In this specification the term card is used to mean any rigid or semi-rigid material with the same or similar characteristics to stiff paper or cardboard, and may comprise paper, cardboard, plastics material, thin metal or the like.

Information is often stored on small cards to be carried around by a person for reference or use. Such cards include telephone cards, bank cards, credit cards, cards bearing emergency telephone numbers and the like. Such card tends to be manufactured from plastics material, thick paper or cardboard.

The cards often require to bear information on both sides and conventionally the printing of such cards has involved a multi-stage process requiring at least the two stages of sequential printing on one side and then the other.

According to the present invention there is provided a method of folding material the method comprising introducing material on a flexible carrier to a release station at which the material is released from the carrier and introduced to a station at which the material is urged to fold in a direction to cause the material to fold onto itself.

Preferably the material is urged for folding toward means for applying pressure on the folded material to reinforce the fold and desirably secure adhesion of the folded material to itself, which means may comprise at least one roller and desirably a pair of nip rollers.

Preferably a plurality of pieces of material mounted on a flexible carrier are folded desirably sequentially but may also be folded simultaneously. The material may be provided on a roll or web of carrier material which is fed to the release station, desirably by a conveyor arrangement, which may comprise rollers or similar.

Preferably the carrier is moved around a releasing formation at the release station at which formation the direction of movement of the carrier changes generally away from the general direction of movement of the material whereby to cause release of the material from the carrier. Preferably the carrier is moved in a direction generally perpendicular to the plane of unfolded material entering into the release station.

Preferably material released from its carrier is caused to bear upon a surface in the folding station whereby the material is urged to fold, desirably about a fold line or other weakness provided in the material to provide appropriate folding of the material.

Preferably an end of released material is received by an angled arrangement which causes material urged thereagainst to fold in a desired manner as material continues to be fed into the folding station.

Preferably the distance between the releasing surface and the surface of the folding station is less than the length of the material, the length being measured in the direction of movement of the material into the release station.

Preferably material is not completely released from the carrier before being introduced to the pressure means, whereby the material is driven and thereby controllably moved into the pressure means.

The method is particularly suitable for folding rigid or semi-rigid card, and desirably material with adhesive on at least one side thereof of the proposed fold line, and preferably a surface on both sides which surfaces are folded onto one another to provide for adhesion of the folded material to itself.

Preferably the two parts of the material folded onto each other are similar, particularly in shape and size.

Preferably the material is printed prior to introduction to the release station, preferably on the surfaces thereof which remain visible following folding. The material may be printed such that both exposed surfaces of the folded material carry information and/or an image (s).

Preferably folded material is conveyed away from the folding station, desirably to collection means.

Further according to the present invention there is provided apparatus for folding material releasably mounted on a flexible carrier, the apparatus comprising a release station at which material introduced thereto is released from the carrier and a folding station at which released material is urged to fold in a direction to cause the material to fold onto itself.

Preferably the folding station further comprises pressure means located to receive folded or partially folded material and to apply pressure thereto to reinforce the fold and desirably to secure adhesion of the material to itself. The pressure means may comprise at least one roller and desirably a pair of nip rollers.

Preferably the apparatus is arranged to fold a plurality of pieces of material mounted on a flexible carrier, which pieces may be folded sequentially, simultaneously or both. Preferably the apparatus is operable to fold material releasably mounted on a roll or web of carrier material which is fed into the release station, desirably by a conveyor arrangement which may comprise part of the apparatus and which may comprise a series of rollers or similar.

Preferably the release station comprises a formation around which the carrier is moved to direct movement thereof away from the general direction of movement of the material whereby to cause release of the material from the carrier. The formation preferably directs movement of the carrier in a direction generally perpendicular to the plane of unfolded material entering the station.

Preferably the folding station comprises a surface against which material released from the carrier is caused to bear and which surface is arranged to direct folding of the material, desirably about a fold line or other weakness in the material to provide for appropriate folding of the material.

The folding station may comprise an angled arrangement arranged to receive an end of released material to be folded and to direct the material urged thereagainst in a direction to be folded as material continues to be fed into the folding station.

Preferably the distance between the releasing surface and the surface of the folding station is less than the length of the material, the length being measured in the direction of movement of the material into the release station.

Preferably material is not completely released from the carrier before being introduced to the pressure means, whereby the material is driven and thereby controllably moved into the pressure means.

Preferably the apparatus folds rigid or semi-rigid card and desirably material comprising adhesive on at least one side thereof of the proposed fold line, and desirably a surface on both sides which surfaces are folded onto each other to facilitate secure adhesion. Preferably the two parts of the material folded onto each other are similar particularly in shape and size.

Preferably the material is printed prior to introduction to the release station, preferably on the surfaces thereof which remain visible following folding. The material may be printed such that both exposed surfaces of the folded material carry information and/or images.

Preferably the apparatus comprises conveying means arranged to convey folded material from the folding station, which means may comprise a conveyor belt or similar arrangement.

Still further according to the present invention there is provided printing apparatus for printing material releasably mounted to a flexible carrier, the apparatus comprising a printing station at which material is printed, a release station at which printed material introduced thereto is released from the carrier and a folding station at which released material is urged to fold in a direction to cause the material to fold onto itself.

Preferably the apparatus prints the material in locations which remain visible after the material has been folded.

Preferably the material is printed on the exposed surface thereof whilst mounted on the carrier.

The printing apparatus may be operable to print the same information and/or images on a plurality of pieces of the material and/or print different or unique information on respective pieces of material. The apparatus may comprise a release station and a folding station substantially as defined above.

The invention may further provide a method of printing material releasably mounted to a flexible carrier, the method comprising printing material to be folded whilst on the carrier, introducing printed material to a release station whereat the material is released from the carrier and folding released material by urging the material in a direction to cause the material to fold onto itself.

The invention may still further provide a card blank for folding, the blank comprising at least two joined portions and means associated with said portions operable to direct folding along a predetermined line between the portions as folding pressure is applied to the material.

The means may comprise a line of weakness provided in the material, desirably generally along the desired fold line. Alternatively, or in addition, the means may comprise cut outs in the material, and as nicks in the opposing edges of the material.

The material is preferably releasably mounted to a flexible carrier, and may be adapted for use in one or more of the apparatus and methods discussed above.

Preferably the blank has adhesive on the surface thereof, which surface is one of the surfaces of the blank folded together to form a card.

Preferably both contacting surfaces comprise adhesive.

The blank may comprise paper, cardboard, plastics, metal or other appropriate rigid or semi-rigid material.

An embodiment of the present invention will now be described by way of example only, in which:- Fig. 1 is a schematic illustration of folding apparatus according to the present invention; Fig. 2 is a schematic representation of printing apparatus according to a further aspect of the present invention; and Fig. 3 is a diagrammatic perspective detail of the release and folding stations of the apparatus of Fig. 1.

Referring to the drawings, there is provided apparatus 8 for folding material 10 releasably mounted on a flexible carrier 12, the apparatus 8 comprising a release station 14 at which material 10 introduced thereto is released from the carrier 12 and a folding station 16 at which released material 10'is urged to fold in a direction to cause the material 10'to fold onto and adhere to itself.

In more detail, the apparatus 8 is primarily for use in folding a plurality of distinct pieces of material releasably mounted on a flexible carrier 12 in the form of a roll or web.

Individual pieces of material 10 are described as being sequentially folded, but it will be appreciated that a plurality of pieces of material could be folded simultaneously.

The apparatus 8 can be used to fold any rigid or semi-rigid material, including thick paper, cardboard, plastics material, metal and the like.

The flexible carrier 12 may comprise any suitable backing from which the material 10 can be released in accordance with the invention, such as a waxed paper or plastics material. Alternatively, the material could be formed in the carrier itself, for example by releasable perforations or other weaknesses.

The release station 14 comprises a member 18 illustrated in the form of a flat bar, around which the flexible carrier 12 is fed to move through a generally 90° angle. The member 18 may comprise a rounded surface 20 around which the carrier 12 moves to provide for release of material 10 from the carrier 12 as will be described. The surface 20 may be rounded or otherwise shaped to mitigate the possibility of damage or breakage of the flexible carrier 12 as it moves therearound.

The folding station 16 comprises an angled member 22 adjacent the member 18. The member 22 is shown in the form of an elongate arms extending generally parallel to the member 18 and having two planar sides angled to form a generally 90° angle to receive released material 10'for folding as will be explained. The folding station 16 further comprises a pair of nip rollers 24 arranged to receive the folded material 10"therebetween to exert pressure on the folded material 10"to help secure adhesion of the folded material 10"to itself.

A conveyor 26 is provided to carry folded material 10"away from the folding station 16 for collection.

The apparatus 8 is designed for use with material for folding which comprises at least two joined portions 28,30 provided with a fold line between said portions 28,30 to define the line of fold therebetween as folding pressure is applied at one edge 32 of the material 10 as will be explained. The fold line may comprise any suitable form of weakness, such as a crease, cut, perforation or opposing nicks.

In use, the material 10 to be folded is fed from a roll thereof 34, around intermediate directing rollers 36 if necessary, into the release station 14. The material 10 and carrier 12 is moved across the member 18 until the backing 12 and material 10 reach the rounded surface 20 at which point the carrier 12 moves away from the plane of the material 10 at a substantially 90° angle. This movement in conjunction with the rigid or semi-rigid nature of the material 10 overcomes the adhesion mounting the material 10 on the carrier 12 whereby the carrier 12 is peeled from the material 10. Continued movement of the material 10 and carrier 12 causes the leading edge 32 of the material 10 to be received in the angled member 22 and as further movement of the released material 10 and carrier 12 occurs, the released material 10'is urged to fold about the fold line toward the nip rollers 24.

As the carrier 12 and material 10'continues to be fed through the apparatus 8, the nip rollers 24 engage the release material 10'about the fold line and draw the material 10'therethrough urging the two portions 28,30 against each other such that adhesive on one or both of said portions cause the two portions 28,30 to be securely stuck together to form a card of folded material 10". It is preferred that the fold of the material is engaged by the nip rollers 24 before the material 10 is completely released from the carrier 12, whereby movement of the material 10 is continually driven and controlled through the apparatus 8.

The carrier 12 leaving the release station is fed to a storage drum 38 for disposal or otherwise.

The folded cards 10"are received on the conveyor 26 and conveyed to be collected.

As illustrated in Fig. 3, a particular application of the apparatus of the present invention is for folding material 10 that has been pre-printed with information or images illustrated diagrammatically in Fig. 3 using the letters A, B, C and D, E, F.

Fig. 2 is a schematic representation of printing apparatus 40 according to the present invention which apparatus 40 comprises the folding apparatus 8 described above. The apparatus 40 is illustrated as further comprising a printing unit 42 which may be digital (for variable data print), a print/curing station 44 which may be a UV print/curing station (for conventional fixed print in one colour) and a material cutting station 46. It will be appreciated that the nature and number of printing units/stations can be varied according to the nature of the information and images to be printed on the material.

A roll of material from which the material 10 is derived is stored on a drum 48 and is drawn therefrom to be printed with desired information on areas thereof corresponding to or within the dimensions of the portions 28,30.

The information printed may be repeated along the length of the material so that subsequent individual pieces of material 10 comprise the same information, or the printing unit 42 may be suitable for printing unique information or images on the different pieces of material 10.

Conventional print in one or more colours is printed and cured in the station 44 and cured printed material is then passed through the cutting station 46 which comprises one or more dies (not shown) to cut the material 10 into a blank comprising the two portions. The excess material or waste from around the cut pieces 10 is removed at a station 50 such that the material 10 and carrier 12 as described above can be fed to the folding apparatus 8.

The principal advantage of the apparatus and methods described above are that cards, such as phone cards, credit cards and the like which require information to be provided on both sides thereof, can be produced by a printing process that requires a single stage of printing on one side of a card blank (the material 10). This introduces considerable savings in both handling time and apparatus required.

Various modifications may be made without departing from the spirit or scope of the present invention.

Whilst endeavouring in the foregoing specification to draw attention to those features of the invention believed to be of particular importance it should be understood that the Applicant claims protection in respect of any patentable feature or combination of features hereinbefore referred to and/or shown in the drawings whether or not particular emphasis has been placed thereon.