18

The envelope of claim 15 including insert sheet positioning fiducial markings printed upon portions of said envelope with an ink which substantially disappears upon upon the application of heat thereto during heat lamination of said plastic cover sheet to said core sheet.

Claim 19

The plastic envelope of claim 1 wherein said plastic cover sheet and said plastic backing sheet each have a polyester base and a heat activatable adhesive layer thereon, and wherein the thickness of the polyester base of said backing sheet varies no more than plus or minus twenty-five percent of the thickness of the polyester base of said cover sheet.

Claim 20

The warped plastic envelope of claim 17 wherein said backing sheet and said heat activatable light transmissive plastic cover sheet are congruent.

Claim 21

The plastic envelope of claim 17 wherein said plastic cover sheet and said plastic backing sheet each have a total thickness of 3-5 mils.

Claim 22

The warped plastic envelope of claim 19 wherein said backing sheet and said heat activatable light transmissive plastic cover sheet are congruent.

Claim 23

The plastic envelope of claim 1 wherein said core sheet is made of paper having a substantially greater stiffness than said plastic backing sheet.

Claim 24

The warped plastic envelope of claim 21 wherein said backing sheet and said heat activatable light transmissive plastic cover sheet are congruent.

Claim 25

Method of producing a substantially flat laminated display product by sequential lamination of plastic sheets, each of which warps to an unacceptable degree when laminated to a core sheet during lamination by heat and pressure thereto comprising the steps of: (a) manufacturing a warped plastic envelope by: (a-1) providing a core sheet having a front face and a rear face opposite said front face; (a-2) laminating a heat activatable plastic backing sheet to substantial rear face portions of said core sheet by the application of heat and pressure thereto, said plastic backing sheet having physical characteristics which produce substantial bowing of said backing sheet and said core sheet after lamination by heat and pressure of said backing sheet to said core sheet; (a-3) affixing a heat activatable light transmissive plastic cover sheet having an approximate size at least as great as a file folder when folded, to minor portions of the front face of said core sheet for enabling the subsequent lamination by heat and pressure of an indicia bearing insert sheet between said heat activatable light transmissive plastic cover sheet and said core sheet, said light transmissive heat activatable plastic cover sheet having physical characteristics which would produce substantial bowing of said cover sheet and said core sheet after being subsequently laminated to said core sheet by a user in the absence of said backing sheet; (b) making the warped plastic envelope fabricated in accordance with steps (a) available to a user; (c) thereafter inserting said indicia bearing insert sheet between said core sheet and said light transmissive heat activatable plastic cover sheet; and (d) laminating said core sheet and said light transmissive heat activatable plastic cover sheet together by the application of heat and pressure thereto, for producing a substantially flat final laminated product.

Claim 26

Method of producing a substantially flat laminated display product by sequential lamination of plastic sheets, each of which warps to an unacceptable degree when laminated to a core sheet during lamination by heat and pressure thereto comprising the steps of: (a) manufacturing a warped plastic envelope by: (a-1) providing a core sheet having a front face and a rear face opposite said front face; (a-2) laminating a heat activatable plastic backing sheet to substantial rear face portions of said core sheet by the application of heat and pressure thereto, said plastic backing sheet having physical characteristics which produce substantial bowing of said backing sheet and said core sheet after lamination by heat and pressure of said backing sheet to said core sheet; (a-3) affixing a heat activatable light transmissive plastic cover sheet having an approximate size at least as great as a file folder when folded, to minor portions of the front face of said core sheet for enabling the subsequent lamination by heat and pressure of an indicia bearing insert sheet between said heat activatable light transmissive plastic cover sheet and said core sheet, said light transmissive heat activatable plastic cover sheet having physical characteristics which would produce substantial bowing of said cover sheet and said core sheet after being subsequently laminated to said core sheet by a user in the absence of said backing sheet; (b) making the warped plastic envelope fabricated in accordance with steps (a) available to a user; (c) thereafter inserting said indicia bearing insert sheet between said core sheet and said light transmissive heat activatable plastic cover sheet; and (d) laminating said core sheet and said light transmissive heat activatable plastic cover sheet together by the application of heat and pressure thereto, for producing a substantially flat final laminated product.

Claim 27

The method of claim 23 wherein step (a-1) comprises laminating said backing sheet to the entire rear face of said core sheet.

Claim 28

The method of claim 23 including the step of laminating carbonless pressure sensitive paper within said plastic envelope and impacting said carbonless pressure sensitive paper in a pattern to produce visible characters within said carbonless pressure sensitive paper.

Claim 29

The method of claim 25 including laminating said carbonless pressure sensitive paper between said core sheet and said backing sheet.

Claim 30

The method of claim 23 further including the step of imprinting fiducial markings upon said core sheet with ink which disappears upon the application of said heat to said core sheet.

Claim 31

Method of manufacturing a warped plastic envelope for subsequent use by a user comprising the steps of: (a) providing a core sheet having a front face and a rear face opposite said front face; (b) laminating a heat activatable plastic backing sheet to substantial rear face portions of said core sheet by the application of heat and pressure thereto, said plastic backing sheet having physical characteristics which produce substantial bowing of said backing sheet and said core sheet after lamination by heat and pressure of said backing sheet to said core sheet; and (c) affixing a heat activatable light transmissive plastic cover sheet having an approximate size at least as great as a file folder when folded, to minor portions of the front face of said core sheet for enabling subsequent lamination by heat and pressure of an indicia bearing insert sheet between said heat activatable light transmissive plastic cover sheet and said core sheet, said light transmissive heat activatable plastic cover sheet having physical characteristics which would produce substantial bowing of said cover sheet and said core sheet after being subsequently laminated to said core sheet by a user in the absence of said backing sheet.

Claim 32

Method of manufacturing a warped plastic envelope for subsequent use by a user comprising the steps of: (a) providing a core sheet having a front face and a rear face opposite said front face; (b) laminating a heat activatable plastic backing sheet to substantial rear face portions of said core sheet by the application of heat and pressure thereto, said plastic backing sheet having physical characteristics which produce substantial bowing of said backing sheet and said core sheet after lamination by heat and pressure of said backing sheet to said core sheet; and (c) affixing a heat activatable light transmissive plastic cover sheet having an approximate size at least as great as a file folder when folded, to minor portions of the front face of said core sheet for enabling subsequent lamination by heat and pressure of an indicia bearing insert sheet between said heat activatable light transmissive plastic cover sheet and said core sheet, said light transmissive heat activatable plastic cover sheet having physical characteristics which would produce substantial bowing of said cover sheet and said core sheet after being subsequently laminated to said core sheet by a user in the absence of said backing sheet.

Claim 33

The method of claim 28 wherein step (b) includes laminating said backing sheet to the entire rear surface portion of said core sheet.

Claim 34

The method of claim 28 further including the step of imprinting fiducial markings upon said core sheet with ink which disappears upon the application of said heat to said core sheet.